V - Monolithic Power Systems

MP020
Customer Support Report
FAE
Dave Baker
AE
Hui Li
Manager
En Li
MPS Confidential- Sigma Design Use Only
The Future of Analog IC Technology®
Contents
1. Specification
6.4
2. Schematic
6.4.1 Short Circuit Protection
3. Circuit Board
3.1
PCB Layout
3.2
Board Photograph
Protection
6.4.2 Over Current Protection
6.5 Output and Timing
6.5.1
6.5.2
6.5.3
6.5.4
4. Bill of Materials
5. Transformer Information
5.1 Winding Spec
Output Ripple
Startup Time
Output Rise Time
Load Transient
6.6 Thermal
6. Performance Data
6.6.1 Parts Thermal
6.1 Test Setup
6.7 EMC and Safety
6.1.1 Test Equipment
6.7.1 Conducted Emission
6.2 Efficiency
6.7.2 Surge Test
6.2.1 Full Load Efficiency
6.2.2 No Load Power Consumption
6.3 Stress and Steady Status
6.3.1 Mosfet VDS
6.3.2 3.3V Output Diode VRRM
6.3.3 12V Output Diode VRRM
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1. Specification
Parameter
Symbol
Condition
Min
Typ
Max
Units
Input Supply Voltage
VIN
2 Wire
85
110/220
265
VAC
AC Line Frequency
fLINE
Output Voltage
Load Current
50/60
Hz
Vo1
Full Range
3.135
3.3
3.465
V
Vo2
Full Range
10.8
12
13.2
V
Io1
500
1500
mA
Io2
5
100
mA
Efficiency
80%
No Load Consumption
230Vac
70
mW
Vo1_Ripple
Full Load
200
mV
Vo2_Ripple
Full Load
800
mV
Output Rise Time
TRise
Full Load
10
ms
Overshoot during startup
Vov
Full Load
10%
Load Transient Recovery Time
TRise
Operation Temperature Rise
TR
Output Ripple
us
100
℃
6
kV
Full Load
Vin=230Vac
Conducted Emission
Surge Voltage
Full Load
900
Vs
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2. Schematic
Vin=85Vac-265Vac
Vout1=3.3V, Iout1=1.5A
Vout2=12V, Iout2=0.1A
R7
L1
20/1206
C7 1.2nF/50V
EE16
Lp=1.65mH
Np:Np_au:Nsec1:Nsec2=150:5:11:16
1000uH/0.25A
Vo1
R1
D3 B220A
10K/0805
C3
2.2nF/630V/1206
R3
150K/1206
Np
C8
680uF/6.3V
Nsec1
C11
R9
2.0K/1206
C12
10uF/6.3V 4.7uF/6.3V
3.3V/1.5A
L
AGND
FR1 10/1W
85VAC~265VAC
CR1
C1
4.7uF/400V
C2
10uF/400V
600V/0.5A
AGND
D1
D4
FR107
Np_au
C9
100uF/25V
1000V/1A
N
B180
Vo2
Nsec2
R8
C10
0.1uF/25V 5.1K/1206
12V/0.1A
R2
PGND
357/1206
CY1
AGND
AGND
1nF
PGND
PGND
AGND
D2
BAV21W
200V/0.2A
C4
0
U1
5
6
GND
CP
GND
FB
GND
R4
10/1206
4
R5
27K/1%
3
R6
2
PGND
14K/1%
8
Drain
VCC
1
C5
1uF/25V
MP020-5/SO8-7A
C6
22uF/50V
PGND
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3. Circuit Board
3. Circuit Board
3.1 PCB Layout
TOP & TSK
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BOT & BSK
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3. Circuit Board
3.2 Board Photograph
W=3.0cm
H=1.5cm
L=4.7cm
Note: Dimension is strongly needed.
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4. Bill of Materials
Qty
Reference
Value
Description
Package
Manufacturer
Manufactuer_P/N
1
C1
4.7uF
Capacitor;400V;20%
DIP
Nichicon
UVY2G4R7MPD
1
C2
10uF
Capacitor;400V;20%
DIP
Ltec
10uF/400V
1
C3
2.2nF
Ceramic Capacitor;630V;X7R
1206
Murata
GRM31BR72J222KW01
0
C4,
0
Shorted with 0Ohm Resistor
1
C5
1uF
Ceramic Capacitor;25V;X5R;
0603
TDK
C1608X5R1E105K
1
C6
22uF
Electrolytic Capacitor;50V
DIP
Jianghai
CD281L-50V22
1
C7
1.2nF
Ceramic Capacitor;50V;X7R
0603
TDK
C1608X7R1H122KT
1
C8
680uF
Electrolytic Capacitor;6.3V
DIP
Jianghai
HCN0J681MC13
1
C9
100uF
Electrolytic Capacitor;25V
DIP
Rubycon
25YXF100M 6.3*11
1
C10
0.1uF
Ceramic Capacitor;25V;X7R
0603
Murata
GRM188R71E104KA01D
1
C11
10uF
Ceramic Capacitor, 6.3V, X7R
1206
Murata
GRM31MR60J106KE19L
1
C12
4.7uF
Ceramic Capacitor,6.3V, X7R
0805
Murata
GRM219R60J475KE19D
1
CR1
MB6F
Diode;600V;0.5A
SOP-4
Diodes
MB6F
1
CY1
1nF
Y1 Capacitor
DIP
Hongke
JNK09E102MY02N
1
D1
FR107
Diode;1000V;1A
DO-41
Diodes
FR107
1
D2
BAV21W
Diode;200V;0.2A;
SOD-123
Diodes
BAV21W-7-F
1
D3
B220A
Schottky Diode;20V;2A
SMA
Diodes
B220A
1
D4
B180
Schottky Diode, 80V, 1A
SMA
Diodes
B180
1
FR1
10Ω
Yageo
DIP
FKN1WSJT-52-10R
1
L1
1000uH
Inductor;1000uH;6 Ohm;0.25A
DIP
Wurth
7447462102
1
R1
10kΩ
Film Resistor;1%
0805
Yageo
RC0805FR-0710KL
Fusible Resistor,
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1 W, 1%
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4. Bill of Materials
…Continued
Qty
Reference
Value
Description
Package
Manufacturer
Manufactuer_P/N
1
R2
357Ω
Film Resistor;1%;1/4W
1206
Yageo
RC1206JR-07357RL
1
R3
150kΩ
Film Resistor; 1%
1206
Panasonic
ERJ8ENF1503V
1
R4
10Ω
Film Resistor;5%;1/4W
1206
Yageo
RC1206JR-0710R
1
R5
27kΩ
Film Resistor;1%;
0603
Yageo
RC0603FR-0727KL
1
R6
14kΩ
Film Resistor;1%
0603
Yageo
RC0603FR-0714KL
1
R7
20Ω
Film Resistor;5%;1/4W
1206
Yageo
1206J0200T5E
1
R8
5.1kΩ
Film Resistor;1%;
0603
Yageo
RC0603FR-075K1L
1
R9
2.0kΩ
Film Resistor, 1%
0603
Yageo
RC0603FR-072KL
1
U1
MP020-5
Primary side regulator
SOIC8-7A
MPS
MP020-5
1
T1
Transformer;1.6mH;
Np:Np_au:Nsec1:Nsec2=150:16:5:11
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EE16
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5. Transformer Information
5.1 Winding Spec
Electrical Diagram
Electric Characteristic
Parameter
Condition
Test Value
LP (3-1)
Primary Inductance
1.65mH±5%
Core/Bobbin
EE16
Core material
PC40
Turn Ratio
Np:Np_au:Nsec1:Nsec2
150:16:5:11
Winding Diagram
Winding Order
Tape Layer
Number
Winding
No.
Margin Tape
(Pri. Side)
Start & End
Margin Tape
(Sec. Side)
Turns
Magnet Wire
(Φ)
3
Np
\
3 to 1
\
150
0.15*1
10
1
Nsec1
5
0.5*2 TIW
6
10-6
4
5
7
1
Nsec2
\
7 to 10
\
11
0.2*1 TIW
1
Np_au
\
5 to 4
\
16
0.15*1 TIW
10
Np_au: 0.15mm×1P ×16Ts
Nsec2: 0.2mm ×1P ×11Ts
TIW
Nsec1: 0.5mm ×2P ×5Ts
TIW
1
Np: 0.15mm ×1P ×150Ts
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6. Performance Data
6.1 Test Setup
6.1.1 Test Equipment
AC Source: Chroma, Model 61601
Power Meter: Yokogawa, Model WT210
Oscilloscope: Tektronix, Model TDS3014C
Current Probe/Amplifier: Tektronix, Model TCP312
EMC Receiver: Rohde & Schwarz, Model ESPI3+ESPI-B2
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6. Performance Data
6.2 Efficiency
6.2.1 Full load Efficiency
Test Conditions:
The two output channels are @ full load condition and pre-heated until
temperature stabilization was achieved.
Criteria To Pass:
The average efficiency must be > 80% at the continuous output load.
(The design can’t satisfy such high efficiency demand)
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6. Performance Data
…Continued
Vin=110Vac
Pin (W)
Vo1 (V)
Io1 (A)
Vo2 (V)
Io2 (A)
Po (W)
Efficiency
2.495
3.289
0.445
11.83
0.0253
1.762904
0.671471
4.406
3.298
0.764
11.8
0.0506
3.116752
0.689854
6.435
3.314
1.114
11.82
0.0758
4.587752
0.701033
8.59
3.326
1.495
11.85
0.0979
6.132485
0.71391
Average Efficiency: 69.4%
Comment: Pass
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6. Performance Data
…Continued
Vin=220Vac
Pin (W)
Vo1 (V)
Io1 (A)
Vo2 (V)
Io2 (A)
Po (W)
Efficiency
2.528
3.277
0.446
11.78
0.0253
1.759576
0.696035
4.339
3.288
0.765
11.77
0.0506
3.110882
0.716958
6.286
3.3
1.116
11.78
0.0758
4.575724
0.727923
8.35
3.312
1.495
11.8
0.0995
6.12554
0.733598
Average Efficiency: 71.8%
Comment: Pass
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6. Performance Data
6.2.2 No Load Power Consumption
Test Conditions:
No load input power consumption are tested based on 10mins preheat.
Criteria To Pass:
The no load input power consumption must be <70mV.
VAC (Vac)
85
265
PIN(mW)
54
56
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6. Performance Data
6.3 Stress
6.3.1 Mosfet VDS
Test Conditions:
The main input voltage was set to265VAC.
The unit is loaded at maximum output current.
Criteria To Pass:
The Mosfet VDS must be < 700V at both startup and steady status.
Steady
Startup
CH1: VDS
CH1: VDS
VMAX: 650V
VMAX: 654V
Comment: Pass
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6. Performance Data
6.3.2 Output Diode VRRM
Test Conditions:
The main input voltage was set to 265VAC.
The unit is loaded at maximum output current.
Criteria To Pass:
The diode VRRM must be < 20V at both startup and steady status.
3.3V Rail
Steady
Startup
CH1: VRRM
CH1: VRRM
VMAX: 17.2V
VMAX: 17.2V
Comment: Pass
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6. Performance Data
6.3.3 Output Diode VRRM
Test Conditions:
The main input voltage was set to 265VAC.
The unit is loaded at maximum output current.
Criteria To Pass:
The diode VRRM must be < 80V at both startup and steady status.
12.0V Rail
Steady
Startup
CH1: VRRM
CH1: VRRM
VMAX: 57.4V
VMAX: 57.6V
Comment: Pass
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6. Performance Data
6.4 Protection
6.4.1 Short Circuit Protection (SCP)
Test Conditions:
The unit was switched on with normal load on the output. A short circuit was
applied manually to the output at the end of the cable. The mains voltage was
adopted to obtain the worst-case condition.
A short circuit was applied to the output at the end of the cable before startup
of the unit. The unit was switched on with a short circuit at the output. The
mains voltage was adopted to obtain the worse-case condition.
Criteria To Pass:
The unit shall be capable of withstanding a continuous short-circuit at the
output without damage or overstress of the unit under any input conditions.
After removal of the short circuit, the unit shall recover automatically.
VAC
85
110
120
135
SCP
ok
ok
ok
ok
18
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6. Performance Data
…Continued
SCP at 220VAC
SCP Startup
SCP Entry
CH1: VDS
CH1: VDS
CH2: VCC
CH2: VCC
SCP Recovery
CH1: VDS
CH2: VCC
Input Power: 0.8W
Comment: Pass
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6. Performance Data
…Continued
Ta=25.7℃
Transformer
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12V Output Diode
20
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6. Performance Data
6.4.2 Over Current Protection (OCP)
Test Conditions:
Both the output current are at full load condition. Then enlarge one output
current until the circuitry enters OCP.
Criteria To Pass:
The unit shall be capable of withstanding a continuous over current at the
output without damage or overstress of the unit under any input conditions.
After removal of the over current condition, the unit shall recover automatically.
VAC
110
220
Channel 1 Output Current
1685mA
1702mA
Channel 2 Output Current
100mA
100mA
Channel 1 Output Current
1500mA
1500mA
Channel 2 Output Current
135mA
143mA
Rail 1 OCP
Rail 2 OCP
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6. Performance Data
OCP Startup
OCP Entry
OCP Recovery
Vds_max: 558V
Vds_max: 642V
Vds_max: 642V
Input Power: 1.8W
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6. Performance Data
…Continued
Ta=25.7℃
Bottom PCB Heated by Diode
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3.3V Output Diode
23
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6. Performance Data
6.5 Output and Timing
6.5.1 Output Voltage Ripple
Test Conditions:
The output voltage ripple and noise are measured at output terminal with full
load (Test with 47uF electrolytic cap and 0.1uF ceramic cap).
Criteria To Pass:
The ripple of the output current must remain within the specified limits (3.3V
rail<200mV, 12V rail<800mV).
3.3V Rail
110VAC Input
220VAC Input
CH1: V_Ripple
CH1: V_Ripple
VP-P: 164mV
VP-P: 164mV
Comment: Pass
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6. Performance Data
…Continued
12.0V Rail
110VAC Input
220VAC Input
CH1: V_Ripple
CH1: V_Ripple
VP-P: 316mV
VP-P: 320mV
Comment: Pass
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6. Performance Data
6.5.2 Startup Time
Test Conditions:
The Unit start with full load
The startup time is measured from bus capacitor is charged up to output
voltage rises to its 90% set value.
Criteria To Pass:
The startup time must remain in 0.5 second.
110VAC Input
220VAC Input
Ch1: Vds
Ch1: Vds
Ch2: Vo1
Ch3: Vo2
Ch2: Vo1
Ch3: Vo2
TStart-up: 398ms
TStart-up: 280ms
Comment: Pass
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6. Performance Data
6.5.3 Output Rise Time
Test Conditions:
The Unit start with full load
The output rise time is measured from 0% output voltage to 100% output
voltage
Criteria To Pass:
The startup time must remain in 0.01 second.
(The output rise time can’t satisfy the demand)
110VAC Input
220VAC Input
CH2: Vo1
CH2: Vo1
CH2: Vo2
CH2: Vo2
TStart-up: 51.2ms
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TStart-up: 32.4ms
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6. Performance Data
6.5.4 Output Voltage Ripple
Test Conditions:
The load of output1 changed from 500mA to 1500mA at a slew rate of
0.5A/usec. The load of output2 is changed from 5mA to 100mA at a slew
rate of 0.25A/usec .
The frequency of change was set to give the best readability of the deviation
and setting time.
110VAC Input
220VAC Input
CH1: V_Ripple
CH1: V_Ripple
CH4: Iout
CH4: Iout
VP-P: 232mV
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VP-P: 244mV
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6. Performance Data
6.6 Thermal
6.6.1 Parts Thermal
Test Conditions:
The input voltage was set to 85V.
The electronic load was set to the maximum output current.
The unit was covered, and the data was recorded until temperature
stabilization was achieved. Ta=27℃
Criteria To Pass:
The △ temperature must be < 60℃.
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6. Performance Data
…Continued
Top Side
Bottom Side
PCB area heated by
Output Diode D3
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3.3V output diode D3
Comment: Pass
30
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6. Performance Data
6.7 EMC and Safety
6.7.1 Conducted Emission
Test Conditions:
The unit was subjected to 220VAC line and with maximum load.
The output GND floats.
Criteria To Pass:
EN55022 with -8dB margin.
L line
N line
Comment: Pass
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6.7 EMC and Safety
6.7.2 Surge Test
Test Conditions:
 Surge Test with 1.2/50us Waveform
Criteria To Pass:
 The EV Board can work normally during test and after test
Surge Level
(V)
Input Voltage
(Vac)
Injection
Location
Injection Phase
(o)
Number of Surges
Test Result
1000
220
L-N
0
5
PASS
1000
220
L-N
90
5
PASS
1000
220
L-N
180
5
PASS
1000
220
L-N
270
5
PASS
-1000
220
L-N
0
5
PASS
-1000
220
L-N
90
5
PASS
-1000
220
L-N
180
5
PASS
-1000
220
L-N
270
5
PASS
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