EV4078-S-00A

EV4078-S-00A 90VAC/60Hz to 265VAC/50Hz, 50V/600mA, 30W Single-Stage Flyback Converter with PFC Evalutation Board DESCRIPTION FEATURES The EV4078-S-00A evaluation board is designed for smart LED lighting and front-end pre-regulator applications with the MP4078.   The MP4078 is a single-stage offline controller with active power factor correction (PFC) for constant output voltage applications. The MP4078 implements primary-side regulation (PSR) control without any secondary feedback circuit or optocoupler for flyback applications. The EV4078-S-00A features a universal input voltage (90VAC to 265VAC) with a 50V, 600mA constant voltage output and 30W rated power. The EV4078-S-00A has ultra-low no-load power consumption and good efficiency under full-load conditions. The EV4078-S-00A can meet IEC61000-3-2 Class C standards, and conducted emission (CE) EN55022 standards. The device features integrated protections, such as brownout functionality, over-current protection (OCP), output over-voltage protection (OVP), output short circuit protection, and overtemperature protection (OTP). ELECTRICAL SPECIFICATIONS Parameter Symbol Value Units Input voltage Output voltage Output current VIN VOUT IOUT 90 to 265 50 600 VAC V mA Output power POUT 30 W          Universal Input Voltage (90VAC to 265VAC) Ultra-Low No-Load Power Consumption, Typically 40mW with 230VAC Power Factor > 0.95 and THD < 10% with 230VAC, Full Load Primary-Side Control Maximum Operating Frequency Limitation (65kHz) Cycle-by-Cycle Peak Current Limitation Brownout Function Over-Current Protection (OCP) Output Short-Circuit Protection (SCP) Output Over-Voltage Protection (OVP) Available in a 98mmx38.5mmx25mm (Except Pins) Package APPLICATIONS   Smart LED Lighting Front-End Pre-Regulator All MPS parts are lead-free, halogen-free, and adhere to the RoHS directive. For MPS green status, please visit the MPS website under Quality Assurance. “MPS”, the MPS logo, and “Simple, Easy Solutions” are trademarks of Monolithic Power Systems, Inc. or its subsidiaries. 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. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 1 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EV4078-S-00A EVALUATION BOARD Top View Bottom View (LxWxH) 98mmx38.5mmx25mm (Except Pins) Board Number MPS IC Number EV4078-S-00A MP4078GS EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 2 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD QUICK START GUIDE 1. Preset the power supply (VIN) between 90VAC and 265VAC. 2. Turn the power supply off. 3. Connect the power supply terminals to their corresponding ports: a. Line terminal: L port b. Neutral terminal: N port 4. Connect the terminals of the load to the corresponding output ports: a. Positive (+): VO+ b. Negative (-): VO5. Turn the power supply on after making the connections. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 3 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EVALUATION BOARD SCHEMATIC Figure 1: Evaluation Board Schematic EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 4 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EV4078-S-00A BILL OF MATERIALS Qty Ref Value Description Package Manufacturer Manufacturer P/N 1 BR1 DF06S Bridge rectifier, 600V, 1A SMD Fairchild DF06S 2 C1, C2 220nF Capacitor, CBB, 450V DIP Carli 1 C3 220pF 1206 Murata 2 C4, C7 1μF 1206 Murata 2 C5, C6 330μF DIP Jianghai CD263-63V330 C8, C13, C15 NS 1 C9 47μF DIP Jianghai CD286-25V47 1 C10 2.2μF 0603 Murata 1 C11 0.1μF 0603 Murata 1 C12 2.2nF 1206 Murata 1 C14 22pF 0603 Murata 1 CX1 220nF DIP Carli 1 CY1 2.2nF DIP Hongke JN12E222MY02N 1 D1 MUR860 TO-220 ON Semiconductors MUR860 1 D2, D6, D7 D3 BZT52C24 Zener diode, 24V Rectifier, 1000V, 1A, DIP SOD-123 Diodes BZT52C24 1 D4 1N4007 DIP MIC 1N4007 1 D5 SIML Diode, 1000V, 1A SOD-123 1 F1 SS-5-1A 1 Ceramic capacitor, 1000V, U2J Ceramic capacitor, 100V, X7R Electrolytic capacitor, 63V Electrolytic capacitor, 25V Ceramic capacitor, 10V, X7R Ceramic capacitor, 50V, X7R Ceramic capacitor, 630V, U2J Ceramic capacitor, 50V, X7R X-capacitor, 275V, 10% Y-capacitor, 4000V, 20% Ultra-fast rectifier, 600V, 8A DIP HS1 Heatsink for Q1 TO-220 1 JW1 Jumper wire, 9mm 1 L1 3.3mH 1 LCM1 30mH 1 Q1 SMK0870 1 1 4 GRM188R71A225KE 15D GRM188R71H104KA 93D GRM31BR72J222KW 01L GRM1885C1H220JA 01D PX224K3ID49L270D9 R NS Fuse, 1A, 250V R1, R8, R13, R18 R2 R3 R4, R5, R6, R10 TF224K2Y109L270D 9R GRM31A7U3A221JW 31D GRM31CR72A105KA 01L Inductor, 3.3mH, 0.5A CM chock, 30mH, ESR = 0.4Ω N-channel MOSFET, 700V, 0.9Ω/8A Taiwan Semiconductor Cooper Bussmann S1ML SS-5-1A DIP EmeiGroup DR10X16P2M3.3-00 DIP EmeiGroup TP4M30-02 TO-220F AUK SMK0870F NS 270Ω 249kΩ Film resistor, 1% Film resistor, 1% 1206 1206 Yageo Yageo RC1206FR-07270RL RC1206FR-07249KL 2MΩ Film resistor, 5% 1206 Yageo RC1206JR-072ML EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 5 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EV4078-S-00A BILL OF MATERIALS (continued) Qty Ref Value 1 1 1 1 1 1 0Ω 200mΩ 18kΩ 2.49kΩ 3.83kΩ 100kΩ 1 1 R7 R9 R11 R12 R14 R15 R16, R17 RT1 T1 1 U1 MP4078 1 VAR1 VO+, VO-, L, N 431KD10 2 4 20Ω 2Ω 230µH Description Package Manufacturer Manufacturer P/N resistor, 5% resistor, 1% resistor, 1% resistor, 1% resistor, 1% resistor, 1% 1206 1206 1206 0603 0603 1206 Yageo Yageo Yageo Yageo Yageo Yageo RC1206JR-070RL RL1206FR-070R2L RC1206FR-0718KL RC0603FR-072K49L RC0603FR-073K83L RC1206FR-07100KL Film resistor, 1% 1206 Yageo RC1206FR-0720RL Thermal resistor Transformer, EF25 PSR PFC controller, CV Metal oxide varistor DIP DIP Semitec EmeiGroup (1) 2D2-10 FX0563 SOIC-8 MPS MP4078GS R2 DIP Thinking TVR10431KS42Y Film Film Film Film Film Film 1mm contact pin DIP Notes: 1) To complete an EmeiGroup transformer sample request, please login at the following website: www.emeigroup.com. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 6 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VIN = 230VAC, VOUT = 50V, IOUT = 600mA, TA = 25°C, unless otherwise noted. Load Regulation 53.00 0.88 52.50 0.86 52.00 VOUT (V) EFFICIENCY (%) Efficiency 0.9 0.84 0.82 0.8 100% Load 50% Load 10% Load 0.78 51.50 51.00 50.50 50.00 0.76 49.00 90 120 180 VIN (VAC) 220 265 0% 75% 100% 1 0.95 50 0.9 0.85 PF NO LOAD CONSUMPTION (mW) 25% 50% OUTPUT LOAD Power Factor vs. VIN No-Load Consumption 60 40 0.8 0.75 30 0.7 Full load Half load 0.65 20 90 120 220 265 VIN (VAC) 0.6 90 120 180 VIN (VAC) 220 265 Conducted Emissions THD vs. VIN THD (%) 115VAC 230VAC 49.50 Two-wire input, N line 20 18 16 14 12 10 8 6 4 2 0 Full load Half load 90 120 180 220 265 VIN (VAC) EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 7 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN = 230VAC, VOUT = 50V, IOUT = 600mA, TA = 25°C, unless otherwise noted. Conducted Emission Two-wire input, L line EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 8 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN = 230VAC, VOUT = 50V, IOUT = 600mA, TA = 25°C, unless otherwise noted. Input Voltage and Current Input Voltage and Current 115VAC, full load 230VAC, full load CH1: VAC 200V/div. CH1: VAC 200V/div. CH2: COMP 1V/div. CH2: COMP 1V/div. CH3: IAC CH3: IAC 500mA/div. 500mA/div. CH4: IPRI 2A/div. CH4: IPRI 2A/div. 4ms/div. 4ms/div. Input Voltage and Current Input Voltage and Current 115VAC, half-load 230VAC, half-load CH1: VAC 200V/div. CH1: VAC 200V/div. CH2: COMP 1V/div. CH2: COMP 1V/div. CH3: IAC 500mA/div. CH3: IAC 500mA/div. CH4: IPRI 2A/div. CH4: IPRI 2V/div. 4ms/div. 4ms/div. Steady State Steady State 115VAC, full load 230VAC, full load CH1: VZCD 2V/div. CH1: VZCD 2V/div. CH2: COMP 1V/div. CH2: COMP 1V/div. CH4: IPRI 1A/div. CH4: IPRI 1A/div. 10µs/div. 10µs/div. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 9 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN = 230VAC, VOUT = 50V, IOUT = 600mA, TA = 25°C, unless otherwise noted. Start-Up Start-Up 115VAC, full load 230VAC, full load CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH3: COMP 2V/div. CH4: IPRI 2A/div. CH3: COMP 2V/div. CH4: IPRI 2A/div. 40ms/div. 40ms/div. Start-Up Start-Up 115VAC, no load 230VAC, no load CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH3: COMP 2V/div. CH4: IPRI 2A/div. CH3: COMP 2V/div CH4: IPRI 2A/div. 40ms/div. 40ms/div. Shutdown Shutdown 115VAC, full load 230VAC, full load CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH3: COMP 2V/div. CH4: IPRI 2A/div. CH3: COMP 2V/div. CH4: IPRI 2A/div. 40ms/div. 40ms/div. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 10 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN = 230VAC, VOUT = 50V, IOUT = 600mA, TA = 25°C, unless otherwise noted. SCP Short then Start 230VAC, full load 230VAC, full load CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH1: VOUT 20V/div. CH2: VZCD 2V/div. CH3: COMP 2V/div. CH4: VCC 10V/div. CH3: COMP 2V/div. CH4: VCC 10V/div. 400ms/div. 400ms/div. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 11 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD PCB LAYOUT (SINGLE LAYER) Figure 2: Top Layer Figure 3: Bottom Layer EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 12 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD TRANSFORMER SPECIFICATIONS Electrical Diagram 2 N1 10 1 N3 4 9 N2 5 = Winding Start = Teflon Tube Primary Secondary Figure 4: Transformer Electrical Diagram 1. All winding terminals should be added with a Teflon tube. 2. Wrap one copper foil closed around the core. Wrap a second copper foil closed around the windings. Then solder the copper foil to pin 5 (connected to primary ground) using 0.2mm wire (see Figure 5). Copper Foil 2 7mm Copper Foil 1 7mm Figure 5: Copper Foil 1 and Copper Foil 2 3. Cut pin 3 short for assembly. 4. Remove pin 6, pin 7, and pin 8. 5. Varnish the transformer. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 13 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD Winding Diagram 1 N1-2: 0.10Mm x 20 (Litz) x 1P x 27Ts 3 9 N3: 0.50mm (T.I.W) x 1P x 38Ts 10 5 4 N2: 0.20mm x 1P x 11Ts 3 N1-1: 0.10Mm x 20 (Litz) x 1P x 27Ts 2 Primary Side Secondary Side Figure 5: Winding Diagram Winding Order Winding No. Tape Layer No. Start and End Magnet Wire φ (mm) Turns N1-1 N2 N3 N1-2 1 1 1 1 2 to 3 4 to 5 10 to 9 3 to 1 0.10mmx20 Litz 0.20mmx1 0.50mmx1 T.I.W 0.10mmx20 Litz 27 11 38 27 Electrical Specifications No. Item Measuring Terminals Value Test Conditions 1 2 3 Primary inductance Leakage inductance Turn ratio Electrical strength 230μH±5% 10μH (max) 54:11:38 AC: 3500V AC: 500V AC: 3500V 60kHz 60kHz 4 LM (1-2) LM_LKG (1-2), short N3 (9-10) N1:N2:N3 Primary side to secondary side Primary side to core Secondary side to core 1s, 1mA Materials Item 1 2 3 4 5 6 7 8 9 10 Description Core: EF25/7, UI = 2300; AL = 1950nH/N2 ±25%, ungapped Bobbin: EF25 5 + 5 pin, 1 sec, remove pins 6, 7, and 8, PIN_L = 4.0mm ± 0.2mm, UL94V-0 Wire: Φ = 0.20mm, 2UEW, class F Litz wire: Φ = 0.10mmx20P, 2UEW, class F T.I.W wire: Φ = 0.50mm, class B, yellow Copper foil: 0.025mmx7mm Tape: 16.0mmx0.063mmx66m and 7.0mmx0.063mmx66m Tube: AWG20#, clear and AWG30#, clear Varnish: John C Dolph Co, BC-346A Solder: Yik Shing Tat, Sn99.3/Cu0.7 EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 14 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD CIRCUIT DESCRIPTION The EV4078-S-00A is designed for smart LED lighting and front-end pre-regulator applications with a 50V, 600mA constant voltage output, and 30W rated power. D5, R7, and C9 create a biased voltage supply for VCC through the auxiliary winding. The fuse (F1) protects the system from component failure due to excessive short events. R11 and R14 form a resistor divider to sense the plateau voltage of the output voltage feedback’s auxiliary winding. The metal oxide varistor (VAR1) is used for surge tests. C11 is paralleled with C9 to act as a bypass capacitor for U1’s power supply. C14 decouples the sensed voltage noise. To meet EN55022 standards, the X-capacitor (CX1), common chock (CM1), and differential mode filter (C1, L1, and C2) are implemented to filter EMI noise. R10 and C12 create a compensation network for the internal error amplifier. The diode bridge rectifier (BR1) rectifies the input AC voltage. R2 and C3 form an RC snubber to reduce the voltage spike on D1 during switching. An RCD snubber (R16, R17, D4, R15, and C12) suppresses the voltage spike on the main MOSFET (Q1) during switching. The electrolytic capacitors (C5 and C6) stabilize the output voltage and satisfy the output voltage ripple requirements. Place R4, R5, R6, and R10 in series to form a resistor divider with the internal pull-down resistor of the controller (U1); this resistor divider senses the input voltage. The external resistor string can charge the voltage on the GATE pin during start-up. C4 is placed near the output ports to decouple the voltage noise at the output. C7 stabilizes the voltage on the GATE pin. The Zener diode (D3) between the D pin and the S pin of U1 clamp the voltages on D and S, which limits the main MOSFET’s drain-source voltage. D1 is the secondary rectifier diode for the output. R3 is used as a dummy load to regulate the output voltage under no-load and extremely light-load conditions. The Y-capacitor (CY1) isolates the primary side and the secondary side of the circuit, which improves EMI performance. R9 is used as a current-sense resistor that monitors the primary peak current. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 15 EV4078-S-00A – 30W, SINGLE-STAGE CONVERTER WITH PFC EVAL BOARD Revision History Revision # 1.0 1.1 Revision Date 7/5/2019 9/4/2020 Description Initial Release Grammar and Formatting Updates Pages Updated All 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. EV4078-S-00A Rev. 1.1 www.MonolithicPower.com 9/9/2020 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2020 MPS. All Rights Reserved. 16