EV020-5-S-00A 85VAC~265VAC/50Hz, 5V/1A Off-line Primary-side-Regulator Cell phone Charger Evaluation Board Evaluation Board Report 5V 5W ACDC power supply Design Specs Input Voltage Output Voltage Output Current Isolation MPS IC Value 85-265 5 1 Unit VAC VDC A YES MP020-5GS Application • • • Cell Phone Chargers Adapters for Handheld Electronics Stand-By and Auxiliary Power Supplies • Small Appliances Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV020-5-S-00A evaluation board provides a reference design for a universal offline power supply with 5V, 1A output. It contains the complete specification of the power supply, a detailed circuit diagram, the entire bill of materials required to build the power supply, drawing of the power inductors and transformers, and test data of the most important performance. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 1 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER DESCRIPTION FEATURES The EV020-5-S-00A Evaluation Board is designed to demonstrate the capabilities of MP020-5. The MP020-5 is a primary-sidecontrol regulator which can eliminates secondary feedback components. • The EV020-5-S-00A is typically designed for cell phone which output 5V, 1A load from 85VAC to 265VAC, 50HZ/60HZ. The EV020-5-S-00A has an excellent efficiency and meets IEC61000-4-5 surge immunity and EN55022 conducted EMI requirements. It has multi-protection function as open circuit protection, short-circuit protection, cycle by cycle current limit and over-temperature protection, etc. ELECTRICAL SPECIFICATION Parameter Input Voltage Output Voltage Output Current Output Power Efficiency (full load) Symbol V IN V OUT I OUT P OUT η Value Units 85 to 265 5 1 5 >70 VAC V A W % • • • • • • • • • Primary-Side–Control without Opto-Coupler or Secondary Feedback Circuit Precise Constant Current and Constant Voltage Control (CC/CV) Integrated 700V MOSFET with Minimal External Components Variable, Off-Time, Peak-Current Control 550µA High-Voltage Current Source 30mW No-Load Power Consumption Programmable Cable Compensation Multiple Protections: OVP, OCP, OCkP, OTP, and VCC UVLO Natural Spectrum Shaping for Improved EMI Signature Low Cost and Simple External circuit 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. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER EV020-5-S-00A EVALUATION BOARD TOP VIEW BOTTOM VIEW (L x W x H) 47mm x 30mm x 18mm Board Number MPS IC Number EV020-5-S-00A MP020-5GS EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER EVALUATION BOARD SCHEMATIC L N FR110/1W 85VAC~265VAC CR1 600V/0.5A L1 R1 C1 4.7uF/400V PGND 5 6 8 FR107 D1 R3 150K/1206 1 2 3 4 C4 1uF/25V 1000V/1A C2 10uF/400V CP FB VCC GND PGND 1000uH/0.25A 10K/0805 U1 GND GND Drain MP020-5/SOIC8-7A PGND R2 357/1206 R4 10/1206 C5 100nF/50V 1 NP 3 4 NP_AU 5 T1 R5 27K/1% R6 13.3K/1% PGND 6 R7 20/1206 7 NSEC2 9 AGND C8 470uF/10V C7 1.2nF/100V D3 B540C/40V/5A NC CY1 NSEC1 10 EE16 LP=1.6mH NP:NP_AU:NSEC1:NSEC2=127:18:4:4 C3 1nF/630V/1206 PGND D2 S1ML/1000V/1A C11 22pF/50V C6 22uF/50V L2 3.3uH/4A C9 470uF/10V C10 1uF/10V R8 2.2K Vo 5V/1A AGND Figure 1—Schematic 4 EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 5 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER CIRCUIT DESCRIPTION The EV020-5-S-00A 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 accurate constant voltage and constant current. FR1 and CR1 compose the input stage. FR1 is used to protect for the component failure or some excessive short events, also it can restrain the inrush current. C1, L1 and C2 compose π filter to guarantee the conducted EMI meet standard EN55022. R2, R3, D1 and C3 compose the snubber circuit to reduce drain-source voltage spike. CY1 is Y capacitor lowering common mode noise to make sure there is enough EMI margin. T1 is power transformer, the structure of which is also very important to pass EMI test. D3, C8, C9, C10, L2 and R8 compose output circuit. D3 is schottky diode for better efficiency. C10 is ceramic capacitor for lower output voltage ripple and R8 is dummy load, which is used for good regulation. C8, L2 and C9 compose π filter to restrain the output ripple. R7 and C7 are used to depress the spike of schottky. R4, C5, C6 and D2 are used as Vcc power supply. R5 and R6 are resistor divider for detecting output voltage by sampling voltage on primary auxiliary winding. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER EV020-5-S-00A BILL OF MATERIALS Qty 1 1 Ref C1 C2 Value 4.7μF 10μF Package DIP DIP Manufacturer Nichicon Ltec 1206 Murata GRM31A7U2J102JW31D 0603 0603 DIP Murata Murata Jianghai GRM188R71E105KA12D GCJ188R71H104KA12D CD281L-50V22 0603 muRata GRM188R72A122KA01D 1μF Description Capacitor;400V;20% Capacitor;400V;20% Ceramic Capacitor;630V;X7R Ceramic Capacitor;25V;X7R; Ceramic Capacitor;50V;X7R; Electrolytic Capacitor;50V Ceramic Capacitor;100V;X7R Electrolytic Capacitor;10V,Low ESR Ceramic Capacitor;10V;X7R 1 C3 1nF 1 1 1 C4 C5 C6 1μF 100nF 22μF 1 C7 1.2nF Manufacturer_P/N UVY2G4R7MPD TY 10uF/400V Ceramic Capacitor;50V;C0G; 1 C8,C 9 C10 1 C11 22pF 1 CY1 NC 1 CR1 MB6F Diode;600V;0.5A SOP-4 Diodes MB6F 1 D1 FR107 Diode;1000V;1A DO-41 FR107 1 D2 S1ML Diode;1000V;1A; SMA 1 D3 B540C Schottky Diode;40V;5A SMC Diodes Taiwan Semiconduct or Diodes 1 FR1 10Ω Yageo DIP 1 L1 1000μH DIP Wurth 7447462102 1 1 1 1 1 1 1 1 1 1 L2 R1 R2 R3 R4 R5 R6 R7 R8 R9 3.3μH 10kΩ 357Ω Wurth Yageo Yageo 7447462033 RC0805JR-0710KL RC1206FR-07357RL ERJ8ENF1503V RC1206JR-0710R RC0603FR-0727KL RC0603FR-0713K3L 1206J0200T5E RC0603JA0222G RC0805JA0510 1 U1 Primary side regulator R3 DIP 0805 1206 1206 1206 0603 0603 1206 0603 0805 SOIC87A 1 T1 Transformer;1.6mH; N P:N P_AU :N SEC1 :N SEC2 =127:1 8:4:4 2 Notes: 470μF 150kΩ 10Ω 27kΩ 13.3kΩ 20Ω 2.2kΩ 510Ω Fusible Resistor, 1 W, 5% Inductor;1000uH;6 Ohm;0.25A Inductor;3.3uH;0.025Ohm;4A Film Resistor;5% Film Resistor; 1%;1/4W Film Resistor; 1%,1/4W Film Resistor;5%;1/4W Film Resistor;1%; Film Resistor;1% Film Resistor;5%;1/4W Film Resistor;5%; Film Resistor;5%; 0603 Nippon Chemi-con Murata GRM188R71A105KA61D 0603 Murata GRM1885C1H220JA01D DIP EE16 Panasonic Yageo Yageo Yageo Royalohm LIZ LIZ EKZE100ELL471MHB5D S1ML B540C FKN1WSJT-52-10R MPS MP020-5GS Wurth(1) 7508110157 (1) Wurth transformer sample request please login on website: www.we-online.com EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER TRANSFORMER SPECIFICATION Electrical Diagram 10 1 NP NSEC1 3 5 6 7 NP_AU 4 nc NSEC2 NC 9 Core is connected to Pin 4 by wire Primary side WINDING START TEFLON TUBE Secondary side Figure 4—Transformer Electrical Diagram Notes: 1. N SEC1 and N SEC2 are coiled at one layer. 2. Core is connected to Pin 4 with naked wire. 3. N SEC1 and N SEC2 are with Triple Insulation Wire. Winding Diagram 7 10 9 6 nc 4 4 5 1 One layer tape 3 Primary side 2 mm margin tape 1 mm margin tape NSEC2: 0.6mm TIW×1P×4Ts NSEC1: 0.6mm TIW×1P×4Ts NC: 0.18mm×3P×7Ts NP_AU: 0.18mm×1P×18Ts 43Ts 42Ts NP: 0.15mm×1P×127Ts 42Ts Secondary side Figure 5—Winding Diagram EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 8 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER Winding Order Winding No. NP N P_AU NC N SEC1 N SEC2 Tape Layer Number 1 1 1 1 1 Start & End 3→1 5→4 4→nc 10→6 7→9 Magnet WireΦ(mm) 0.15mm * 1 0.18mm * 1 0.18mm * 3 0.6mm * 1 TIW 0.6mm * 1 TIW Turns 127 18 7 4 4 Electrical Specifications Electrical Strength Primary Inductance Primary Leakage Inductance 60 second, 60Hz, from PRI. to SEC. 3000VAC 60 second, 60Hz, from PRI. to CORE. 500VAC 60 second, 60Hz, from SEC. to CORE. 3000VAC Pins 1 - 3, all other windings open, measured at 60kHz, 0.1 VRMS Pins 1 - 3 with all other pins shorted, measured at 60kHz. 0.1 VRMS 1.6mH±10% 50μH±10% Materials Item 1 2 3 4 5 6 7 8 Description Core: EE16, UI=2300±25%, AL=73.2.4nH/N2±3% GAPPED, or equivalent Bobbin: EE16, 5+5PIN 1 SECT TH, UL94V-0 Wire:Φ0.15mm,, 2UEW, Class B Wire:Φ0.18mm,, 2UEW, Class B Triple Insulation Wire: Φ0.60mm TIW Tape: 8.0mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 9 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER EVB TEST RESULTS Performance Data T A=25℃, unless otherwise noted. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 10 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER Electric Strength Test Primary circuit to secondary circuit electric strength testing was completed according to IEC61000-4-2. Input and output was shorted respectively. 3000VAC/50Hz sine wave applied between input and output for 1min, and operation was verified. Surge Test Line to Line 1kV and Line to Power Earth 1kV surge testing was completed according to IEC61000-4-5. Input voltage was set at 220VAC/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) 1000 -1000 1000 -1000 1000 -1000 220 220 220 220 220 220 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 EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 11 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER Conducted EMI Test Test with 230Vac input and full load condition 230Vac, 50Hz, Maximum Load, L Line, Output GND floats, EN55022 Limits 230Vac, 50Hz, Maximum Load, N Line, Output GND floats, EN55022 Limits EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 12 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER Conducted EMI Test (continued) 230Vac, 50Hz, Maximum Load, L Line, Output GND connects to Earth, EN55022 Limits 230Vac, 50Hz, Maximum Load, N Line, Output GND connects to Earth, EN55022 Limits EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 13 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER Thermal Test Test with 85Vac input and full load condition. PCB layout is with 1Oz copper. Ambient temperature is 25°C. PCB area heated by Output Diode D3 Output Diode D3 Top Layer Bottom Layer EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 14 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER EVB TEST RESULTS Performance waveforms are tested on the evaluation board. V IN =115VAC/60Hz, V OUT =5V, IOUT =1A, L P =1.6mH, NP :N P_AU :N SEC1 :N SEC2 =127:18:4:4, T A=25℃, unless otherwise noted. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 15 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER EVB TEST RESULTS (c o n tin u e d ) Performance waveforms are tested on the evaluation board. V IN =230VAC/50Hz, V OUT =5V, IOUT =1A, L P =1.6mH, NP :N P_AU :N SEC1 :N SEC2 =127:18:4:4, T A=25℃, unless otherwise noted. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 16 EV020-5-S-00A – UNIVERSAL INPUT, 5W CELL PHONE CHARGER QUICK START GUIDE 1. Preset Power Supply to 85VAC ≤ V IN ≤ 265VAC. 2. Turn Power Supply off. 3. Connect the Line and Neutral terminals of the power supply output to L and N port. For threewire input application, make OUTPUT GND connected to Earth. 4. Connect Load to: a. Positive (+): VOUT b. Negative (–): GND 5. Turn Power Supply on after making connections. Contact Information To request this evaluation board, please refer to your local sales offices which can be found from: http://www.monolithicpower.com/Company/Contact-Us Disclaimer Monolithic Power Systems (MPS) reserves the right to make changes to its products and to discontinue products without notice. The applications information, schematic diagrams, and other reference information included herein is provided as a design aid only and are therefore provided as-is. MPS makes no warranties with respect to this information and disclaims any implied warranties of merchantability or non-infringement of third-party intellectual property rights. MPS cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a MPS product. No circuit patent licenses are implied. Certain applications using semiconductor products may involve potential risks of death, personal injury, or severe property or environmental damage (“Critical Applications”). MPS PRODUCTS ARE NOT DESIGNED, INTENDED, AUTHORIZED, OR WARRANTED TO BE SUITABLE FOR USE IN LIFE‑SUPPORT APPLICATIONS, DEVICES OR SYSTEMS, OR OTHER CRITICALAPPLICATIONS. Inclusion of MPS products in critical applications is understood to be fully at the risk of the customer. Questions concerning potential risk applications should be directed to MPS. MPS semiconductors are typically used in power supplies in which high voltages are present during operation. High voltage safety precautions should be observed in design and operation to minimize the chance of injury. 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. EV020-5-S-00A Rev.1.02 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 17