EV020-5-S-00D - Monolithic Power Systems

EV020-5-S-00D
85VAC~265VAC/50Hz, 18V/0.3A, 5V/0.1A
Off-line Primary-side-Regulator, Dual
Outputs Evaluation Board for Small Appliances
Evaluation Board Report
Dual Output 5.9W AC-DC power supply
Design Specs
Input Voltage
Output 1
Output 2
Isolation
MPS IC
Value
85-265
Unit
VAC
18V, 0.3A
5V, 0.1A
YES
MP020-5GS
Small Appliances
AC-DC power supply with additional 5V output
Application
Document Number
EBXXX
Author
Application Engineering Department
Date
Nov, 2014
Revision
1.0
Design Summary
EV020-5-S-00D evaluation board provides a reference design for a universal offline power supply with
18V, 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-00D Rev.1.0
www.MonolithicPower.com
3/31/2015
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© 2015 MPS. All Rights Reserved.
1
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
DESCRIPTION
FEATURES
The EV020-5-S-00D 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.
•
The EV020-5-S-00D is typically designed for
small appliances which output 18V/0.3A and
5V/0.1A load from 85VAC to 265VAC,
50HZ/60HZ.
The EV020-5-S-00D 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
18
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
5.9
W
η
>75
%
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-00D Rev.1.0
www.MonolithicPower.com
3/31/2015
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© 2015 MPS. All Rights Reserved.
2
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
EV020-5-S-00D EVALUATION BOARD
TOP VIEW
BOTTOM VIEW
(L x W x H) 47mm x 30mm x 17mm
Board Number
MPS IC Number
EV020-5-S-00D
MP020-5GS
EV020-5-S-00D Rev.1.0
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3
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
EVALUATION BOARD SCHEMATIC
FR1 10/1W
85VAC~265VAC
L
N
CR1
600V/0.5A
L1
R1
C1
10uF/400V
PGND
GND
GND
U1
R3
150K/1206
FR107
1000V/1A
VCC
GND
FB
CP
1
2
3
4
R2
357/1206
C2
D1
4.7uF/400V
PGND
1000uH/0.25A
10K/0805
5
6
8
Drain
MP020-5/SOIC8-7A
C4
0
PGND
1
3
4
5
Np
Np_au
R5
28.7K/1%
R6
13.7K/1%
T1
PGND
8
Nsec2
6
Nsec1
10
EE16
Lp=1.8mH
Np:Np_au:Nsec1:Nsec2=134:16:17:7
22uF/50V
C6
PGND
C3
470pF/1000V
D2
BAV21W
200V/0.2A
R4
10/1206
C5
1uF/25V
R7
CY1
1nF/
4000V
20
D3
D4
C7 100pF
250V
C8
220uF
25V
C9
100uF
10V
ES1D
B140
AGND
C10
1uF
10V
C11
1uF
25V
R8
5.1K
1206
AGND
R9
20K/1206
Vo2
5V/0.1A
AGND
Vo1
AGND
18V/0.3A
AGND
Figure 1—Schematic
4
EV020-5-S-00D Rev.1.0
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EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
PCB LAYOUT (SINGLE-SIDED)
Figure 2—Top Layer
Figure 3—Bottom Layer
EV020-5-S-00D Rev.1.0
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5
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
CIRCUIT DESCRIPTION
The EV020-5-S-00D 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.
D3 is rectifier for 18V 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 18V 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 18V
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.
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.
EV020-5-S-00D Rev.1.0
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3/31/2015
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© 2015 MPS. All Rights Reserved.
6
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
EV020-5-S-00D BILL OF MATERIALS
Qty
1
1
1
1
1
1
1
1
1
1
1
Ref
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
Value
10μF
4.7μF
470pF
0
1μF
22μF
100pF
220μF
100μF
1μF
1μF
Description
Capacitor;400V;20%
Capacitor;400V;20%
Ceramic Capacitor;1000V;U2J
Shorted
Ceramic Capacitor;25V;X7R
Electrolytic Capacitor;50V
Ceramic Capacitor;250V;COG
Electrolytic Capacitor;25V
Electrolytic Capacitor;10V
Ceramic Capacitor;10V;X7R
Ceramic Capacitor;25V;X7R
1
CR1
MB6F
Diode;600V;0.5A
1
1
1
CY1
D1
D2
1nF
FR107
BAV21W
1
D3
ES1D
1
D4
1
1
1
1
1
1
1
1
1
1
1
B140
FKN1WSJT
FR1
-52-10R
L1
1000μH
R1
10kΩ
R2
357Ω
R3
150kΩ
R4
10Ω
R5
28.7kΩ
R6
13.7kΩ
R7
20Ω
R8
5.1kΩ
R9
20kΩ
1
T1
1
U1
MP020-5
Y Capacitor;4000V;20%
Diode;1000V;1A
Diode;200V;0.2A;
Diode;200V;1A;
Schottky Diode;40V;1A;
Package Manufacturer
DIP
Ltec
DIP
Beryl
1206
muRata
0603
DIP
0805
DIP
DIP
0603
1206
muRata
Jianghai
Murata
Lelon
Jianghai
Murata
TDK
Taiwan
SOP-4
Semiconductor
DIP
Hongke
DO-41
Diodes
SOD-123
Diodes
Taiwan
SMA
Semiconductor
SMA
Diodes
Manufacturer_P/N
TY Series 10uF/400V
4.7μF/400V
GRM31B7U3A471JW31L
GRM188R71E105KA12D
CD281L-50V22
GRM21A5C2E101JW01D
RXW221M1EBK-0811P
HCN1A101MB12
GRM188R71A105KA61D
C3216X7R1E105K
MB6F
JN09E102MY02N
FR107
BAV21W-7-F
ES1D
B140
Fusible Resistor ;10Ω/1W
DIP
Yageo
FKN1WSJT-52-10R
Inductor;1000μH;6Ω;0.25A
Film Resistor;5%;
Film Resistor;1%;1/4W
Film Resistor;1%;
Film Resistor;5%
Film Resistor;1%;
Film Resistor;1%
Film Resistor;5%;1/4W
Film Resistor;5%;1/4W
Resistor;5%; 1/4W
EE16 Transformer, Lp=1.8mH
Np:Np_au:Nsec1:Nsec2
=134:16:17:7
Primary Side Regulator
DIP
0805
1206
1206
1206
0603
0603
1206
1206
1206
Wurth
Yageo
Yageo
Panasonic
Yageo
Yageo
Yageo
7447462102
RC0805JR-0710KL
RC1206FR-07357RL
ERJ8ENF1503V
RC1206JR-0710R
RC0603FR-0728K7L
RC0603FR-0713K7L
1206J0200T5E
CR06T05NJ5K1
CR1206J40203G
EE16
Emei
FX0294
SOIC8-7A
MPS
MP020-5GS R3
LIZ
LIZ
EV020-5-S-00D Rev.1.0
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7
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
TRANSFORMER SPECIFICATION
Electrical Diagram
PRI
1
SEC1
N1
22Ts
NC
N2
3
5
6
SEC2
N5
16Ts
4
17Ts
N3
134Ts
10
N4
7Ts
8
N6
16Ts
NC
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
5
2
3
2
3
2
3
2
3
2
3
2
3
N6: 0.15mm×1P×16Ts
N5: 0.15mm×1P×16Ts
6
8
10
N4: 0.4mm×1P×7Ts
TIW
N3: 0.32mm×1P×17Ts
TIW
1
N2: 0.15mm×1P×134Ts
3
1
NC
N1: 0.15mm×2P×22Ts
Figure 5—Winding Diagram
EV020-5-S-00D Rev.1.0
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EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
Winding Order
Tapes (T)
Winding
Start-End
Wire
Diameter (Ø)
N1
1—〉NC
N2
Turns ( T )
Tube
0.15mm*2
22
None
3—〉1
0.15mm*1
134
None
N3
10—〉6
0.32mm*1 TIW
17
None
N4
6—〉8
0.4mm*1 TIW
7
None
N5,
N6
5—〉4
4—〉NC
0.15mm*1
0.15mm*1
16
16
None
0
1
1
1
3
Electrical Specifications
Electrical Strength
Primary Inductance
Primary Leakage Inductance
60 second, 60Hz, from PRI. to SEC.
60 second, 60Hz, from PRI. to CORE.
3000VAC
500VAC
60 second, 60Hz, from SEC. to CORE.
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
3000VAC
1.8mH±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-00D Rev.1.0
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9
EV020-5-S-00D – 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)
0.03097
17.83
0
4.95
0
0.00%
V OUT1
Regulation
-0.94%
7.2945
17.6
0.3
5
0.1
79.23%
-2.22%
0.00%
1.3279
17.74
0.03
4.7
0.1
75.47%
-1.44%
-6.00%
0.72949
17.54
0.03
5.04
0.005
75.59%
-2.56%
0.80%
6.6718
17.54
0.3
5.11
0.005
79.25%
-2.56%
2.20%
V OUT2
Regulation
-1.00%
Pin (W) V OUT1 (V) I OUT1 (A) V OUT2 (V) I OUT2 (A) Efficiency
Vin=85Vac/60Hz
V OUT2
Regulation
-1.00%
0.03423
17.81
0
4.95
0
0.00%
V OUT1
Regulation
-1.06%
Vin=115Vac/60Hz 7.0858
1.3112
17.57
0.3
4.99
0.1
79.22%
-2.22%
-0.20%
17.71
0.03
4.69
0.1
76.29%
-1.61%
-6.20%
0.7226
17.54
0.03
5.02
0.005
76.29%
-2.56%
0.40%
6.4962
17.54
0.3
5.11
0.005
81.39%
-2.56%
2.20%
V OUT2
Regulation
-0.80%
Pin (W) V OUT1 (V) I OUT1 (A) V OUT2 (V) I OUT2 (A) Efficiency
0.03952
17.86
0
4.96
0
0.00%
V OUT1
Regulation
-0.78%
Vin=230Vac/50H 7.0653
1.3211
17.6
0.3
5
0.1
81.81%
-2.22%
0.00%
17.74
0.03
4.69
0.1
75.79%
-1.44%
-6.20%
0.72883
17.53
0.03
5.02
0.005
75.60%
-2.61% Δ
0.40%
6.471
17.56
0.3
5.12
0.005
81.80%
-2.44%
2.40%
V OUT2
Regulation
-1.00%
Pin (W) V OUT1 (V) I OUT1 (A) V OUT2 (V) I OUT2 (A) Efficiency
0.04261
17.82
0
4.95
0
0.00%
V OUT1
Regulation
-1.00%
Vin=265Vac/50Hz 7.0915
1.3332
17.59
0.3
5
0.1
81.46%
-2.28%
0.00%
17.71
0.03
4.68
0.1
74.95%
-1.61%
-6.40% Δ
0.73666
17.54
0.03
5.02
0.005
74.84%
-2.56%
0.40%
6.5233
17.57
0.3
5.12
0.005
81.20%
-2.39%
2.40%
Pin (W) V OUT1 (V) I OUT1 (A) V OUT2 (V) I OUT2 (A) Efficiency
Notes:
1. The red triangle means the worst case in table.
EV020-5-S-00D Rev.1.0
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10
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
No Load Consumption
No Load Power (mW)
No Load Power Consumption
50
45
40
35
30
25
20
50
100
150
200
250
300
Input AC Voltage (V)
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-00D Rev.1.0
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11
EV020-5-S-00D – 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-00D Rev.1.0
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12
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
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-00D Rev.1.0
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3/31/2015
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13
EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
Thermal Test
Test is conducted at ambient temperature of 25oC, 85Vac/60Hz input.
Top Layer
PCB is heated by MP020-5 at the bottom layer
Bottom Layer
EV020-5-S-00D Rev.1.0
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EV020-5-S-00D – UNIVERSAL INPUT, DUAL OUTPUTS FOR SMALL APPLIANCES
EVB TEST RESULTS
Performance waveforms are tested on the evaluation board.
V IN =115VAC/60Hz, V OUT1 =18V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, T A=25°C.
EV020-5-S-00D Rev.1.0
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15
EV020-5-S-00D – 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 =18V, I OUT1 =0.3A, V OUT2 =5V, I OUT2 =0.1A, CC Mode Load, T A=25°C.
EV020-5-S-00D Rev.1.0
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3/31/2015
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16
EV020-5-S-00D – 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 (+): 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.
EV020-5-S-00D Rev.1.0
www.MonolithicPower.com
3/31/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
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