MAX16841EVKIT+

19-6198; Rev 0; 2/12 MAX16841 Evaluation Kit Evaluates: MAX16841 General Description The MAX16841 evaluation kit (EV kit) demonstrates the MAX16841 LED driver IC used for offline LED lighting applications. The EV kit is configured as a flyback topology to drive 6 to 8 LEDs from a universal AC input supply. The IC is designed for standard offline applications. The typical input power at 230V AC input is 11.7W. The EV kit is designed to pass EM55015 Class B specifications and EN6100-3-2 for harmonic currents. The EV kit is dimmable with most of the leading- and trailing-edge dimmers. Features S Universal AC Input Operation S Drives 6 to 8 Series LEDs S 40V Open-LED Protection S Demonstrates IC Power-Factor Correction S Demonstrates Dimming with Leading- and Trailing-Edge Dimmers S Passes EN55015 B Conducted EMI S Passes IEC 61000-3-2 Class D Harmonic Current Emissions S Proven PCB Layout Ordering Information appears at end of data sheet. S Fully Assembled and Tested Component List DESIGNATION QTY AC1, LED+ 2 Red test points AC2, LED- 2 White test points C1 1 C2 C3 C4 C5 1 1 1 1 DESCRIPTION DESIGNATION QTY DESCRIPTION C10 1 0.022FF Q10%, 630V film capacitor Panasonic ECQE6223KF 2200pF Q20%, 6.3kV ceramic capacitor Murata DECE33J222ZC4B C11 1 47000pF Q10%, 50V X7R ceramic capacitor (0805) Murata GRM21BR71H473K 4.7FF Q10%, 16V X7R ceramic capacitor (0805) Murata GRM21BR71C475K C12 1 0.1FF Q10%, 400V film capacitor Panasonic ECQE4104KF 10FF Q20%, 25V X7R ceramic capacitor (1210) TDK C3225X7R1E106M C13 1 0.22FF Q10%, 400V film capacitor Panasonic ECQE4224kF 0.1FF Q10%, 25V X7R ceramic capacitor (0603) Murata GRM188R71E104K C14 1 0.01FF Q10%, 25V X7R ceramic capacitor (0603) TDK C1608X7R1E103K 0.033FF Q10%, 25V X7R ceramic capacitor (0603) TDK C1608X7R1E333K C15 1 1000pF Q5%, 250V C0G ceramic capacitor (0805) TDK C2012C0G2E102J C16 0 Not installed, ceramic capacitor (0603) C6 1 4.7FF Q20%, 50V X7R ceramic capacitor (1210) TDK C3225X7R1H475M C7 1 1FF Q10%, 50V X7R ceramic capacitor (0805) Murata GRM21BR71H105KA C17 1 33pF Q5%, 50V C0G ceramic capacitor (0603) TDK C1608C0G1H330J C8, C9 2 470FF Q20%, 35V electrolytic capacitors (10mm x 16mm) Rubycon 35ZLH470M10x16 C18 1 22pF Q5%, 50V C0G ceramic capacitor (0603) TDK C1608C0G1H220J __________________________________________________________________ Maxim Integrated Products  1 For pricing, delivery, and ordering information, please contact Maxim Direct at 1-888-629-4642, or visit Maxim’s website at www.maxim-ic.com. MAX16841 Evaluation Kit Evaluates: MAX16841 Component List (continued) DESIGNATION QTY D1 1 DESCRIPTION 600V, 1A bridge rectifier (DFS) Vishay DF06S-E3/45 1 100V, 3A Schottky diode (SMB) Comchip CDBB3100-G 5 75V, 150mA diodes (SOD323F) Fairchild 1N4148WS D4, D6 2 400V, 1A rectifier diodes (SMA) Comchip CGRA4004-G D5 1 150V, 3W zener diode (SMB) ON Semi 1SMB5953BT3G D8 1 15V, 500mW zener diode (SOD123) Fairchild MMSZ5245B D2 D3, D7, D9, D12, D13 D10 1 4.8V, 150mW zener diode (SOT523) Diodes Inc. BZX84C5V1T DESIGNATION QTY DESCRIPTION R3, R4 2 549kI Q1%, 1/4W resistors (1206) R5 1 100I Q5% resistor (0805) R6, R25 2 1kI Q5%, 1/2W resistors (1210) R7, R8 2 2.1kI Q1% resistors (0805) R9 1 75kI Q1%, 1/2W resistor (1210) R10, R11 2 100kI Q1%, 1/4W resistors (1206) R12 1 33I Q5%, 1/2W resistor (1206) Vishay CRCW120633R0JNEAHP R13 2 1.24MI Q1% resistors (0603) R14 1 22I Q5% resistor (0805) R15, R16 2 604kI Q1% resistors (1206) R17 1 73.2kI Q1%, 1/4W resistor (0603) 1 300I Q5%, 1W resistor Panasonic-ECG ERG-1SJ301A D11 1 600V, 1A rectifier(SMB) Vishay MURS160-E3/52T R18 F1 1 250V AC, 1.25A fuse Bel Fuse Inc RST 1.25 R19 1 32.4kI Q1% resistor (0603) R20 1 20.5kI Q1% resistor (0603) 3 1000FH inductors Coilcraft LPS6235-105ML R21, R26 2 12.1kI Q1% resistors (0603) R22 1 68.1kI Q1% resistor (0805) 1 600V, 2.4A n-channel MOSFET (DPAK) STMicroelectronics STD3NK60ZT4 R23 1 430V transient/surge absorber Panasonic ERZV10D431 R24 1 0I Q5% resistor (0603) R27, R28 2 332kI Q1%, 1/4W resistors (1206) R29 1 78.7kI Q1% resistor (0603) R30 1 22kI Q5% resistor (0603) R31 1 150kI Q5% resistor (0603) 1 350mA, 1.17:6.84:4.19:1 transformer Würth 750815148 L1, L2, L3 N1 N2, N4 Q1 2 1 400V n-channel MOSFETs (SOT223) Fairchild FQT1N60C 35V, 50mA npn dual transistor (SOT363) Central Semi CMKT5088 1 600V, 800mA thyristor (SOT223) ON Semi MCR08MT1G T1 R1 1 3I Q1%, 1/2W resistor (1206) Susumu RL1632R-3R00-F U1 1 Dimmable offline LED lamps controller (8 SO) Maxim MAX16841ASA+ R2 1 150I Q5%, 3/4W resistor (1812) Panasonic-ECG ERJ-S12J151 — 1 PCB: MAX16841 EVALUATION KIT Q2 __________________________________________________________________ Maxim Integrated Products  2 MAX16841 Evaluation Kit Evaluates: MAX16841 Component Suppliers SUPPLIER PHONE WEBSITE Bel Fuse Inc. 201-432-0463 www.belfuse.com Central Semiconductor Corp. 631-435-1110 www.centralsemi.com Coilcraft, Inc. 847-639-6400 www.coilcraft.com Diodes Incorporated 805-446-4800 www.diodes.com Fairchild Semiconductor 888-522-5372 www.fairchildsemi.com Murata Electronics North America, Inc. 770-436-1300 www.murata-northamerica.com ON Semiconductor 602-244-6600 www.onsemi.com Panasonic Corp. 800-344-2112 www.panasonic.com Rubycon Corp. 408-467-3864 www.rubycon.com Susumu International USA 208-328-0307 www.susumu-usa.com TDK Corp. 847-803-6100 www.component.tdk.com Vishay 402-563-6866 www.vishay.com Würth Electronik GmbH & Co. KG 201-785-8800 www.we-online.com Note: Indicate you are using the MAX16841 when contacting these component suppliers. Quick Start • MAX16841 EV kit Required Equipment • 85V to 264V AC source • 6 to 8 series-connected LED strings rated no less than 500mA • Current probe to measure the LED current (the LED should be illuminated) Procedures The EV kit is fully assembled and tested. Follow the steps below to verify board operation. Caution: Do not turn on the power supply until all connections are completed. 1) Connect the AC source to the AC1 and AC2 test points. 2) Connect the LED string anode and cathode to the LED+ and LED- test points, respectively. 3) Clip the current probe across the LED+ wire to measure the LED current. 4) Enable the power supply. 5) Measure the LED current using the current probe. Detailed Description of Hardware The MAX16841 EV kit demonstrates the MAX16841 LED driver IC. The device is an average current-mode- control HB LED driver IC for buck and flyback topologies in offline LED lamp applications. The IC uses a proprietary input current-control scheme to achieve power-factor correction. The IC’s LED driver uses constant-frequency, aver- age current-mode control to control the duty cycle of the external switching MOSFET (N1). The IC is available in an 8-pin SO package. The EV kit circuit is configured in a flyback topology and provides up to 10W of output power for a string of 8 series LEDs connected at the LED+ and LED- test points. The converter switching frequency is set at 70kHz. The EV kit circuit operates from an AC supply voltage of 90VRMS to 265VRMS. The EV kit is designed on a proven 2oz copper, two-layer small PCB footprint design. The EV kit is optimized for operation in the 180VRMS to 265VRMS range. The IC uses average current-mode control, with the circuit configured such that the average current flowing into the current-sense resistor (R1) on a cycle-by-cycle (switching frequency) basis is set by the voltage on the REFI pin. The average current per switching cycle flowing into R1 is as follows: V - 0.1V I av = REFI 5 × R1 where VREFI is in volts, R1 is in ohms, and Iav is in amps. Circuit components L1, L2, L3, and C1 provide EMI filtering. During the turn-on instant of the triac dimmer, there would be significant ringing due to high inrush current to charge the input capacitor, C3. The ringing can cause the line current to fall to zero and turn off the dimmer. Components R2, R6, and C4 function as a damper and help to limit the inrush current and ringing. Resistor R2 is bypassed by Q1 after approximately 55Fs of dimming instant, thereby reducing power dissipation in R2 and improving efficiency. Diode D4 provides fast discharge of C2 during off instant of the dimmer. __________________________________________________________________ Maxim Integrated Products  3 MAX16841 Evaluation Kit Evaluates: MAX16841 Capacitor C3 provides a path for the input switchingfrequency currents for the flyback converter. Maximum value of this capacitor is limited by the input power-factor requirement. The greater the value of C3, the lower the input power factor. Electrolytic capacitors C8 and C9 filter the double-line frequency ripple in the LED current. During startup, bias for the IC comes from the linear regulator circuit formed by N2, R10, R11, and D8. During running condition, bias comes from the auxiliary winding of the flyback transformer (T1). Resistors R15, R16, and R17 program the switching threshold of the flyback converter. The rising threshold is set at 22V input voltage. When the line voltage is at an instant below VTH falling threshold, DIMOUT drives MOSFET N4 on and resistor R18 connects across the diode-bridge positive and GND. This load ensures that there is a closed-circuit path for the timing circuit of the triac in the external dimmer. The flyback converter starts switching again when the line voltage is at an instant above the VTH rising threshold. At the same time, DIMOUT goes low and the resistor is disconnected. Diode D6 blocks capacitors C3 and C4 to discharge through R18 during the off-time of dimming. Circuit components R27, R28, R29, D13, R13, C6, Q1, R21, and R26 are used to set the reference for the input current. Transistor Q1 is a pair of matched transistors. The voltage information on C6 is used to control the current in the current-mirror circuit formed by R13, R21, R26, and Q1. The current flowing into R13 is approximately proportional to the voltage across C6 and gets reflected on collector Q1A and sinks the same amount of current from collector Q1B as that flows into R13. The IC has a 50FA current source at the REFI pin. The current flowing into R19 sets the input current or the average current flowing into R1. The circuit tries to keep the input power over the line voltage almost constant. Circuit components R30, C11, D10, D12, and R31 affect the input current reference during dimming and a wide dimming range is accomplished. During an open-LED condition, the output voltage increases and this increase in voltage is reflected on the auxiliary winding side; therefore, the IC’s IN voltage increases. Once IN voltage exceeds 22.5V (typ), switching stops and the energy transfer from primary to secondary side is stopped. Switching restarts wehn IN goes below 22V (typ). EV Kit Dimming Waveforms and Performance Using 8 LEDs The EV kit was tested with 8 LEDs for dimmer compatibility. Table 1 list the dimmers tested using the EV kit. Table 1. Recommended Dimmers Tested on EV Kit DIMMER Busch-Jaeger 6513-102 Busch-Jaeger 9250 Busch-Jaeger GER 2247 Busch 2250 Busch 6519 Berker 2875 Berker 2874 Berker 2873 Merten 5724 Berker 2885 Berker 2875 Lutron GLS09-C02889 ABB STD50-3 Clipsal 32E450LM Clipsal 32E450UDM Clipsal 32E450TM __________________________________________________________________ Maxim Integrated Products  4 MAX16841 Evaluation Kit Evaluates: MAX16841 Figures 1–6 depict waveforms when the EV kit is powered at different input voltages with 8 LEDs connected at LED+ and LED-. N1 DRAIN VOLTAGE (100V/div) INPUT VOLTAGE (100V/div) INPUT CURRENT (100mA/div) VCS (1V/div) 4ms 4µs Figure 1. Input Voltage and Current at 90V Input Figure 4. Switching Waveforms at 230V Input LED CURRENT INPUT VOLTAGE (200V/div) LED CURRENT (200mA/div) LED VOLTAGE LED VOLTAGE (5V/div) INPUT CURRENT (100mA/div) WAVEFORM INTENSITY: 23% 4ms/div 4ms Figure 2. Input Voltage and Current at 230V Input Figure 5. LED Voltage and Current at 230V Input LED VOLTAGE (10V/div) INPUT VOLTAGE (200V/div) INPUT CURRENT (100mA/div) 4ms Figure 3. Input Voltage and Current at 265V Input INPUT CURRENT (200mA/div) 20ms/div Figure 6. LED Voltage and Input Current During Startup __________________________________________________________________ Maxim Integrated Products  5 MAX16841 Evaluation Kit Evaluates: MAX16841 Figures 7, 8, and 9 depict the EV kit dimming performance current waveforms using the Busch 2250 (leading-edge) dimmer. Figures 10, 11, and 12 depict the EV kit dimming performance waveforms using the Busch 6519 (trailing-edge) dimmer. INPUT CURRENT (100mA/div) INPUT CURRENT (100mA/div) LED CURRENT (200mA/div) LED CURRENT (200mA/div) 10ms/div 10ms/div Figure 7. Dimmer At 100% Dimming Using Busch 2250 Figure 10. Dimmer at 100% Dimming Using Busch 6519 INPUT CURRENT (100mA/div) INPUT CURRENT (100mA/div) LED CURRENT (200mA/div) LED CURRENT (200mA/div) 10ms/div 10ms/div Figure 8. Dimmer at 50% Dimming Using Busch 2250 Figure 11. Dimmer at 50% Dimming Using Busch 6519 INPUT CURRENT (100mA/div) INPUT CURRENT (100mA/div) LED CURRENT (20mA/div) 10ms/div Figure 9. Dimmer at Very Low Dimming Using Busch 2250 LED CURRENT (200mA/div) 10ms/div Figure 12. Dimmer at Very Low Dimming Using Busch 6519 __________________________________________________________________ Maxim Integrated Products  6 MAX16841 Evaluation Kit Evaluates: MAX16841 Figures 13, 14, and 15 depict the EV kit dimming performance waveforms using the ABB STD 50-3 dimmer. Table 2 lists the performance results of the EV kit with 8 series LEDs connected at the LED+ and LED- PCB pads. INPUT CURRENT (100mA/div) INPUT CURRENT (100mA/div) LED CURRENT (200mA/div) LED CURRENT (200mA/div) 10ms/div 10ms/div Figure 13. Dimmer at 100% Dimming Using ABB STD50-3 Figure 15. Dimmer at Very Low Dimming Using ABB STD50-3 90 80 70 EFFICIENCY (%) INPUT CURRENT (100mA/div) 60 50 40 30 LED CURRENT (200mA/div) 20 EFFICIENCY (%) 10 90 10ms/div 140 190 240 290 INPUT VOLTAGE (V AC) Figure 14. Dimmer at 50% Dimming Using ABB STD50-3 Figure 16. Efficiency vs. Line Voltage Table 2. Performance Data with 8 Series LEDs FREQUENCY (Hz) VIN (V) PIN (W) ILED (mA) VLED (V) POUT (W) EFFICIENCY (%) POWER FACTOR 60 90 6.84 248 22.6 60 110 8.03 291 22.8 5.61 82 0.948 6.68 83.1 60 120 8.57 312 0.94 22.9 7.17 83.6 0.935 60 130 9.08 50 185 11.05 329 23 7.58 83.4 0.93 398 23.3 9.28 83.9 0.895 50 200 50 215 11.42 410 23.3 9.6 84 0.883 11.69 419 23.3 9.77 83.5 0.87 50 50 230 11.9 422 23.3 9.87 82.9 0.854 245 12 424 23.3 9.89 82.4 50 0.835 265 11.97 419 23.3 9.78 81.7 0.809 __________________________________________________________________ Maxim Integrated Products  7 MAX16841 Evaluation Kit Evaluates: MAX16841 EMI Testing A precompliance-conducted emissions test was done with EN55015 B limits with the results viewable in Figures 17a, 17b, and 17c. Harmonic Data The EV kit passes IEC 61000-3-2 Class D limits. Figure 18 shows the current harmonics profile at 230V, 50Hz input, and 8 LEDs at output. Configuring the EV Kit for Nondimming Applications The EV kit can be modified for nondimming applications. To configure the EV kit for nondimming applications, see Figure 24 and perform the following steps: • Remove all components shown in blocks 1–4 (i.e., C2, C4, C11; D4, D10, D12; R3–R6, R18, R25, R30, R31; N4, Q2) dBµV 1 PKZ CLRWB 2 AV CLRWB 120 100 C15_QPL 1 MHz 10 MHz SGL 80 TDS 60 40 6DB AC 20 0 2 9kHz 30MHz Figure 17a. Conductance Disturbance Test Data (8 LEDs) • Short components R2 and D6 Figure 17b. EMI Test Data (Part 1) __________________________________________________________________ Maxim Integrated Products  8 MAX16841 Evaluation Kit Evaluates: MAX16841 Figure 17c. EMI Test Data (Part 2) CURRENT HARMONICS 45 IEC61000-3-2 CLASS D 40 EV KIT 35 30 25 20 15 10 5 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Figure 18. Input Line Current Harmonics __________________________________________________________________ Maxim Integrated Products  9 MAX16841 Evaluation Kit Evaluates: MAX16841 Figures 19–23 depict the EV kit performance when modified for nondimming operations. Table 3 shows the performance data when the EV kit is configured for nondimming applications. Figure 22 illustrates the EV kit efficiency performance during nondimming operations. Harmonic Data Results The EV kit passes IEC 61000-3-2 Class D limits (see Figure 23). The harmonic data was recorded without the dimming circuit. INPUT VOLTAGE (100V/div) INPUT VOLTAGE (200V/div) LED CURRENT (100mA/div) LED CURRENT (100mA/div) 10ms 10ms Figure 19. Waveform at 90V, 60Hz Input (Nondimming) Figure 21. Waveform at 265V, 50Hz Input (Nondimming) 100 90 EFFICIENCY (%) 80 INPUT VOLTAGE (200V/div) LED CURRENT (100mA/div) 70 60 50 40 30 20 EFFICIENCY (%) 10 90 10ms 140 190 240 290 INPUT VOLTAGE (V AC) Figure 20. Waveform at 230V, 50Hz Input (Nondimming) Figure 22. Efficiency vs. Line Voltage (Nondimming) Table 3. EV Kit Performance without Dimming FREQUENCY (Hz) VIN (V) PIN (W) ILED (mA) VLED (V) POUT (W) EFFICIENCY (%) POWER FACTOR 60 90 6.86 251 23.2 5.84 85.1 0.956 60 110 8.0 296 23.2 6.89 86.1 0.952 60 120 8.54 316 23.3 7.39 86.5 0.949 60 130 8.99 333 23.3 7.78 86.5 0.945 50 185 11.06 402 23.3 9.43 85.3 0.935 50 200 11.36 414 23.4 9.69 85.3 0.934 50 215 11.64 421 23.4 9.87 84.8 0.931 50 230 11.8 427 23.4 9.98 84.6 0.926 50 245 11.87 425 23.4 9.96 83.9 0.92 50 265 11.82 422 23.4 9.88 83.6 0.912 _________________________________________________________________ Maxim Integrated Products  10 MAX16841 Evaluation Kit Evaluates: MAX16841 CURRENT HARMONICS 45 IEC61000-3-2 CLASS D 40 EV KIT 35 30 25 20 15 10 5 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Figure 23. Input Line Current-Harmonics Profile at 230V, 50Hz Input, and 8 LEDs at Output _________________________________________________________________ Maxim Integrated Products  11 MAX16841 Evaluation Kit Evaluates: MAX16841 Figure 24. MAX16841 Circuit for Nondimming Applications _________________________________________________________________ Maxim Integrated Products  12 MAX16841 Evaluation Kit Evaluates: MAX16841 Figure 25. MAX16841 EV Kit Schematic _________________________________________________________________ Maxim Integrated Products  13 MAX16841 Evaluation Kit Evaluates: MAX16841 1.0” Figure 26. MAX16841 EV Kit Component Placement Guide— Component Side 1.0” Figure 27. MAX16841 EV Kit PCB Layout—Component Side 1.0” Figure 28. MAX16841 EV Kit Component Placement Guide— Solder Side 1.0” Figure 29. MAX16841 EV Kit PCB Layout—Solder Side _________________________________________________________________ Maxim Integrated Products  14 MAX16841 Evaluation Kit Evaluates: MAX16841 Ordering Information PART TYPE MAX16841EVKIT# EV Kit #Denotes RoHS compliant. _________________________________________________________________ Maxim Integrated Products  15 MAX16841 Evaluation Kit Evaluates: MAX16841 Revision History REVISION NUMBER REVISION DATE 0 2/12 DESCRIPTION Initial release PAGES CHANGED — Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are implied. Maxim reserves the right to change the circuitry and specifications without notice at any time. Maxim Integrated Products, 120 San Gabriel Drive, Sunnyvale, CA 94086 408-737-7600 ©  2012 Maxim Integrated Products 16 Maxim is a registered trademark of Maxim Integrated Products, Inc.