EV020-5-S-00C 85VAC~265VAC/50Hz, 12V/0.3A, 5V/0.1A Off-line Primary-side-Regulator, Dual Outputs Evaluation Board for Small Appliances Evaluation Board Report Dual Output 4.1W ACDC power supply Design Specs Input Voltage Output 1 Output 2 Isolation MPS IC Value 85-265 Unit VAC 12V, 0.3A 5V, 0.1A YES MP020-5GS Small Appliances AC-DC power supply with supplemental 5V output Application Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV020-5-S-00C evaluation board provides a reference design for a universal offline power supply with 12V,0.3A and 5V, 0.1A 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-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES DESCRIPTION The EV020-5-S-00C Evaluation Board is designed to demonstrate the capabilities of MP020-5. The MP020-5 is a primary-side-control regulator which can eliminates secondary feedback components. FEATURES • • • The EV020-5-S-00C is typically designed for small appliances which output 12V/0.3A and 5V/0.1A load from 85VAC to 265VAC, 50HZ/60HZ. • • • The EV020-5-S-00C 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 Symbol Value Units 85 to 265 12 0.3 5 VAC V A V Input Voltage Output Voltage 1 Output Current 1 Output Voltage 2 V IN V OUT1 I OUT1 V OUT2 Output Current 2 I OUT2 0.1 A Output Power P OUT 4.1 W η >70 % Efficiency (full load) • • Primary-Side–Control without Opto-Coupler or Secondary Feedback Circuit Precise Constant Voltage Control (CV) Integrated 700V MOSFET with Minimal External Components Variable, Off-Time, Peak-Current Control 550µA High-Voltage Current Source Programmable Cable Compensation (By adding 1μF/25V ceramic cap at CP pin) 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-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES EV020-5-S-00C EVALUATION BOARD TOP VIEW BOTTOM VIEW (L x W x H) 50mm x 28mm x 17mm Board Number MPS IC Number EV020-5-S-00C MP020-5GS EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES EVALUATION BOARD SCHEMATIC FR1 10/1W 85VAC~265VAC L N CR1 600V/0.5A L1 R1 1000uH/0.25A 10K/0805 D1 R3 150K/1206 C2 VCC GND FB CP 1 2 3 4 FR107 1000V/1A C1 PGND GND GND Drain U1 4.7uF/400V 5 8 6 4.7uF/400V PGND MP020-5/SOIC8-7A C3 470pF D2 C5 1uF/25V R4 10/1206 BAV21W 200V/0.2A R2 100/1206 C4 0 PGND PGND 1 Np 3 4 5 Np_au R5 30K/1% R6 13.7K/1% T1 PGND 8 Nsec2 6 Nsec1 10 EE16 Lp=1.25mH Np:Np_au:Nsec1:Nsec2=105:18:6:12 C6 22uF/50V R7 CY1 1nF 4000V 20 D3 D4 C7 100pF C11 1uF/16V C10 1uF/10V C8 470uF/16V ES1D B190A C9 100uF/10V AGND R8 5.1K AGND R9 10K AGND Vo1 AGND 5V/0.1A Vo2 12V/0.3A AGND C12 1uF/10V L78L05 U3 Figure 1—Schematic 4 EV020-5-S-00C Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. EV020-5-S-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES CIRCUIT DESCRIPTION The EV020-5-S-00C 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 accurate constant voltage and acceptable cross regulation. 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. R1 paralleled with L1 is used to damp resonant between L1 and C1, C2. R2, R3, D1 and C3 compose the snubber circuit to reduce drain-source voltage spike. R4, C5, C6 and D2 are used as Vcc power supply. C5 is high frequency decoupling capacitor and should be placed with Vcc pin as near as possible. R5 and R6 are resistor divider for detecting output voltage by sampling voltage on primary auxiliary winding. 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 is rectifier for 12V output. Schottky diode is recommended for better efficiency and regulation.C7 and R7 are composed snubber for D3, which is to restrain the voltage spike between D3. C8 and C11 are output capacitors for 12V output. C8 should be low ESR electrolytic capacitor for better load regulation. C11 is ceramic capacitor to reduce high frequency voltage ripple. R9 is dummy load to lower the output voltage of 12V rail at no load condition. D4 is rectifier for 5V output. Schottky diode is recommended for better efficiency and regulation. Due to the output current is low at this rail and there is no obvious spike on D4, so no RC snubber is needed. C9 and C10 are output capacitors for 5V output. C9 should be low ESR electrolytic capacitor for better load regulation. C10 is ceramic capacitor to reduce high frequency voltage ripple. R8 is dummy load to lower the output voltage of 5V rail at no load condition. U3 is three terminals voltage regulator for precise 5V output. C12 is output capacitor for U3. EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES EV020-5-S-00C BILL OF MATERIALS Qty Ref Value Description 2 C1, C2 4.7μF 1 C3 470pF 1 C4 0Ω 1 C5 1μF 1 C6 22μF 1 C7 100pF 1 C8 470μF 1 C9 100μF 2 C10, C12 1μF 1 C11 1μF Capacitor;400V;20% Ceramic Capacitor; 1000V;U2J; Shorted with 0Ω resistor Ceramic Capacitor; 25V;X7R; Electrolytic Capacitor; 50V;Electrolytic; Ceramic Capacitor; 250V;COG Electrolytic Capacitor; 16V;Electrolytic; Electrolytic Capacitor; 10V;Electrolytic; Ceramic Capacitor; 10V;X7R Ceramic Capacitor; 25V;X7R; 1 CR1 MB6F 1 1 1 CY1 D1 D2 1nF FR107 BAV21W 1 D3 ES1D 1 D4 1 FR1 1 L1 1 1 1 1 1 1 1 1 1 R1 R2 R3 R4 R5 R6 R7 R8 R9 B190A FKN1WSJT -52-10R 1000μH/ 0.25A 10kΩ 100Ω 150kΩ 10Ω 30kΩ 13.7kΩ 20Ω 5.1kΩ 10kΩ 1 T1 1 U1 MP020-5 1 U3 L78L05 Package Manufacturer DIP Beryl 1206 muRata 0603 Yageo 0603 muRata GRM188R71E105KA12D DIP Jianghai CD281L-50V22 0805 Murata DIP Lelon RXW471M1CBK-1012P DIP Lelon RXW101M1ABK-0511P 0603 Murata 1206 TDK Diode;200V;1A; SMA Schottky Diode;90V;1A; SMA Taiwan Semiconductor Hongke Diodes Diodes Taiwan Semiconductor Diodes Fusible Resistor ;10Ω/1W DIP Yageo Diode;600V;0.5A Y Capacitor;4000V;20% Diode;1000V;1A Diode;200V;0.2A; SOP-4 DIP DO-41 SOD-123 Inductor;1000μH;6 DIP Wurth Ohm;0.25A Film Resistor;5%; 0805 Yageo Film Resistor;5%;1/4W 1206 Yageo Film Resistor;1%; 1206 Panasonic Film Resistor;5% 1206 Yageo Film Resistor;1%; 0603 Yageo Film Resistor;1% 0603 Yageo Film Resistor;5%;1/4W 1206 Film Resistor;5%; 0603 Yageo Resistor;5%; 1206 Yageo EE16 Transformer, Lp=1.25mH EE16 Np:Np_au:Nsec1:Nsec2= 105:18:6:12 Primary Side Regulator SOIC8-7A MPS Three-Terminal Voltage SOT-89 STMicroelectronics Regulator Manufacturer_P/N 4.7μF/400V GRM31B7U3A471JW31L RC0603JR-070RL GRM21A5C2E101JW01D GRM188R71A105KA61D C3216X7R1E105K MB6F JN09E102MY02N FR107 BAV21W-7-F ES1D B190A FKN1WSJT-52-10R 7447462102 RC0805JR-0710KL RC1206JR-07100RL ERJ8ENF1503V RC1206JR-0710R RC0603FR-0730KL RC0603FR-0713K7L 1206J0200T5E RC0603JR-075K1L RM12JTN103 FX0295 MP020-5GS R3 L78L05ACUTR EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES TRANSFORMER SPECIFICATION Electrical Diagram PRI 1 N1 22Ts NC SEC1 N2 N3 105Ts 3 5 6 12Ts 8 SEC2 N5 18Ts 4 N4 N6 18Ts NC 10 6Ts 6 WINDING START Figure 4—Transformer Electrical Diagram Notes: 1. N1 is with 2 wires which are paralleled together. 2. N3 and N4 are both triple insulation wires. 3. One layer tape is between each layer winding. 3 layers tape is at the outside of last winding Winding Diagram 4 NC 4 2 5 3 2 3 2 3 2 3 2 3 2 3 N6 : 0.15mmx1P 18Ts N5 : 0.15mm x1P 18Ts 6 10 N4 : 0.32mm x1P 6Ts TIW 8 6 N3 : 0.4 mm x1P 12Ts TIW 1 N2 : 0.15mm×1P 105Ts 3 1 NC N1 : 0.15mm×2P 22Ts Figure 5—Winding Diagram EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES Winding Order Tapes (T) Winding Start-End Wire Diameter (Ø) Turns ( T ) Tube N1 1—〉NC 0.15mm*2 22 None N2 3—〉1 0.15mm*1 105 None N3 6—〉8 0.4mm*1 TIW 12 None N4 10—〉6 0.32mm*1 TIW 6 None N5, N6 5—〉4 4—〉NC 0.15mm*1 0.15mm*1 18 18 None 0 1 1 1 3 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 1.25mH±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 Triple Insulation Wire: Φ0.40mm, TIW Triple Insulation Wire: Φ0.32mm 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-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES EVB TEST RESULTS Performance Data Ta=25℃, unless otherwise noted. Efficiency and Load/Line Regulation (Test at the end of board) Pin (W) 0.06293 V OUT1 (V) 11.9 I OUT1 (A) 0 V OUT2 (V) 5 I OUT2 (A) 0 0.00% V OUT1 Regulation -0.83% V OUT2 Regulation 0.00% Vin=85Vac/60Hz 5.5626 1.4909 11.75 0.3 5 0.1 72.36% -2.08% 0.00% 11.89 0.03 0.56577 11.72 0.03 5 0.1 57.46% -0.92% 0.00% 5 0.005 66.56% -2.33% Δ 0.00% 4.5994 11.79 0.3 5 0.005 77.44% -1.75% 0.00% Pin (W) 0.06221 V OUT1 (V) 11.89 I OUT1 (A) 0 V OUT2 (V) 5 I OUT2 (A) 0 0.00% V OUT1 Regulation -0.92% V OUT2 Regulation 0.00% Vin=115Vac/60Hz 5.4373 1.4935 11.76 0.3 5 0.1 74.08% -2.00% 0.00% 11.89 0.03 5 0.1 57.36% -0.92% 0.00% 0.5646 11.72 0.03 5 0.005 66.70% -2.33% Δ 0.00% 4.5104 11.72 0.3 5 0.005 78.51% -2.33% Δ 0.00% Pin (W) 0.06338 V OUT1 (V) 11.94 I OUT1 (A) 0 V OUT2 (V) 5 I OUT2 (A) 0 0.00% V OUT1 Regulation -0.50% V OUT2 Regulation 0.00% 5.475 11.77 0.3 5 0.1 73.63% -1.92% 0.00% 1.5214 11.89 0.03 5 0.1 56.31% -0.92% 0.00% 0.57955 11.74 0.03 5 0.005 65.08% -2.17% 0.00% 4.5556 11.74 0.3 5 0.005 77.86% -2.17% 0.00% Pin (W) 0.06514 V OUT1 (V) 11.98 I OUT1 (A) 0 V OUT2 (V) 5 I OUT2 (A) 0 0.00% V OUT1 Regulation -0.17% V OUT2 Regulation 0.00% Vin=265Vac/50H 5.5176 z 1.5205 11.77 0.3 5 0.1 73.06% -1.92% 0.00% 11.9 0.03 5 0.1 56.36% -0.83% 0.00% 0.58397 11.75 0.03 5 0.005 64.64% -2.08% 0.00% 4.5994 11.75 0.3 5 0.005 77.18% -2.08% 0.00% Vin=230Vac/50H Efficiency Efficiency Efficiency Efficiency Notes: 1. The red triangle means the worst case in table. EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES No Load Consumption No Load Power Consumption Input Power (mW) 66 65 64 63 62 61 50 100 150 200 Input AC Voltage (V) 250 300 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 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 230 230 230 230 230 230 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-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES 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-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES Conducted EMI Test (continued) Test with 115Vac input and full load condition 115Vac, 60Hz, Maximum Load, L Line, Output GND floats, EN55022 Limits 115Vac, 60Hz, Maximum Load, N Line, Output GND floats, EN55022 Limits EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES Thermal Test Test is conducted at ambient temperature of 25oC, 85Vac/60Hz input. Top Layer Bottom Layer EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES EVB TEST RESULTS Performance waveforms are tested on the evaluation board. V IN =115VAC/60Hz, V OUT1 =12V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, Ta=25℃ EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. V IN =230VAC/50Hz, V OUT1 =12V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, Ta=25℃ EV020-5-S-00C Rev.1.0 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-00C – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES 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 (+): 12V 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. EV020-5-S-00C Rev.1.0 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 17