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EV4056-K-00A 198vac~265vac/50hz, 48v/340ma low cost, non-isolated with active pfc triac dimmable led driver evaluation board EV4056-K-00A rev.1.0 www.monolithicpower.com 1 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. the future of analog ic technology description the EV4056-K-00A evaluation board is designed to demonstrate the capabilities of mp4056. the mp4056 is a non-isolated, triac dimmable led controller with active pfc and excellent dimming performance. it works in boundary conduction mode for reducing the mosfet and diode switching losses. its adaptive dimmer type detection and phase-cut-based dimming control can achieve good dimmer compatibility and deep dimming range. the EV4056-K-00A is typically designed for driving a 16w triac dimmable led bulb with 48v typ , 340ma led load from 198vac to 265vac, 50hz. the EV4056-K-00A has a cost effective bom and excellent efficiency. it meets iec61547 surge immunity, iec61000-3-2 class c harmonics and en55015 conducted emi requirements. it has multi-protection function as over-voltage protection; winding short circuit protection; output short-circuit protection; zcd pin short protection; over- temperature protection etc. electrical specification parameter symbol value units input voltage v in 198 to 265 vac output voltage v out 48 v led current i led 340 ma output power p out 16.32 w efficiency (full load) >88 % power factor pf >0.86 thd thd <37 % features ? adaptive dimmer type detection and phase-cut-based dimming control ? good dimmer compatibility ? fast start-up without perceptible delay ? accurate line & load regulation ? high power factor ? high efficiency ? operates in boundary conduction mode ? cycle-by-cycle current limit ? winding short-circuit protection ? output over-voltage protection ? output short-circuit protection ? zcd pin short protection ? over-temperature protection applications ? solid state lighting ? industrial & commercial lighting ? residential lighting all mps parts are lead-free, halogen free, and adhere to the rohs directive. for mps green status, pl ease 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.
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 2 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. EV4056-K-00A evaluation board (l x w x h) 70.5mm x 26.5mm x 24mm board number mps ic number EV4056-K-00A mp4056gk evaluation board schematic 1 2 22nf/ 275v cx1 df06s 3 4 2 1 db1 2 1 1.8mh/ 0.35a l1 stth3r06s 1 2 d2 l n 1 2 330uf/63v c1 1 2 330uf/ 63v c2 30k/1206 r3 led+ led- gnd gnd gnd 1m/1%/ 0. 25w r7 2 1 4.7nf/ 50v c9 5. 1k/ 1206 r10 5. 1k/ 1206 r9 5.1k/1206 r1 200/2w r5 220nf/ 450v 1 2 c5 ssn1n45bta 2 3 1 q1 gnd 3.3k/1% r14 1.1/1%/ 1206 r16 1.2/ 1%/ 1206 r15 gnd gnd cef05n65 2 3 1 q2 48v/340ma 198-265vac 0.27mm*2*125ts lm=800uh 2 1 f1 tvr10431 rv1 gnd 250v/ 2a 450v/ 0.2a 100nf/ 400v 1 2 c3 650v/4.5a 600v/3a 1 2 22uf/50v c10 600v/1. 5a 2 1 2. 2uf/10v c8 2 1 1.8mh/ 0.35a l3 2 1 1. 8mh/ 0. 35a l2 330/ 2w r6 220/2w r2 2 1 470nf/ 25v c7 2 1 4 3 ee20 t1 22nf/50v c6 5. 6k/ 1% r11 1k/1% r12 4. 3k/ 1% r13 d5 1n4148ws d3 rlzte-1118d 16.82v/ 10ma 1m/ 1%/0.25w r4 d1 1n4148w d4 1n4148w 75v/ 0. 15a 75v/0. 15a 1nf/630v c4 0.16mm*26ts 51 r8 led+ mult 1 zcd 2 vcc 3 damp 4 dim 5 d 6 s 7 ntc 8 gnd 9 comp 10 u1 mp4056gk gnd figure 1?schematic
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 3 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. pcb layout (single-sided) figure 2?top layer figure 3?bottom layer
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 4 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. circuit description the EV4056-K-00A is configured in a single- stage buck-boost topology and gets a cost effective bom. it achieves high power factor and excellent triac dimming performance. f1, rv1, l2, l3, r9, r10, cx1 and db1 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. the diode rectifier db1 rectifies the input line voltage. l2, l3, r9, r10, cx1, l1, r1 and c3 form the input emi filter. small bulk cbb capacitor c3 is used for a low impedance path for the switching current. c5, r2 and r6 are used as a passive bleeder which helps keep the triac current above the minimum holding current after triac turns on. q1, c6, r5 associate with the control signal damp compose the active damping circuit to limit the inrush current caused by c3 at leading edge dimmer turn on. r7, r10, c9 provide sine wave reference for the current control loop. d4 and c10 are used to supply the power for mp4056. a 22 f electrolytic capacitor c10 is selected to maintain the supply voltage. at start- up, c10 is charged up through q1, d4 and the internal charging circuit, when the vcc voltage reaches vcc en , the internal charging circuit stops charging. then the power supply is charged by q1, d4 during the switching off time. r4, c7, d1 and d3 are used for the gate driver of the external mosfet q1. r8 is used to adjust the driver capability for better emi and small power loss. r11, r13 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 r11, r13. r12 is used to limit the current flow into zcd pin. d5 is used to clamp the negative voltage on zcd pin when switch on. r15, r16 are sensing resistors for current control. the value of r5 and r16 set the output led current. diode d2 is the output rectifying diode. the capacitors c1, c2 are the output filter. the resistor r3 is placed as a dummy load to consume the output power in open load condition. the capacitor c4 is used to help improve the high frequency emi performance.
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 5 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. EV4056-K-00A bill of materials qty ref value description package manufacturer manufactuer_p/n 2 c1,c2 330uf/63v electrolytic capacitor;63v dip jianghai cd263-63v330 1 c3 100nf/400v cbb;400v dip panasonic ecqe4104kf 1 c4 1nf/630v ceramic capacitor;630v;u2j 1206 murata grm31a7u2j102jw31d 1 c5 220nf/450v cbb;450v dip fala c222s224k31c000 1 c6 22nf/50v ceramic capacitor;50v;x7r 0603 murata grm188r71h223ka01d 1 c7 470nf/25v ceramic capacitor;25v;x7r 0603 tdk grm188r71e474ka12d 1 c8 2.2uf/10v ceramic capacitor;10v;x7r 0603 murata grm188r71a225ke15d 1 c9 4.7nf/50v ceramic capacitor;50v;x7r 0603 tdk grm188r71h472ka01d 1 c10 22uf/50v electrolytic capacitor;50v dip jianghai cd281l-50v22 1 cx1 22nf/275v x capacitor;275v;10% dip carli px223k3ic39l270d9r 2 d1,d4 1n4148w diode;75v;0.15a ; sod-123 diodes 1n4148w-7-f 1 d2 stth3r06s diode;600v;3a smc st stth3r06s 1 d3 rlzte-1118d zener diode;16.82v,10ma minimel f rohm rlzte-1118d 4 d5 1n4148ws diode;75v;0.15a; sod-323 diodes 1n4148ws-7-f 1 db1 df06s diode;600v;1.5a smd fairchild df06s 1 f1 ss-5-2a fuse;250v;2a dip cooper bussmann ss-5-2a 3 l1,l2, l3 1.8mh/0.35a inductor;1.8mh; 3.3 ohm;0.35a dip wurth 768772182 1 q1 ssn1n45bta n-channel mosfet;450v to-92 fairchild ssn1n45bta 1 q2 cef05n65 mosfet;650v;4.5a to-220f maxmega cef05n65 3 r1,r9, r10 5.1k ? film resistor;1% 1206 yageo rc1206fr-075k1l 2 r2 220 ? /2w resistor;5%;2w dip any 510 ohm/2w 1 r3 30k ? film resistor;1% 1206 yageo rc1206fr-0730kl 2 r4,r7 1m ? /0.25w resistor;1%;1/4w dip any 1m ? 2 r5 200 ? /2w resistor;5%;2w dip any 200 ? /2w 2 r6 330 ? /2w resistor;5%;2w dip any 330 ? /2w 1 r8 51 ? film resistor;1%; 0603 yageo rc0603fr-0751rl 1 r11 5.6k ? film resistor;1% 0603 yageo rc0603fr-075k6l 1 r12 1k ? film resistor;1%; 0603 yageo rc0603fr-071kl 1 r13 4.3k ? film resistor;1% 0603 yageo rc0603fr-074k3l 1 r14 3.3k ? film resistor;1% 0603 yageo rc0603fr-073k3l 1 r15 1.2 ? film resistor;1% 1206 yageo rc1206fr-071r2l 1 r16 1.1 ? film resistor;1% 1206 yageo rc1206fr-071r1l
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 6 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. EV4056-K-00A bill of materials (continued) qty ref value description package manufacturer manufactuer_p/n 1 rv1 tvr10431 mov dip tsk tvr10431ksy 1 t1 ef20 l=800uh; np:naux=125:26 dip emei fx0408 1 u1 mp4056 traic dimmable, offline led lighting controller msop10 mps mp4056gk-lf-z r3
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 7 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. transformer specification electrical diagram 2 3 4 125ts 0.27mm*2 26ts 0.15mm*1 ef20 winding start 1 n 1 n 2 figure 4?transformer electrical diagram winding diagram figure 5?winding diagram n 2 pin side pin side 3ts 2ts n 1 1t bobbin
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 8 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. winding order winding no. tape layer number start & end magnet wire (mm) turns 1 n 1 2 2 1 0.27mm * 2 125 n 2 3 4 3 0.15mm*1 26 electrical specifications electrical strength 60 second, 50hz, from windings to core. 1000vac inductance pins 2 - 1, all other windings open, measured at 50khz, 0.1 vrms 800uh5% materials item description 1 core: ef20, ui=250025%, acme p4 or equivalent 2 bobbin: ef20, 4+4pin, remove pin6,7 3 wire: 0.27mm, 0.15mm, 2uew, class f or equivalent 4 tape: 6.5mm(w)0.06mm(th) 5 varnish: john c. dolph co, bc-346a or equivalent 6 solder bar: chen nan: sn99.5/cu0.5 or equivalent
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 9 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. evb test results performance data efficiency, pf and thd f (hz) vin(v) pin(w) vo(v) io(ma) po(w) efficiency(%) pf thd(%) 198 18.44 47.00 346 16.26 88.19 0.910 37.00 210 18.47 47.00 347 16.31 88.30 0.905 36.70 220 18.48 47.00 347 16.31 88.25 0.900 36.40 230 18.51 47.00 347 16.31 88.11 0.894 35.70 240 18.53 47.00 348 16.36 88.27 0.887 35.30 250 18.57 47.00 348 16.36 88.08 0.880 34.80 260 18.61 47.00 349 16.40 88.14 0.872 34.30 50 265 18.62 47.00 349 16.40 88.09 0.868 34.10 dimming compatibility (no flicker with these 26 different dimmers) dimmer no. manufacturer part no. power stage dimming type imax (ma) imin (ma) 1 mika 433/4 60-400w leading 349.1 67 2 busch 2250u 600w leading 349.2 33 3 berker 283010 60-400w leading 348.6 43.1 4 jung 225 nv de 20-500w/va leading 348.7 26.7 5 berker 286610 20-500w leading 349 39.8 6 emc prop400u 40-400w leading 347.7 37.6 7 busch 2247u 500w/va leading 348.4 43.9 8 busch 2200.. 60-400w leading 348.1 49.6 9 jung 225 nv de 20-500w/va leading 349.4 43.7 10 jung 266 gde 60-600w leading 348.9 36.2 11 berker 2875 60-600w leading 348.9 31.7 12 berker 2819 60-400w leading 348.4 75 13 mika 433 60-300 leading 348.1 70 14 gira 0300 00/i01 60-400w leading 347.9 68 15 teller 40600rl 40-600w leading 347.7 37.6 16 lichtregler t46s 20~315w trailing 355 298 17 busch 6513 u-102 420w/va trailing 356.2 26.4 18 mika 433 hab 20-315w trailing 356.1 23.7
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 10 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. 19 mika eim-585 20-300w trailing 267.2 1.3 20 busch 6519u 550w/va trailing 355.6 25.8 21 jung 225 tde 20-525w trailing 354.7 21.9 22 siemens 5tc8 284 20-600w trailing 355.1 21.3 23 jung 254 udie 1 50-420w/va trailing 342.3 37 24 berker 286110 50-420w trailing 353.9 37.5 25 mika 433hab 20-315w trailing 333.1 25.5 26 lumeo eco t46.03 15-150w trailing 354.5 31.8 electric strength test 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 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) 500 230 l to n 90 pass -500 230 l to n 270 pass
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 11 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. thermal test (worst case with/without dimmer) without dimmer without dimmer leading edge dimmer with 50% turn on cycle trailing edge dimmer with 90% turn on phase diode d2: 60.8 transformer: 62.3 damping resistor r5: 84 mosfet q2: 74.2
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 12 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. evb test results performance waveforms are tested on the evaluation board. v in =230vac/50hz, 15leds in series, i led =340ma, v out =48v. s t output current (ma) efficiency vs. v in v in =(198-265)v ac /50hz, full load pf vs. v in v in =(198-265)v ac /50hz, full load pf line regulation v in =(198-265)v ac /50hz, full load v in (v) v in (v) v in (v) thd vs. v in v in =(198-265)v ac /50hz, full load v in (v) dimming curve v in =230v ac /50hz, full load, with different dimmers conducted emi, l-line v in =230v ac /50hz, rbw=9khz, mt=20ms 9khz 1 pk clrwr 2 av clrwr sgl tds 6db 30 mhz conducted emi, n-line v in =230v ac /50hz, rbw=9khz, mt=20ms 9khz 1 pk clrwr 2 av clrwr sgl tds 6db 30 mhz cdn test v in =230v ac /50hz, rbw=120khz, mt=1ms sgl tde 6db 1 pk clrwr 2 av clrwr 30 mhz 300 mhz -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 198 208 218 228 238 248 258 198 208 218 228 238 248 258 198 208 218 228 238 248 258 82.0 83.0 84.0 85.0 86.0 87.0 88.0 89.0 0.7 0.75 0.8 0.85 0.9 0.95 1 10 15 20 25 30 35 40 198 208 218 228 238 248 258 0 50 100 150 200 250 300 350 400 0 20 40 60 80 100 120 140 160 leading edge dimmer trailing edge dimmer 120 110 100 90 80 70 60 50 30 40 20 10 0 en55015q en55015a 100 khz 1 mhz 10 mhz en55015a 120 110 100 90 80 70 60 50 30 40 20 10 0 100 khz 1 mhz 10 mhz en55015q en55015a 120 110 100 90 80 70 60 50 30 40 20 10 0 100 mhz cdn_qp
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 13 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. evb test results (continued) performance waveforms are tested on the evaluation board. v in =230vac/50hz, 15leds in series, i led =340ma, v out =48v. i in 100ma/div. v mult 500mv/div. i out 200ma/div. v mult 500mv/div. v damp 10v/div. v cc 10v/div. i out 200ma/div. v mult 1v/div. v damp 10v/div. v cc 10v/div. i in 200ma/div. v mult 1v/div. v damp 10v/div. v comp 2v/div. i in 200ma/div. v mult 1v/div. v damp 10v/div. v comp 2v/div. i in 200ma/div. v mult 1v/div. v damp 10v/div. v comp 2v/div. i in 200ma/div. v mult 1v/div. v damp 10v/div. v comp 2v/div. v mult 1v/div. v comp 1v/div. v zcd 2v/div. v s 500mv/div. steady state v in =230v ac /50hz, full load steady state v in =230v ac /50hz, full load steady state v in =230v ac /50hz, full load v cc 10v/div. v comp 1v/div. v s 500mv/div. v zcd 2v/div. v in start-up v in =230v ac /50hz, full load dimming performance max dmming on phase with leading-edge dimmer v in =230v ac /50hz dimming performance min dmming on phase with leading-edge dimmer v in =230v ac /50hz dimming performance max dmming on phase with trailing-edge dimmer v in =230v ac /50hz dimming performance min dmming on phase with trailing-edge dimmer v in =230v ac /50hz ovp led load open v in =230v ac /50hz, full load
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver EV4056-K-00A rev.1.0 www.monolithicpower.com 14 7/21/2015 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. evb test results (continued) performance waveforms are tested on the evaluation board. v in =230vac/50hz, 15leds in series, i led =340ma, v out =48v. zcd pin short protection short zcd pin then start up v in =230v ac /50hz, full load v cc 10v/div. v comp 1v/div. v s 500mv/div. v zcd 2v/div. v cc 10v/div. v comp 1v/div. v s 500mv/div. v zcd 50mv/div. scp led+ short to led- and then recovery v in =230v ac /50hz, full load
EV4056-K-00A ? high line voltage, 16w apfc dimmable led driver notice: the information in this document is subject to change wi thout notice. 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. EV4056-K-00A rev.1.0 www.monolithicpower.com 15 7/21/2015 mps proprietary information. patent protect ed. unauthorized photocopy and duplication prohibited. ? 2015 mps. all rights reserved. quick start guide 1. preset ac power supply to 198vac ? v in ? 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 v in terminals (?l? and ?n?) as shown on the board. 5. turn ac power supply on after making connections.

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