EV020-5-S-00B 85VAC~265VAC/50Hz, 12V/0.7A Off-line Primary-Side-Regulator Home Appliances Evaluation Board Evaluation Board Report 12V 8.4W ACDC power supply Design Specs Input Voltage Output Voltage Output Current Isolation MPS IC Value 85-265 12 0.7 Unit VAC VDC A YES MP020-5GS • Small Home Appliances • Cell Phone Chargers • Adapters for Handheld Electronics • Stand-By and Auxiliary Power Supplies • Small Appliances Application Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV020-5-S-00B evaluation board provides a reference design for a universal offline power supply with 12V,0.7A 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-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES DESCRIPTION FEATURES The EV020-5-S-00B Evaluation Board is designed to demonstrate the capabilities of MP020-5. The MP020-5 is a primary-sidecontrol offline regulator which can eliminates secondary feedback components. • The EV020-5-S-00B is typically designed for small home appliances which output 12V, 0.7A load from 85VAC to 265VAC, 50HZ/60HZ. The EV020-5-S-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, short-circuit protection, cycle by cycle current limit and over-temperature protection, etc. Input Voltage Output Voltage Output Current Output Power Efficiency (full load) Symbol V IN V OUT I OUT P OUT η • • • • • • • • APPLICATIONS ELECTRICAL SPECIFICATION Parameter • 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 100mW 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 Value Units 85 to 265 12 0.7 8.4 >80 VAC V A W % • • • • • Small Home Appliances Cell Phone Chargers Adapters for Handheld Electronics Stand-By and Auxiliary Power Supplies Small Appliances 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-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EV020-5-S-00B EVALUATION BOARD TOP VIEW BOTTOM VIEW (L x W x H) 50mm x 30mm x 18mm Board Number MPS IC Number EV020-5-S-00B MP020-5GS EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EVALUATION BOARD SCHEMATIC L N FR1 10/1W 85VAC~265VAC CR1 600V/0.5A 6 5 L1 R1 C1 10uF/400V PGND 8 1000uH/0.25A 10K/0805 D1 R3 150K/1206 1 2 3 4 NC C4 FR107 1000V/1A C2 10uF/400V PGND CP U1 GND FB VCC GND GND Drain MP020-5GS/SOIC8-7A PGND R2 357/1206 R4 2.2/1206 C5 NC C11 22uF/50V C6 BAV21W 200V/0.2A D2 PGND C3 1nF/630V/1206 100nF/50V PGND NS 6 R7 20/1206 C7 1.2nF/100V AGND C8 470uF/25V D3 B560C/60V/5A 2.2nF/250V CY1 T1 EE16 LP=2.48mH NP:NP_AU:NS=184:15:16 1 10 NP 3 4 NP-AU 5 R5 27K/1% R6 14.3K/1% C9 470uF/25V 1uF/25V C10 10K R8 Vo 12V/0.7A AGND Figure 1—Schematic 4 EV020-5-S-00B Rev.1.01 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. EV020-5-S-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES CIRCUIT DESCRIPTION The EV020-5-S-00B 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 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. 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-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EV020-5-S-00B BILL OF MATERIALS Qty 2 Ref C1,C2 Value 10μF 1 C3 1nF 1 C4 0Ω 1 C5 100nF 1 C6 22μF 1 C7 1.2nF 2 C8,C9 470μF 1 C10 1μF 1 C11 NC 1 CY1 2.2nF 1 CR1 1 Package DIP Manufacturer Ltec 1206 Murata GRM31A7U2J102JW31D 0603 Yageo RC0603JR-070RL 0603 Murata GCJ188R71H104KA12D DIP Jianghai CD281L-50V22 0603 muRata GRM188R72A122KA01D DIP Rubycon 25ZLF470MEFC10X12.5 0603 Murata GRM188R71E105KA12D Y Capacitor; 250V DIP Hongke JNK12E222ML02N MB6F Diode;600V;0.5A SOP-4 Diodes MB6F D1 FR107 Diode;1000V;1A DO-41 Diodes FR107 1 D2 BAV21W Diode;200V;0.2A; SOD-123 Diodes BAV21W-7-F 1 D3 B560C 1 FR1 1 L1 1 1 1 1 1 1 1 1 1 R1 R2 R3 R4 R5 R6 R7 R8 U1 1 T1 Notes: Description Capacitor;400V;20% Ceramic Capacitor;630V;X7R Film Resistor;5% Ceramic Capacitor;50V;X7R; Electrolytic Capacitor;50V Ceramic Capacitor;100V;X7R Electrolytic Capacitor;25V,Low ESR Ceramic Capacitor;25V;X7R Manufacturer_P/N TY 10uF/400V Schottky Diode;60V;5A SMC Diodes B560C Fusible Resistor, 1 W, 10Ω Yageo DIP FKN1WSJT-52-10R 5% Inductor;1000uH;6 1000μH DIP Wurth 7447462102 Ohm;0.25A 10kΩ Film Resistor;5% 0805 Yageo RC0805JR-0710KL 357Ω Film Resistor;1%;1/4W 1206 Yageo RC1206FR-07357RL 150kΩ Film Resistor; 1%,1/4W 1206 Yageo RC1206FR-07150KL 2.2Ω Film Resistor;5%;1/4W 1206 Royalohm 1206F220KT5E 27kΩ Film Resistor;1%; 0603 Yageo RC0603FR-0727KL 14.3kΩ Film Resistor;1% 0603 Yageo RC0603FR-0714K3L 20Ω Film Resistor;5%;1/4W 1206 Royalohm 1206J0200T5E 10kΩ Film Resistor;5%; 0603 Yageo RC0603JR-0710K Primary side regulator SOIC8-7A MPS MP020-5GS R3 Wurth(1) 7508110328 Transformer;2.48mH; EE16 Emei(2) N P:N P_AU :N S =184:15:16 FX0303 (1) Wurth transformer sample request please login on website: www.we-online.com (2) Emei transformer sample request please login on website: www.emeigroup.com EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES TRANSFORMER SPECIFICATION Electrical Diagram nc NC 1 2 3 10 NP1 NS NP2 6 5 NP_AU WINDING START 4 Core is connected to Pin 4 by wire Primary side TEFLON TUBE Secondary side Figure 4—Transformer Electrical Diagram Notes: 1) Core is connected with Pin 4 with naked wire. 2) NS is with Triple Insulation Wire. Winding Diagram 3 layer tape 1 46Ts NP2: 0.14mm×1P×92Ts 46Ts 2 6 1 layer tape NS: 0.55mm TIW×1P×16Ts 10 4 NP_AU: 0.18mm×1P×15Ts 5 2 46Ts NP1: 0.14mm×1P×92Ts 3 46Ts nc 1 NC: 0.15mm×2P×22Ts Primary side Secondary side Figure 5—Winding Diagram EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES Winding Order Winding No. NC NP1 NP_AU NS NP2 Tape Layer Number 1 1 1 1 1 Start & End 1→nc 3→2 5→4 10→6 2→1 Magnet WireΦ(mm) 0.15mm * 2 0.14mm * 1 0.18mm * 1 0.55mm * 1 TIW 0.14mm * 1 Turns 22 92 15 16 92 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 50kHz, 0.1 VRMS Pins 1 - 3 with all other pins shorted, measured at 50kHz. 0.1 VRMS 2.48mH±10% 60μH±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:Φ0.14mm,, 2UEW, Class B Wire:Φ0.15mm,, 2UEW, Class B Wire:Φ0.18mm,, 2UEW, Class B Triple Insulation Wire: Φ0.55mm TIW Tape: 8.0mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EVB TEST RESULTS Performance Data TA=25℃, unless otherwise noted. EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES 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-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES Conducted EMI Test Test with 230Vac input and full load condition 230Vac, 50Hz, Maximum Load, L Line, EN55022 Limits 230Vac, 50Hz, Maximum Load, N Line, EN55022 Limits EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES Conducted EMI Test (continued) Test with 115Vac input and full load condition 115Vac, 60Hz, Maximum Load, L Line, EN55022 Limits 115Vac, 60Hz, Maximum Load, N Line, EN55022 Limits EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES 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 MP020-5 Top Layer MP020-5 Bottom Layer Test with 265Vac input and full load condition. PCB layout is with 1Oz copper. Ambient temperature is 25°C. Output Diode Transformer MP020-5 Top Layer Bottom Layer EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES Temperature Chamber Test The EVB setup in constant temperature chamber with full load and 85Vac input. Full load (0.7A) output in 85℃ ambient temperature will trigger the OTP. EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VIN=115VAC/60Hz, VOUT=12V, IOUT=0.7A, LP=2.48mH, NP:NP_AU:NS=184:15:16, TA=25℃, unless otherwise noted. EV020-5-S-00B Rev.1.01 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-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EVB TEST RESULTS(c o n tin u e d ) Performance waveforms are tested on the evaluation board. VIN=115VAC/60Hz, VOUT=12V, IOUT=0.7A, LP=2.48mH, NP:NP_AU:NS=184:15:16, TA=25℃, unless otherwise noted. EV020-5-S-00B Rev.1.01 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 17 EV020-5-S-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EVB TEST RESULTS (c o n tin u e d ) Performance waveforms are tested on the evaluation board. VIN=230VAC/50Hz, VOUT=12V, IOUT=0.7A, LP=2.48mH, NP:NP_AU:NS=184:15:16, TA=25℃, unless otherwise noted. EV020-5-S-00B Rev.1.01 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 18 EV020-5-S-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES EVB TEST RESULTS (c o n tin u e d ) Performance waveforms are tested on the evaluation board. VIN=230VAC/50Hz, VOUT=12V, IOUT=0.7A, LP=2.48mH, NP:NP_AU:NS=184:15:16, TA=25℃, unless otherwise noted. EV020-5-S-00B Rev.1.01 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 19 EV020-5-S-00B – UNIVERSAL INPUT, 8.4W HOME APPLIANCES QUICK START GUIDE 1. Preset Power Supply to 85VAC ≤ VIN ≤ 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-00B Rev.1.01 www.MonolithicPower.com 3/31/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 20