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EV4033-K-00A 198vac~265vac/50hz, 24v/420ma primary-side-control with active pfc off-line dimmable led driver evaluation board EV4033-K-00A rev.1.0 www.monolithicpower.com 1 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. the future of analog ic technology description the EV4033-K-00A evaluation board is designed to demonstrate the capabilities of mp4033 with ripple suppressor. the mp4033 is a primary-side-control offline led lighting controller which can achieve high power factor and accurate current for triac dimmable led lighting application. its adaptive dimmer type detection and phase-cut-based dimming control can achieve good dimmer compatibility and deep dimming range. it works in boundary conduction mode for reducing the mosfet and diode switching losses. the new ripple suppressor can obviously reduce the output current ripple and escape the flicker or shimmer happened in deep dimming situation with a little influence in efficiency. the EV4033-K-00A is typically designed for driving a 10w triac dimmable led bulb with 24v typ , 420ma led load from 198vac to 265vac, 50hz. the EV4033-K-00A 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; winding short circuit protection; output short-circuit protection, cycle by cycle current limit, etc. electrical specification paramete r symbol v alue units input voltage v in 198 to 265 vac output voltage v out 24 v led current i led 420 ma output power p out 10 w efficiency (full load) >83 % power factor pf >0.8 thd thd <28 % features ? fast start up ? adaptive dimmer type detection and phase-cut-based dimming control ? triac dimmable, with good dimmer compatibility and deep dimming range ? the dimming curve meets standard ssl6 ? direct pwm dimming ? real current control without secondary- feedback circuit ? programmable current fold-back to prolong the led lifetime (ntc) ? accurate line & load regulation ? high power factor over 198vac to 265vac ? boundary conduction mode improves efficiency ? input uvlo ? cycle-by-cycle current limit ? over-voltage protection (ovp) ? output short-circuit protection (scp) ? winding short circuit protection ? zcd pin short circuit protection ? over-temperature protection (otp) ? fit inside a19 bulb enclosure applications ? solid state lighting ? industrial & commercial lighting ? residential lighting a ll 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 o f 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.
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 2 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. EV4033-K-00A evaluation board (l x w x h) 62mm x 25mm x 23mm board numbe r mps ic numbe r EV4033-K-00A mp4033gk evaluation board schematic 22nf/630v c9 499k/1206 r11 tvr10431 rv1 2.2nf/250v cy1 f1 250v/1a 1mh/0.1a l1 1mh/0.1a l2 5.1k/1206 r1 5.1k/1206 r2 22nf/275v cx1 220nf/450v c1 510/2w r3 510/2w r4 bd1 mb6s 5.1k/1206 r5 100nf/400v c3 470nf/25v c7 d3 rlz t e-11 18d d4 wsgc10mh 1 2 2.2mh/0.21a l3 470/1w r6 2 3 1 q1 ssn1n45bta 450v/0.5a 2 3 1 q2 isu04n65a 650v/4a 1m/1%/0.25w r8 470k/0.5w r10 1kv/1a 2 1 6 aux+ b w rm6 t1 10nf/50v c2 l n 198vac-265vac np:ns:naux=132:24:25 lp=3.4mh 4.7nf/50v c5 bav21w d2 bzt52c27 d1 3.9k/1% r7 22uf/50v c6 9.53k/1% r14 47k/1% r15 2.2uf/10v c8 2.2/1%/1206 r13 0.2/1%/1206 r12 d5 1n4148w 200v/0.2a mult 1 zcd 2 vcc 3 damp 4 di m 5 d 6 s 7 ntc 8 gnd 9 comp 10 u1 mp4033k ntc 220k 75v/0.15a 16.82v/10ma 27v/5ma 2.2nf/630v c4 20/1206 r9 d7 1n4148w 75v/0.15a 51 r1 9 led+ led- 2k/1206 r16 200v/3a d6 mbrs3200t3g 10nf/100v/0805 c12 20k r21 bav21w d10 51k r20 10k r17 20k r18 22uf/50v c13 d8 1n4148 bzt52c2v4 d9 bzt52c4v7 d11 1 2 330uf/35v c11 1 2 330uf/35v c10 3 2 1 q3 am2340ne/sot23 bav21w d12 200v/0.2a 200v/0.2a 2.4v/5ma 4.7v/5ma 40v/5.2a bead/1.5k/1a l4 30k/1206 r22 output: 24v/420ma 4.7nf/50v c14 figure 1?schematic
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 3 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. pcb layout (single-sided) figure 2?top layer figure 3?bottom layer
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 4 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. circuit description the EV4033-K-00A is configured in a single- stage flyback topology; it uses primary-side- control 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, l4, r1, r2, r5, cx1, bd1, c4 and c3 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, l4, r1, r2, r5, cx1, c3 and c4 associated with cy1 form the emi filter which can meet the standard en55015. the diode rectifier bd1 rectifies the input line voltage. small bulk cbb capacitor c3 is used for a low impedance path for the primary switching current, to maintain high power factor, the capacitance of c3 should be selected with low value. r6, q1 with c2 compose the damping circuit for reducing the inrush current at the dimmer turning on time. the circuit let the inrush current flow through r6 at first when triac dimmer turns on. then q1 turns on and shorts r6, this can save power from r6. r4, r3, c1 are used as a bleeder circuit which keeping the triac current above the minimum holding current after triac turns on. r8, r7, c5 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. r9, d1, c6 and d2 are used to supply the power for mp4033. a 22 f bulk capacitor c6 is selected to maintain the supply voltage. at start-up, c6 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. then the power supply is taken over by the auxiliary winding through r9, d2. r10, c7, r19, d3 and d7 are used for the gate drive of the external mosfet q2. r15, r14 and d5 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 and r14. r12, r13 are primary sensing resistors for primary side current control. the value of r12, r13 set the output led current. c9, r11, d4 are used to damp the leakage inductance energy so the drain voltage can be suppressed at a safe level. diode d6 rectifies the secondary winding voltage and the capacitor c10, c11 are the output filter. the resistor r22 is placed as pre-load to limit the output voltage rise too high in open load condition. r16, r17, r18, r20, r21, c12, d8, d9, d10, d11, d12, c13 and q3 compose the ripple suppressor. r17, r18 and c13 offer a stable drive voltage to q3. d8 and d9 compose the fast start up circuit, which help charge c13 quickly at the moment power on. d10, r21, r20, c12, d12 and r17 add a bias voltage to the gate of q3, which will help save the power loss of the ripple suppressor obviously.
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 5 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. EV4033-K-00A bill of materials qty des value description package manufacturer manufactuer_p/n 1 bd1 mb6s bridge, 600v, 0.5a soic-4 taiwan semiconductor mb6s 1 c1 220nf/450v cbb,450v dip fala c222s224k31c000 1 c2 10nf/50v ceramic cap,x7r,50v 0603 murata grm188r71h103ka01d 1 c3 100nf/450v 104/450v dip fala c222s104k30c000 1 c4 2.2nf/630v ceramic cap, x7r 1206 murata grm31br72j222kw01l 1 c5 4.7nf/50v ceramic cap,x7r,50v 0603 murata grm188r71h472ka01d 1 c6 22uf/50v electrolytic capacitor; 50v;electrolytic dip jianghai cd281l-50v22 1 c7 470nf/50v ceramic cap,x7r,50v 0603 murata grm188r71e474ka12d 1 c8 2.2uf/10v ceramic cap,10v,x7r 0603 murata grm188r71a225ke15d 1 c9 22nf/630v ceramic cap, 630v x7r 1206 tdk c3216x7r2j223k 2 c10, c11 330uf/35v electrolytic capacitor, 35v, electrolytic dip jianghai cd263-35v330 1 c14 4.7nf/50v ceramic cap,50v,x7r 0603 murata grm188r71h472ka01d 1 cx1 22nf/275v x capacitor,275v dip kaili px223k3ib19l270d9r 1 cy1 2.2nf/4000v y capacitor,4000v dip hongke jnk12e222my02n 1 d1 bzt52c27 zener diode, 27v, 2ma sod-123 diodes bzt52c27 1 d2 bav21w diode;200v;0.2a; sod-123 diodes bav21w-7-f 1 d3 rlz te-11 18d zener diodes 16.82v, 10ma sod-123 rohm rlz te-11 18d 1 d4 wsgc10mh diodes,1000v,1a sod-123 zowie wsgc10mh 2 d5, d7 1n4148ws diode;75v;0.15a; sod-323 diodes 1n4148ws-7-f 1 d6 mbrs320t3 g diode;200v;3a smb qianlongxin mbrs320t3g 1 f1 250v/1a fuse dip any 2 l1, l2 inductor,1mh inductor,1mh/0.1a dip bangdayuan ckl0410-102 1 l3 inductor,2.2m h inductor,2.2mh/0.21 a dip wurth 744741222 1 l4 bead magnetic bead 1.5k/1a 0805 wurth 742792097 1 ntc 220k ? thermistor 0603 murata mcp13wm224e03r8 1 q1 ssn1n45bt a n-channel mosfet 450v;4250/10v;8.5 to-92 fairchild ssn1n45bta 1 q2 isu04n65a n-channel mosfet, 650v, 4a to-251 ips isu04n65a
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 6 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. EV4033-K-00A bill of materials (continued) qty des value description package manufacturer manufactuer_p/n 3 r1, r2, r5 5.1k ? film resistor;1%;1/4w 1206 yageo rc1206fr-075k1l 2 r3, r4 510 ? dip,2w resistor dip any 510 ? /2w 1 r6 470 ? dip,1w resistor dip any 470 ? /1w 1 r7 3.9k ? film res, 1% 0603 yageo rc0603fr-073k9l 1 r8 1m ? dip,0.25w resistor dip any 1m ? /0.25w 1 r9 20 ? film res;1% 1206 yageo rc1206fr-0720rl 1 r10 470k ? /0.5w resistor;5%;0.5w dip any 470k ? /0.5w 1 r11 499k ? film res, 1% 1206 yageo rc1206fr-07499kl 1 r12 200m ? film res, 1% 1206 yageo rc1206fr-070r2l 1 r13 2.2 ? film res, 1% 1206 royalohm 1206tf2r20 1 r14 9.53k ? film res, 1% 0603 yageo rc0603fr-079k53l 1 r15 47k ? film res, 1% 0603 yageo rc0603fr-0747kl 1 r19 51 ? film res,1% 0603 yageo rc0603fr-0751rl 1 r22 30k ? resistor;1% 1206 yageo rc1206fr-0730kl 1 rv1 tvr10431ks y 430v/2500a dip tks tvr10431ksy 1 t1 rm6 rm6, lp=3.4mh np:ns:naux=132:24: 25, rm6 emei fx0342 1 u1 mp4033gk mp4033gk msop10 mps mp4033gk 1 c12 10nf/250v ceramic cap,x7r,250v 0805 tdk c2012x7r2e103k 1 c13 22uf/50v electrolytic capacitor; 50v;electrolytic dip jianghai cd281l-50v22 2 d10, d12 bav21w diode;200v;0.2a; sod-123 diodes bav21w-7-f 1 d11 bzt52c4v7 s zener diode, 4.7v, 5ma sod-323 diodes bzt52c4v7s 1 d9 bzt52c2v4 s zener diode, 2.4v, 5ma sod-323 diodes bzt52c2v4s 1 d8 1n4148ws diode;75v;0.15a; sod-323 diodes 1n4148ws-7-f 1 q3 am2340ne n-channel mosfet, 40v,5.2a sot23 analog power am2340ne 1 r16 2k ? film res;1% 1206 yageo rc1206fr-072kl 1 r17 10k ? film res;1% 0603 yageo rc0603fr-0710kl 2 r18, r21 20k ? film res;1% 0603 yageo rc0603fr-0720kl 1 r20 51k ? film res;1% 0603 yageo rc0603fr-0751kl note: the components in blue compose the ripple suppressor. it is optional.
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 7 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. transformer specification electrical diagram 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. e 1 is one layer of cooper foil applied to core, and connected to pin3 by a wire. winding diagram n 4 n 3 n 1 to p . side 1ts 1ts 3ts pin. side 1ts n 2 bobbin figure 5?winding diagram
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 8 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. winding order winding no. tape layer numbe r start & end magnet wire (mm) turns n 1 0 2 nc 0.15mm * 1 66 n 2 1 aux+ 6 0.15mm * 1 25 n 3 1 w b 0.30mm (t.i.w) 24 n 4 1 nc 1 0.15mm * 1 66 e 1 3 one layer cooper foil electrical specifications electrical strength 60 second, 60hz, from pri. to sec. 2500vac 60 second, 60hz, from pri. to core. 1000vac 60 second, 60hz, from sec. to core. 1000vac primary inductance pins 1 - 2, all other windings open, measured at 100khz, 0.1 vrms 3.4mh8% primary leakage inductance pins 1 - 2 with all other pins shorted, measured at 100khz. 0.1 vrms 43 h10% materials item description 1 core: rm6, ui=250025%, al=221.5h/n 2 2% gap, acme p4 or equivalent 2 bobbin: rm6, 3+3pin rmmove pin6 1sect th, pm9630 ul94v-0 3 wire: 0.16mm, 2uew, class f or equivalent 4 triple insulation wire: great 0.30mm,trw(b) or equivalent 5 teflon tube: tfl awg#30 6 teflon tube: tfl awg#24 7 tape: 6.5mm(w)0.06mm(th) 8 tape: 4.0mm(w)0.06mm(th) 9 varnish: john c. dolph co, bc-346a or equivalent 10 solder bar: chen nan: sn99.5/cu0.5 or equivalent
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 9 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 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(%) 50 198 11.53 23.24 419 9.74 84.45 0.938 17.00 210 11.55 23.24 420 9.76 84.51 0.925 19.00 220 11.57 23.23 421 9.78 84.53 0.914 20.10 230 11.61 23.23 422 9.80 84.44 0.902 21.10 240 11.65 23.23 422 9.80 84.15 0.890 22.60 250 11.70 23.23 423 9.83 83.99 0.877 23.40 260 11.75 23.23 424 9.85 83.83 0.864 24.80 265 11.78 23.23 424 9.85 83.61 0.857 25.50 dimming compatibility (no flicker with these 19 different dimmers) manufacturer part no. power stage dimming type imax(ma) imin(ma) dimming ratio gira 0302 00/i01 60-600w leading 533 30 5.63% mika 433/4 60-400w leading 531 91 17.14% berker 283010 60-400w leading 531 43 8.10% jung 225 nv de 20-500w/va leading 531 22 4.14% jung 225 nv de 20-500w/va leading 532 105 19.74% berker 286610 20-500w leading 531 40 7.53% jung 266 gde 60-600w leading 527 33 6.26% emc prop400u 40-400w leading 531 28 5.27% busch 2247u 500w/va leading 531 50 9.42% busch 2200.. 60-400w leading 530 54 10.19% busch 6513 u-102 420w/va trailing 531 50 9.42% grundtyp et1_53850 25~300w trailing 445 40 8.99% mika 433 hab 20-315w trailing 406 46 11.33% mika? eim-585 20-300w trailing 458 1 0.22% busch 6591u-101 420w/va trailing 462 39 8.44% busch 6519u 550w/va trailing 527 50 9.49% jung 225 tde 20-525w trailing 504 44 8.73% siemens 5tc8 284 20-600w trailing 481 30 6.24% lichtregler t46s 20~315w trailing 514 61 11.87% jung 254 udie 1 50-420w/va trailing 527 71 13.47% berker 286110 50-420w trailing 526 72 13.69%
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 10 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. 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. 3750v ac/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) 500 230 l to n 90 pass -500 230 l to n 270 pass 1000 230 l to pe 90 pass -1000 230 l to pe 270 pass 1000 230 n to pe 90 pass -1000 230 n to pe 270 pass thermal test test without dimmer and with dimmer at 90% dimming on phase. without dimmer with dimmer at 90% dimming on phase emi inductor l3 : 6 8.8 damping resister: 108 .0
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 11 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. evb test results performance waveforms are tested on the evaluation board. v in =230vac/50hz, 8 leds in series, i led =420ma, v out =24v, l p =3.4mh, n p :n s :n aux =132:24:25
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 12 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. evb test results (continued) performance waveforms are tested on the evaluation board. v in =230vac/50hz, 8 leds in series, i led =420ma, v out =24v, l p =3.4mh, n p :n s :n aux =132:24:25.
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 13 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 mps. all rights reserved. evb test results (continued) performance waveforms are tested on the evaluation board. v in =230vac/50hz, 8 leds in series, i led =420ma, v out =24v, l p =3.4mh, n p :n s :n aux =132:24:25.
EV4033-K-00A ? high line voltage, 10w psr with pfc dimmable led driver EV4033-K-00A rev.1.0 www.monolithicpower.com 14 7/15/2014 mps proprietary information. patent protected. unauthorized photocopy and duplication prohibited. ? 2014 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 as shown on the board. 5. turn ac power supply on after making connections.

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