EV4030A-S-00B 198VAC~265VAC/50Hz, 30V/530mA Primary-side-control with Active PFC Off-line Dimmable LED Driver Evaluation Board
DESCRIPTION
FEATURES
The EV4030A-S-00B Evaluation Board is designed to demonstrate the capabilities of MP4030A. The MP4030A is a primary-sidecontrol offline LED lighting controller which can achieve high power factor and accurate current for Triac dimmable LED lighting application. It works in boundary conduction mode for reducing the MOSFET and Diode switching losses.
The EV4030A-S-00B is typically designed for driving a 16W Triac dimmable LED bulb with 30VTYP, 530mA LED load from 198VAC to 265VAC, 50Hz. The EV4030A-S-00B has an excellent efficiency and meets IEC61547 surge immunity, IEC61000-3-2 Class C harmonics and EN55015 conducted EMI requirements. It has multi-protection function as over-voltage protection, short-circuit protection, cycle by cycle current limit, etc.
ELECTRICAL SPECIFICATION Parameter
Symbol
Value
Units
Input Voltage Output Voltage LED Current Output Power
VIN VOUT ILED POUT
198 to 265 30 530 16
VAC V mA W
Efficiency (full load) Power Factor THD
η PF THD
>84 >0.9 0.9 over 198VAC to 265VAC Boundary conduction mode improves efficiency Input UVLO Cycle-by-cycle current limit Over-voltage protection (OVP) Short-circuit protection (SCP) Over-temperature protection (OTP) Fit inside PAR38 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.
%
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
1
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
EV4030A-S-00B EVALUATION BOARD
(L x W x H) 88mm x 30mm x 23mm Board Number
MPS IC Number
EV4030A-S-00B
MP4030AGS
EVALUATION BOARD SCHEMATIC
Figure 1—Schematic
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
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EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
PCB LAYOUT (SINGLE-SIDED)
Figure 2—Top Layer
Figure 3—Bottom Layer
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3
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
CIRCUIT DESCRIPTION The EV4030A-S-00B is configured in a singlestage Flyback topology, it uses primary-sidecontrol which can mostly simplify the schematic and get a cost effective BOM. It can also achieve high power factor and accurate LED current. F1, RV1, L1, L2, L3, R1, R14, R13, CX1, DB1, and C1 compose the input stage. F1 fuses the AC input to protect for the component failure or some excessive short events. RV1 is used for surge test. L1, L2, L3, R1, R14, CX1, R13 and C1 associated with CY1 form the EMI filter which can meet the standard EN55015. The diode rectifier DB1 rectifies the input line voltage. Small bulk CBB capacitor C1 is used for a low impedance path for the primary switching current, to maintain high power factor, the capacitance of C1 should be selected with low value. R3, R8, R5, R23, C4, C11, D1, D4, Q1, Q3 with R12 compose the damping circuit for reducing the inrush current at the dimmer turning on time. The circuit let the inrush current flow through R12 at first when triac dimmer turns on. Then Q1 turns on and shorts R12, this can save power from R12. Q3 is used to discharge C4 when the triac is off. D4 is used to clamp the gate voltage of Q1 to 15V. R4, R7, C3 are used as a bleeder circuit which keeping the triac current above the minimum holding current after triac turns on.
R11, D7, C10 and D10 are used to supply the power for MP4030A. A 47μF bulk capacitor C10 is selected to maintain the supply voltage. At start-up, C10 is first charged up through the external MOSFET Q2 and internal charging circuit, when the VCC voltage reaches 10V, the internal charging circuit stops charging and the control logic works. Then the power supply is taken over by the auxiliary winding through R11, D7. R6, C7, D6 and D5 are used for the gate drive of the external MOSFET Q2. R15, R16 are used to detect the auxiliary winding to get the transformer magnetizing 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 R15, R16. R18, R20 are primary sensing resistors for primary side current control. The value of R18, R20 set the output LED current. C2, R2, R22, D3 are used to damp the leakage inductance energy so the drain voltage can be suppressed at a safe level. Diode D2 rectifies the secondary winding voltage and the capacitor C5, C6 are the output filter. The resistor R9 is placed as pre-load to limit the output voltage rise too high in open load condition.
R10, R17, C9 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.
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4
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
EV4030A-S-00B BILL OF MATERIALS Qty
Ref
Value
Description
1
C1
100nF/630V
1
C2
22nF/630V
1
C3
220nF/400V
1
C4
33nF/50V
2
C5,C6
330uF/50V
1
C7
1uF/25V
1
C8
2.2uF/10V
1
C9
2.2nF/50V
1
C10
47uF/50V
1
C11
470pF/1kV
1 1
CX1 CY1
22nF/275V 2.2nF/4000V
2
D1,D5
1N4148WS
Diode;75V;0.15A;
1 1
D2 D3
MBRS320T3G WSGC10MH
1
D4
BZT52C15
1
D6
BZT52C16
Diode;200V;3A Diode;1000V;1A Zener Diode;15V; 5mA/500mW; Zener Diode;16V; 5mA/500mW;
1
D7
BAV21W
2
D8,D9
NS
1
D10
BZT52C27
1
DB1
DF06S
1
F1
SS-5-2A
1
L1
1mH/0.42A
2
L2,L3
2.2mH/0.3A
1
Q1
SSN1N45BTA
1
Q2
CEF04N7G
1
Q3
MMBT3906LT1
Ceramic Capacitor; 630V;10% Ceramic Capacitor; 630V;X7R Capacitor;400V;CBB Ceramic Capacitor; 50V;X7R Electrolytic Capacitor; 50V;Electrolytic;DIP Ceramic Capacitor; 25V;X7R;0603 Ceramic Capacitor; 10V;X7R Ceramic Capacitor;50V;X7R Electrolytic Capacitor; 50V;Electrolytic;DIP Ceramic Capacitor;1kV;1206 Capacitor;275V;10% Capacitor;4000V;20%
Diode;200V;0.2A; Zener Diode;27V ;5mA/500mW; Diode;600V;1.5A Fuse;250V;2A Inductor;1000uH; 2.5 Ohm;0.42A Inductor;1.8mH; 4.73 Ohm;0.3A N-Channel Mosfet 450V;4250/10V;8.5 Mosfet;700V;4A Transistor;-40V;0.2A;
Package
Manufacturer
DIP
Fala
C312J104K63CC30
1206
TDK
C3216X7R2J223K
DIP
Panasonic
0603
muRata
GRM188R71H333KA61D
DIP
Jianghai
CD263-50V330
0603
TDK
0603
muRata
0603
TDK
DIP
Jianghai
CD281L-50V47
1206
muRata
GRM31B7U3A471JW31L
DIP DIP SOD323 SMB 1206 SOD123 SOD123 SOD123
Carli Hongke
PX223K3IC39L270D9R JNK12E222MY02N
Diodes
1N4148WS-7-F
Qianlongxin MAXMEGA
MBRS320T3G WSGC10MH
SOD123 SMD DIP
Manufactuer_P/N
ECQE4224KF
C1608X5R1E105K GRM188R71A225KE15D C1608X7R1H222K
Diodes
BZT52C15
Diodes
BZT52C16
Diodes
BAV21W-7-F
Diodes
BZT52C27
Fairchild COOPER BUSSMANN
DF06S SS-5-2A
DIP
Wurth
744743102
DIP
Wurth
7447720222
TO-92
Fairchild
TO-220F
MAXMEGA ON Semiconductor
SOT-23
SSN1N45BTA CEF04N7G MMBT3906LT1
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
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EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
EV4030A-S-00B BILL OF MATERIALS (continued) Qty 3 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
Ref R1, R13, R14 R2 R3, R10 R4,R7 R5 R6 R8 R9 R11 R12 R15 R16 R17 R18 R19 R20 R21 R22 R23 RV1 JP1, JP2
Value
Package
Manufacturer
Film Resistor;1%;1/4W
1206
Yageo
RC1206FR-075K1L
499K/1206
Film Resistor;1%;
1206
Yageo
RC1206FR-07499KL
1M
Resistor;1%;1/4W
DIP
510/2W 10 470K/1W 68K/1% 30K/1206 51/1206 330/2W 25.5K/1% 5.9K/1% 4.12K/1% 100m 357/1206 1.5 NS 200 10K/1% TVR10431
Resistor;5%;2W Film Resistor;1%; Resistor;5%;1W Film Resistor;1% Resistor;1% Film Resistor;1% Resistor;5%;2W Film Resistor;1%; Film Resistor;1% Film Resistor;1% Resistor;1% Resistor;1% Resistor;1%
DIP 0603 DIP 0603 1206 1206 DIP 0603 0603 0603 1206 1206 1206
any Yageo any Yageo Royalohm Yageo any Yageo Yageo Yageo CYNTEC Yageo Royalohm
510 Ohm/2W RC0603FR-0710RL 100K Ohm RC0603FR-0768KL 1206F3002T5E RC1206FR-0751RL 330 Ohm/ 2W RC0603FR-0725K5L RC0603FR-075K9L RC0603FR-074K12L RL1632H-R100-FN RC1206FR-07357RL 1206F150KT5E
Resistor;5% Film Resistor;1% THERMAL R
1206 0603 DIP
Yageo Yageo TSK
RC1206FR-07200RL RC0603FR-0710KL TVR10431KSY
Jumper
DIP
any
DIP
Wurth
750341840
SOIC8
MPS
MP4030AGS-Z
5.1K
Short
1
T1
EF20
1
U1
MP4030A
Description
L=2.15mH, Np:Ns:Naux=145:29:19 TRAIC Dimmable, Offline LED Lighting Controller
Manufactuer_P/N
1M Ohm
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
6
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
TRANSFORMER SPECIFICATION Electrical Diagram Y
1
N5 6
W N1
T.I.W
N3
2
B
N2 3 Sec. Side
3 N4 4
WINDING START 3
E1: Cooper foil
TEFLON TUBE
Pri. Side Figure 4—Transformer Electrical Diagram Notes: 1. Don’t connect Y to any pin of Bobbin. 2. W and B are pulled out and marked with different Teflon tube. 3. E1 is one layer of cooper foil applied to core, and connected to PIN3 by a wire.
Winding Diagram
1 6 3 4 B
W
3 6
2
P.S. :
Winding start Winding transfer Winding end
Figure 5—Winding Diagram
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
7
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
Winding Order Winding No. N1 N2 N3 N4 N5 E1
Tape Layer Number 2 2 2 2 3 3
Start & End 2→6 3→Y W→B 4→3 6→1
Magnet WireΦ(mm) 0.18mm * 1 0.15mm * 1 0.20mm * 2 (T.I.W) 0.18mm * 1 0.18mm * 1 One layer Cooper foil
Turns 73 one layer 29 19 72
Electrical Specifications
Electrical Strength
Primary Inductance Primary Leakage Inductance
60 second, 60Hz, from PRI. to SEC.
2500VAC
60 second, 60Hz, from PRI. to CORE.
1000VAC
60 second, 60Hz, from SEC. to CORE.
1000VAC
Pins 1 - 2, all other windings open, measured at 100kHz, 0.1 VRMS Pins 1 - 2 with all other pins shorted, measured at 100kHz. 0.1 VRMS
2.15mH±8% 43μH±10%
Materials Item 1 2 3 4 5 6 7 8 9 10
Description 2 Core: EF20, UI=2500±25%, AL=1540nH/N ±25% GAPPED, SUNSHINE SSP-4 or equivalent Bobbin: EF20, 4+4PIN RMMOVE PIN6,7 1SECT T375J UL94V-0 HUAXING HX-2004 Wire: Φ0.18mm/Φ0.15mm,, UEW, TAI-I ELECTRIC WIRE&CABLE CO.,LTD or equivalent Triple Insulation Wire: Φ0.20mm,TRW(B) GREAT LEOFLON INDUSTRIAL CO.,LTD or equivalent TFL TUBE: GREAT AWG#18/26/30, CLEAR TFL TUBE: GREAT AWG#18 BLACK, CLEAR COOPER FOIL: 6.0X0.05mm(TH) DIAN QIANG or equivalent Tape: 12.5mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
8
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
EVB TEST RESULTS Performance Data Efficiency, PF and THD f (Hz)
50
Vin (VAC) 198 210 220 230 240 250 265
Pin (W) 18.71 18.69 18.67 18.66 18.67 18.69 18.77
Vout (V) 29.98 29.96 29.94 29.93 29.92 29.90 29.90
Iout (mA) 531 531 531 531 531 531 532
Pout (W) 15.92 15.91 15.90 15.89 15.89 15.88 15.91
Efficiency (%) 85.1 85.1 85.2 85.2 85.1 84.9 84.7
PF 0.97 0.97 0.96 0.95 0.94 0.94 0.92
THD (%) 13.0 13.8 14.0 14.2 14.3 14.6 14.8
Dimming Compatibility (No Flicker with these 17 different Dimmers) Manufacturer
Part No.
Power Stage
VIN (VAC)
Dimming Type
Io_max (mA)
Io_min (mA)
Dimming Ratio
Busch Schneider Busch MIKA MIKA MIKA BUSCH Busch GIRA JUNG Berker Berker MIKA MIKA MIKA GIRA Busch
2210..-510 SD300 2250 U 434 433/4 EIM-672 2247U 2200.. 030200/I01 225 NVDE 283010 286610 433 HAB EIM-673 433HAB 0307 00 6513 U-102
60-400W 300W 600W 60-400W 60-400W 20-400W 500W/VA 60-400W 60-600W 20-500W 60-400W 20-500W 20-315W 20-300W 20-315W 20-520W 420W/VA
230 230 230 230 230 230/240 230 230 230/240 230/240 230/240 230/240 230 230/240 230 230 230
leading leading leading leading leading leading leading leading leading leading leading leading trailing trailing trailing trailing trailing
521 525 529 504 529 529 527 523 526 528 526 529 531 463 462 531 530
33 0 12 31 74 0 31 31 25 11 31 18 54 0.53 58 50 62
6.33% 0.00% 2.27% 6.15% 13.99% 0.00% 5.88% 5.93% 4.75% 2.08% 5.89% 3.40% 10.17% 0.11% 12.55% 9.42% 11.70%
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
9
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
Electric Strength Test Primary circuit to secondary circuit electric strength testing was completed according to IEC61347-1 and IEC61347-2-13. Input and output was shorted respectively. 3750VAC/50Hz sine wave applied between input and output for 1min, and operation was verified. Surge Test Line to Line 500V and Line to Power Earth 1kV surge testing was completed according to IEC61547. Input voltage was set at 230VAC/50Hz. 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 1000 -1000 1000 -1000
230 230 230 230 230 230
L to N L to N L to PE L to PE N to PE N to PE
90 270 90 270 90 270
Pass Pass Pass Pass Pass Pass
Thermal Test Test without dimmer and with dimmer at 90% dimming on phase.
Bleeding resister: 46.0℃
Without dimmer
Bleeding resister: 86.4℃
With dimmer at 90% dimming on phase
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
10
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VIN=220VAC/50Hz, 9 LEDs in series, ILED=530mA, VOUT=30V, LP=2.15mH, NP:NS:NAUX =145:29:19
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
11
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=220VAC/50Hz, 9 LEDs in series, ILED=530mA, VOUT=30V, LP=2.15mH, NP:NS:NAUX =145:29:19.
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
12
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
QUICK START GUIDE 1. Preset AC Power Supply to 198VAC VIN 265VAC. 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.
EV4030A-S-00B Rev.1.0 www.MonolithicPower.com 10/21/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved.
13
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER
APPENDIX RIPPLE SUPPRESSOR (Innovative Proprietary) For dimming LED lighting application, a single stage PFC converter needs large output capacitor to reduce the ripple whose frequency is double of the Grid. And in deep dimming situation, the LED would shimmer caused by the dimming on duty which is not all the same in every line cycle. What’s more, the Grid has noise or inrush which would bring out shimmer even flicker. Figure 6 shows a ripple suppressor, which can shrink the LED current ripple obviously.
Drain current level can be selected as decuple as the LEDs’ current at least. About the RC filter, it can be selected by RC 50 / fLineCycle . Diode D can select 1N4148, and the Zener voltage of DZ is as small as possible when guarantee VD VDZ 0.5 VCO _PP . Optional Protection Circuit In large output voltage or large LEDs current application, MOSFET M may be destroyed by over-voltage or over-current when LED+ shorted to LED- at working. Gate-Source (GS) Over-voltage Protection:
DO NS
RO
DM
+ R
CO C
DO
DZ +
NS
D RO
+ R
CO C
M
DG
DZ RG +
Figure 6: Ripple Suppressor
Figure 7: Gate-Source OVP Circuit
Principle: Shown in Figure 6, Resister R, capacitor C, and MOSFET M compose the ripple suppressor. Through the RC filter, C gets the mean value of the output voltage VCo to drive the MOSFET M. M works in variable resistance area. C’s voltage VC is steady makes the LEDs voltage is steady, so the LEDs current will be smooth. MOSFET M holds the ripple voltage vCo of the output. Diode D and Zener diode DZ are used to restrain the overshoot at start-up. In the start-up process, through D and DZ, C is charged up quickly to turn on M, so the LED current can be built quickly. When VC rising up to about the steady value, D and DZ turn off, and C combines R as the filter to get the mean voltage drop of VCo. The most important parameter of MOSFET M is the threshold voltage Vth which decides the power loss of the ripple suppressor. Lower Vth is better if the MOSFET can work in variable resistance area. The BV of the MOSFET can be selected as double as VCo and the Continues
Figure 7 shows GS over-voltage protection circuit. Zener diode DG and resistor RG are used to protect MOSFET M from GS over-voltage damaged. When LED+ shorted to LED- at normal operation, the voltage drop on capacitor C is high, and the voltage drop on Gate-Source is the same as capacitor C. The Zener diode DG limits the voltage VGS and RG limits the charging current to protect DG. RG also can limit the current of DZ at the moment when LED+ shorted to LED-. VDG should bigger than Vth. Drain-Source Over-voltage and Over-current Protection As Figure 8 shows, NPN transistor T, resistor RC and RE are set up to protect MOSFET M from over-current damaged when output short occurs at normal operation. When LED+ shorted to LED-, the voltage vDS of MOSFET is equal to the vCo which has a high surge caused by the parasitic parameter. Zener Dioder DDS protects MOSFET from over-voltage damaged. Transistor T is used
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14
EV4030A-S-00B – HIGH LINE VOLTAGE, 16W PSR WITH PFC DIMMABLE LED DRIVER to pull down the VGS of M. When M turns off, the load is opened, MP4030A detects there is an OVP happened, so the IC functions in quiescent.
MOSFET LIST In the Table 1, there are some recommended MOSFET for ripple suppressor.
The pull down point is set by RC and RE:
VC RE O 0.7V . RC RE 2 RC DDS RE T DO NS
RO
D M
+ R
CO C
DZ
RG
+
Figure 8: Drain-Source OVP and OCP Circuit Table 1: MOSFET LIST Manufacture P/N Si4446DY FTD100N10A P6015CDG
Manufacture Vishay IPS NIKO-SEM
VDS/ID 40V/3A 100V/17A 150V/20A
Vth(VDS=VGS@TJ=25°C) 0.6-1.6V@ Id=250μA 1.0-2.0V@ Id=250μA 0.45-1.20V@ Id=250μA
Power Stage
