EV157-J-00B 85VAC~265VAC, 18V/0.3A, 5V/0.1A Dual Output Buck Regulator Evaluation Board for Small Appliances PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE Evaluation Board Report 5.9W ACDC power supply with Dual Output Design Specs Input Voltage Output1 Output2 Isolation MPS IC Value 85-265 Unit VAC 18V, 0.3A 5V, 0.1A No MP157GJ Small Appliances ACDC Power Supply with additional 5V output Application Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV157-J-00A evaluation board provides a reference design for a universal offline power supply with dual outputs, one with 18V,0.3A and the other 5V,0.1A. 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. EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 1 EV157-J-00B 85VAC~265VAC, 18V/0.3A, 5V/0.1A Dual Output Buck Regulator Evaluation Board for Small Appliances PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE DESCRIPTION FEATURES The EV157-J-00B Evaluation Board is designed to demonstrate the dual output capabilities of MP157. The MP157 is a primary-side constant voltage regulator. • The EV157-J-00B is typically designed for small appliances which output 18V/0.3A and 5V/0.1A load from 85VAC to 265VAC, 50HZ/60HZ. The EV157-J-00B 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, over load protection, short-circuit protection, and over-temperature protection, etc. ELECTRICAL SPECIFICATION Parameter Symbol Value Units 85 to 265 18 0.3 5 0.1 VAC V A V A Input Voltage Output Voltage 1 Output Current 1 Output Voltage 2 Output Current 2 V IN V OUT1 I OUT1 V OUT2 I OUT2 Output Power P OUT 5.9 W η >70 % Efficiency (full load) • • • • • Primary-Side non-isolated Constant Voltage Control (CV) Integrated 500V MOSFET with Minimal External Components Peak-Current Control with Peak Current Compression Limited Maximum Frequency and Frequency Foldback, Multiple Protections: SCP, OCP, OTP, and VCC UVLO 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. EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 2 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EV157-J-00B EVALUATION BOARD TOP VIEW BOTTOM VIEW (L x W x H) 68mm x 28mm x 17mm Board Number MPS IC Number EV157-J-00B MP157GJ EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 3 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EVALUATION BOARD SCHEMATIC D2 D1 L1 1mH F1 10/1W D3 D4 1N4007 1N4007 CX1 C4 10uF/400V NC Drain Vcc 1 30K 30.9K C1 FB 2 Source 3 220nF R5 NC 4 85~265VAC RV1 NC R1 U1 5 L 1N4007 1N4148WS R2 C5 10uF/400V Source C3 470pF C2 2.2uF R3 R4 NC 4.99K N1 1.4mH Vout1 MP157 D5 D6 1N4007 18V/300mA C6 STTH1R06 D7 1N4007 100uF/25V C7 1uF/25V R7 3.9K GND N T1 is coupled inductor. EE13 Vertical Core/Bobbin N1=200Ts, N2=94Ts GND U2 N2 D8 STTH1R06 C9 C8 100uF/16V 1uF/16V 5V/100mA Vout2 C10 1uF/6.3V GND Figure 1—Schematic EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 4 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 5 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE CIRCUIT DESCRIPTION The EV157-J-00B is configured in a buck regulator topology, it uses primary-side-control which can mostly simplify the schematic and get a cost effective BOM. It can also achieve accurate constant voltage and acceptable cross regulation. F1 is used to protect circuit from component failure or some excessive short events; also it can restrain the inrush current. C4, L1 and C5 compose π filter to guarantee the conducted EMI meet standard EN55022. R2, C2, and D1 are used as VCC power supply. Though MP157 is equipped with an internal high voltage current source, using this circuit can achieve better efficiency. C1 is the sample-hold capacitor, used for reflecting output voltage. R1 and R4 are resistor divider for detecting output voltage by sampling voltage on C1. T1 is power transformer; it has two coupling windings to achieve dual output. D5 is freewheeling diode for 18V output. Select a diode with a maximum reverse block voltage rating that exceeds the maximum input voltage. For universal voltage applications, use a diode with a 600V reverse block voltage. Ultra-fast recovery diode is recommended for better efficiency. C6 and C7 are output capacitors for 18V output. C6 should be low ESR electrolytic capacitor for better output ripple. C7 is ceramic capacitor to reduce high frequency voltage ripple. R7 is dummy load to lower the output voltage of 18V rail at no load condition. D8 is freewheeling diode for 5V output. Simply select a diode same as D5. C8 and C9 are output capacitors for 5V output. C9 should be low ESR electrolytic capacitor for better load regulation. C9 is ceramic capacitor to reduce high frequency voltage ripple. U2 is three terminals voltage regulator for precise 5V output. C10 is output capacitor for U3. EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 6 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EV157-J-00B BILL OF MATERIALS Qty 1 Ref CX1 1 C1 1 C2 1 C3 2 C4, C5 1 L1 1 C6 1 C7 1 C8 1 C9 1 C10 1 2 1 1 1 1 1 1 1 1 D1 D2, D3, D4, D6, D7 D5, D8 F1 R1 R2 R3 R4 R5 R7 RV1 1 T1 5 1 1 6 Value NC Description No Connected Ceramic Capacitor; 220nF 25V;X5R Ceramic Capacitor; 2.2μF 10V;X7R Ceramic Capacitor; 470pF 50V;C0G Electrolytic Capacitor; 10μF/400V 400V Inductor;1mH; 1mH 6Ohm;0.25A 100μF Electrolytic Capacitor;25V Ceramic Capacitor; 1μF 25V;X7R 100μF Electrolytic Capacitor;16V Ceramic Capacitor; 1μF 16V;X7R Ceramic Capacitor; 1μF 6.3V;X5R 1N4148WS Diode;75V;0.15A 1N4007 STTH1R06 10Ω 30.9kΩ 30kΩ NC 4.99kΩ NC 3.9k NC 1.4mH Package Manufacturer Manufactuer_P/N 0603 Murata GRM188R71E224KA01D 0603 Murata GRM188R71A225KE15D 0603 Murata GRM1885C1H471JA01D DIP Ltec DIP Wurth DIP Rubycon 25YXF100M6.3X11 0603 TDK C2012X7R1E105K DIP 江海 CD11C-16V100 0603 TDK C1608X7R1C105K 0603 Murata GRM188R60J105KA01D SOD323 Diodes 1N4148WS-7-F Diode;1000V;1A DO-41 Diodes 1N4007 Diode;600V;1A Fuse Resistor;5%;1W Film Resistor;1% Film Resistor;1% No Connected Film Resistor;1% No Connected Film Resistor;1% No Connected DO-41 DIP 0603 0603 ST Yageo Yageo Yageo STTH1R06 FKN1WSJT-52-10N RC0603FR-0730K9L RC0603FR-0730KL 0603 Yageo RC0603FR-074K99L 1206 Yageo RC1206FR-073K9L N1:N2=200:94 EE13 Wurth 750342025 Emei MPS ANY FX0336 MP157GJ TY Series, 10uF/400V 7447462102 U1 MP157 Buck regulator TSOT23-5 U2 L78L05ACUTR LDO, 5V, 100mA SOT89 L, N, Vout1, GND, Vout2 Connecter, 1mm GND (1) Wurth transformer sample request please log on website: www.we-online.com Notes: (2) Emei transformer sample request please log on website: www.emeigroup.com EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 7 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE TRANSFORMER SPECIFICATION Electrical Diagram 1 N1 2 N3 3 10 N 2 9 Figure 4—Transformer Electrical Diagram Notes: 1. Remove pin2, 4, 5, 6, 7, 8. 2. One layer tape is between each layer winding. 1 layers tape is at the outside of last winding Winding Diagram N3 N2 N1 Figure 5—Winding Diagram Winding Order Tapes (T) Winding Start-End Wire Diameter (Ø) Turns ( T ) Tube N1 3—〉2 0.23*1 106 None N2 9—〉10 0.15*1 94 None N3 2—〉1 0.23*1 94 None 0 1 1 1 EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 8 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE Electrical Specifications Electrical Strength Primary Inductance 60 seconds 60Hz, from PRI. to SEC. 500VAC 60 seconds 60Hz, from PRI. to CORE. 500VAC 60 seconds 60Hz, from SEC. to CORE. 500VAC Pins 1 - 3, all other windings open, measured at 60kHz, 0.1 VRMS 1.4mH±10% Materials Item 1 2 3 4 6 7 8 Description Core: EE13, PC40 Bobbin: EE13, 4+4PIN Wire:Φ0.15mm,, 2UEW, Class B Wire:Φ0.23mm,, 2UEW, Class B Tape: 7.5mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent Surge Test Line to Line 1kV surge tested according to IEC61000-4-5. 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) 1000 1000 1000 1000 -1000 -1000 -1000 -1000 230 230 230 230 230 230 230 230 L to N L to N L to N L to N L to N L to N L to N L to N 0 90 180 270 0 90 180 270 Pass Pass Pass Pass Pass Pass Pass Pass EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 9 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE Thermal Test Test with 115Vac input and full load condition, Ta=30℃ Top Layer Bottom Layer EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 10 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EVB TEST RESULTS Performance waveforms are tested on the evaluation board. V IN =85-265VAC, V OUT1 =18V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, Ta=30℃ EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 11 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. V IN =85-265VAC, V OUT1 =18V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, Ta=30℃ EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 12 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. V IN =85-265VAC, V OUT1 =18V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, Ta=30℃ EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 13 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. V IN =85-265VAC, V OUT1 =18V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, Ta=30℃ EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 14 EV157-J-00B – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PRELIMINARY SPECIFICATIONS SUBJECT TO CHANGE 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 three-wire input application, make OUTPUT GND connected to Earth. 4. Connect Different Load to Corresponding Outputs : a. Positive 1 (+): 18V OUT b. Positive 2 (+): 5V OUT c. 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. EV157-J-00B Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 15