EV4027-J-00B Low Line Voltage, 10W High side Buck PFC Offline WLED Driver Evaluation Board The Future of Analog IC Technology DESCRIPTION FEATURES The EV4027-J-00B Evaluation Board is designed to demonstrate the capabilities of MP4027. The MP4027 is an offline LED lighting controller which can achieve high power factor and accurate LED current for both isolated and non-isolated lighting application in a single stage converter. It works in boundary conduction mode for reducing the MOSFET and Diode switching losses. • • • • • The EV4027-J-00B is typically designed for driving a non-isolated 10W Buck PFC LED bulb with 72VTYP, 140mA LED load at low line voltage (90V~132VAC, 60Hz). The EV4027-J-00B has high performances in efficiency, line/load regulation and meets IEC61547 surges, IEC61000-3-2 Class C harmonics and EN55015 conducted EMI. It has multi-protection function as over-voltage protection, short-circuit protection, inductor OCP, Vin Brown out, NTC, etc. ELECTRICAL SPECIFICATION Parameter Symbol Value Units Input Voltage Output Voltage LED Current VIN VOUT ILED 90 ~ 132 72 140 VAC V mA Output Power Efficiency (full load) POUT η 10 90 W % PF • • • • • • • Small IC package: SOT23-8 Real current control Good line/load regulation High power factor>0.92 over input voltage Boundary conduction mode improves efficiency NTC function Input UVLO Inductor over current protection Over-voltage protection Short-circuit protection Over-temperature protection Fit inside B10 bulb enclosure APPLICATIONS • • • Solid State Lighting Industrial & Commercial Lighting Residential Lighting All MPS parts are lead-free and adhere to the RoHS directive. For MPS green status, please visit MPS website under Quality Assurance. “MPS” and “The Future of Analog IC Technology”, are Registered Trademarks of Monolithic Power Systems, Inc. Warning: Although this board is designed to satisfy safety requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. >0.92 EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 1 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD EV4027-J-00B EVALUATION BOARD (L x W x H) 50.5mm x 22.4mm x 16mm Board Number MPS IC Number EV4027-J-00B MP4027GJ EVALUATION BOARD SCHEMATIC Figure 1 - Schematic EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 2 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD PCB LAYOUT (DOUBLE-SIDED) Figure 2 - Top Layer Figure 3 - Bottom Layer EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 3 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD CIRCUIT DESCRIPTION The EV4027-J-00B is configured in High Side Buck topology with simple schematic, small size and a low cost BOM. It can also achieve high power factor and accurate LED current. F1, RV1, BD1, L1, C1 and C2 compose the input stage. F1 fuses the AC input to protect for the component failure or some excessive short events. RV1 is used to absorb the high ring voltage of surge test, the diode rectifier BD1 rectifies the input line voltage. L1, C1, R3 and C2 form the EMI filter which can meet the requirement for low line voltage test.. The bulk CBB capacitor C2 is also used for a low impedance path for the switching current, to maintain high power factor, the capacitance of C2 should be selected with low value. the mid of R7 and R11 can help decrease the mis-trigger of OVP. L2 is the Buck inductor. Diode D1 rectifies the secondary winding voltage and the capacitor C6 is the output filter. The resistor R2 is placed as pre-load to limit the output voltage rise too high in open load condition. R5, R6, C4 provide sine wave reference for the primary peak current to get an active PFC function. The divided voltage should be lower than the max voltage rating of MULT pin. R4, C3, D3, D2, R1 are used to supply the power for MP4027. A 4.7μF ceramic capacitor C3 is selected to maintain the supply voltage. At startup, C3 is first charged up by the starter resistor R4 from the line voltage, when the VCC voltage passes the turn on threshold the IC starts to work and the gate begins to switch, then the VCC power supply is taken over by the output cap through R1 and D2. D3 is used to clamp the Vcc voltage in a safe range, as the supply of Vcc is directly from output voltage which is much high than the internal BV of Vcc. R9, R10, D4 are used to get the inductor current zero crossing signal for realizing the boundary conduction operation, and also monitor the output OVP condition. The OVP voltage is set by the divider ratio of R9, R10. D4 is used to block the negative plateau voltage when MOSFET is turn on. R7, R11 are sensing resistors for current control and peak current detection. The value of R7, R11 set the output LED current through FB Pin. In Buck solution, the inductor current is always through the sense resistor, so the voltage on ZCD Pin will be added by sense resistor voltage when gate off, it’s easy to mis-trigger OVP. Connecting the peak current detection point to EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 4 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD EV4027-J-00A BILL OF MATERIALS Qty Ref Value Description 1 BD1 MB6S BRIDGE, 600V, 0.5A 1 1 1 1 1 C1 C2 C3 C4 C5 100nF/400V 220nF/450V 4.7uF/50V 3.3nF/50V 2.2uF/6.3V 1 C6 100uF/100V 1 2 1 D1 D2,D4 D3 STTH3R06U BAV3004W-7-F BZT52C27 1 F1 250V/2A 1 1 1 2 1 L1 L2 Q1 R1,R3 R2 1.5mH 1.3mH SMK0460I 5.1kΩ 100kΩ 1 R4 470kΩ 1 R5 10.2kΩ 1 R6 1MΩ 1 R7 1.8Ω 1 R8 20Ω 1 R9 2.2kΩ 1 R10 39kΩ 1 R11 1.1Ω 1 RV1 430V/2500A 1 U1 MP4027GJ 1 JR1 0Ω CBB,400V CBB,450V Ceramic Capacitor,50V Ceramic Cap,50V,X7R Ceramic Cap,6.3V,X5R Electrolytic Capacitor,100V Diode,3A,600V Diode,225mA,300V Zener Diode, 27V SS-5-2A Inductor, 1.5mH, 0.21A Buck Inductor SMK0460I Film RES,1% Film RES,1% Metal Film RES,1/2W, 1% Film Chip RES, 1% Metal Film RES, 1/4W, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% MOV Offline LED Lighting Controller Thick Film Chip RES, 1% Package DIP DIP 1206 0603 0603 Manufacturer Taiwan Semiconductor Panasonic Carli Murata TDK Murata DIP Jianghai CD263-100V100 SMB SOD-123 SOD-123 STTH3R06U BAV3004W-7-F BZT52C27 DIP EE13 I-PAK 1206 1206 ST Diodes Diodes COOPER BUSSMANN TDK Emei AUK Yageo Yageo DIP Any 0603 Yageo DIP Any 1206 Yageo RL1206FR-071R8L 0805 Yageo RC0805JR-0720RL 0603 Yageo RC0603FR-072K2L 0603 Yageo RC0603FR-0739KL 1206 Yageo RL1206FR-071R1L DIP TKS TVR10431KSY SOT23-8 MPS MP4027GJ 0603 Yageo SOIC-4 DIP Manufactuer_P/N MB6S ECQE4104KF TF224K2Y109L270D9R GRM31CR71H475KA12L C1608X7R1H332K GRM188R60J225KE19D SS-5-2A TSL0808RA-152KR21 FX0332 SMK0460I RC1206FR-075K1L RC1206FR-07100KL Any RC0603FR-0710K2L Any RC0603FR-070L EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 5 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD TRANSFORMER SPECIFICATION Electrical Diagram 3 N 195Ts F 0.25mm 9 Figure 4 – Transformer Electrical Diagram Winding Diagram Pin. Side Top. Side 3Ts N Bobbin Figure 5 – Winding Diagram EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 6 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD Winding Order Winding No. N Tape Layer Number 3 Start & End 3→9 Magnet WireΦ(mm) 0.25 Turns 195 Electrical Specifications Inductance Pins 3- 9, measured at 35kHz 1.3mH±8% Materials Item 1 2 3 4 5 6 7 8 Description 2 Core: EE13, UI=2500±25%, AL=184.5H/N ±3% GAP, ACME P4 or equivalent Bobbin: EE13, 5+5PIN RMMOVE PIN1, 2, 4, 7, 8, 10, 1SECT TH, PM9630 UL94V-0 Wire: Φ0.25mm, 2UEW, CLASS B or equivalent Tape: 6.5mm(W)×0.06mm(TH) Tape: 7.7mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Adhesive: 400-36 or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 7 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD EVB TEST RESULTS Performance Data Vin(V) 90 100 110 120 132 Iin(mA) 133 118 107 97 89 Pin(W) 11.18 11.21 11.26 11.31 11.39 Vo(V) 71.7 71.7 71.7 71.7 71.7 Io(mA) 141 141 142 143 143 Po(W) 10.11 10.11 10.18 10.25 10.25 Efficiency 90.43% 90.18% 90.42% 90.66% 90.02% PF 0.929 0.947 0.957 0.963 0.965 THD 39.20% 33.30% 29.00% 25.80% 23.40% Surge Test Line to Line 500V surge testing was completed according to IEC61547. Input voltage was set at 115VAC/60Hz. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) Input Voltage (VAC) Injection Location Injection Phase (°) Test Result (Pass/Fail) 500 -500 115 115 L to N L to N 90 270 Pass Pass EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 8 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD EVB TEST RESULTS Performance waveforms are tested on the evaluation board. ILED=140mA, VOUT=72V, LP=1.3mH, N =195 EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 9 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. ILED=140mA, VOUT=72V, LP=1.3mH, N =195 EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 10 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. ILED=140mA, VOUT=72V, LP=1.3mH, N =195 EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 11 EV4027-J-00B–10W HIGH SIDE BUCK PFC OFFLINE WLED DRIVER EV BOARD QUICK START GUIDE 1. Preset AC Power Supply to 90VAC ≤ VIN ≤132VAC. 2. Turn Power Supply off. 3. Connect the LED string between “LED+” (anode of LED string) and “LED-” (cathode of LED string). 4. Connect Power Supply terminals to AC VIN terminals as shown on the board. 5. Turn AC Power Supply on after making connections. NOTICE: The information in this document is subject to change without notice. Please contact MPS for current specifications. Users should warrant and guarantee that third party Intellectual Property rights are not infringed upon when integrating MPS products into any application. MPS will not assume any legal responsibility for any said applications. EV4027-J-00B Rev. 1.0 www.MonolithicPower.com 12/19/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 12