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EV020-5-S-00A 85vac~265vac/50hz, 5v/1a off-line primary-side-regulator cell phone charger evaluation board EV020-5-S-00A rev.1.02 www.monolithicpower.com 1 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. the future of analog ic technology description the EV020-5-S-00A 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-00A is typically designed for cell phone which output 5v, 1a load from 85vac to 265vac, 50hz/60hz. the EV020-5-S-00A 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 input voltage v in 85 to 265 vac output voltage v out 5 v output current i out 1 a output power p out 5 w efficiency (full load) >70 % features ? 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 ? 550a high-voltage current source ? 30mw 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 applications ? 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 o f 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-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 2 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. EV020-5-S-00A evaluation board top view bottom view (l x w x h) 47mm x 30mm x 18mm board number mps ic number EV020-5-S-00A mp020-5gs
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 3 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. evaluation board schematic figure 1?schematic
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 4 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. pcb layout (single-sided) figure 2?top layer figure 3?bottom layer
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 5 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. circuit description the EV020-5-S-00A 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 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 filter to guarantee the conducted emi meet standard en55022. 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. 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, c8, c9, c10, l2 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. c8, l2 and c9 compose filter to restrain the output ripple. r7 and c7 are used to depress the spike of schottky.
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 6 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. EV020-5-S-00A bill of materials qty ref value description package manufacturer manufacturer_p/n 1 c1 4.7 f capacitor;400v;20% dip nichicon uvy2g4r7mpd 1 c2 10 f capacitor;400v;20% dip ltec ty 10uf/400v 1 c3 1nf ceramic capacitor;630v;x7r 1206 murata grm31a7u2j102jw31d 1 c4 1 f ceramic capacitor;25v;x7r; 0603 murata grm188r71e105ka12d 1 c5 100nf ceramic capacitor;50v;x7r; 0603 murata gcj188r71h104ka12d 1 c6 22 f electrolytic capacitor;50v dip jianghai cd281l-50v22 1 c7 1.2nf ceramic capacitor;100v;x7r 0603 murata grm188r72a122ka01d 2 c8,c 9 470 f electrolytic capacitor;10v,low esr dip nippon chemi-con ekze100ell471mhb5d 1 c10 1 f ceramic capacitor;10v;x7r 0603 murata grm188r71a105ka61d 1 c11 22pf ceramic capacitor;50v;c0g; 0603 murata grm1885c1h220ja01d 1 cy1 nc 1 cr1 mb6f diode;600v;0.5a sop-4 diodes mb6f 1 d1 fr107 diode;1000v;1a do-41 diodes fr107 1 d2 s1ml diode;1000v;1a; sma taiwan semiconduct or s1ml 1 d3 b540c schottky diode;40v;5a smc diodes b540c 1 fr1 10 ? fusible resistor, 1 w, 5% yageo dip fkn1wsjt-52-10r 1 l1 1000 h inductor;1000uh;6 ohm;0.25a dip wurth 7447462102 1 l2 3.3 h inductor;3.3uh;0.025ohm;4a dip wurth 7447462033 1 r1 10k ? film resistor;5% 0805 yageo rc0805jr-0710kl 1 r2 357 ? film resistor; 1%;1/4w 1206 yageo rc1206fr-07357rl 1 r3 150k ? film resistor; 1%,1/4w 1206 panasonic erj8enf1503v 1 r4 10 ? film resistor;5%;1/4w 1206 yageo rc1206jr-0710r 1 r5 27k ? film resistor;1%; 0603 yageo rc0603fr-0727kl 1 r6 13.3k ? film resistor;1% 0603 yageo rc0603fr-0713k3l 1 r7 20 ? film resistor;5%;1/4w 1206 royalohm 1206j0200t5e 1 r8 2.2k ? film resistor;5%; 0603 liz rc0603ja0222g 1 r9 510 ? film resistor;5%; 0805 liz rc0805ja0510 1 u1 primary side regulator r3 soic8- 7a mps mp020-5gs 1 t1 transformer;1.6mh; n p :n p_au :n sec1 :n sec2 =127:18 :4:4 ee16 wurth (1) 7508110157 notes: (1) wurth transformer sample request pl ease login on website: www.we-online.com
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 7 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. transformer specification electrical diagram n p n p_au 3 5 4 6 primary side 1 10 n sec1 core is connected to pin 4 by wire nc teflon tube winding start 9 7 n sec2 n c secondary side figure 4?transformer electrical diagram notes: 1. n sec1 and n sec2 are coiled at one layer. 2. core is connected to pin 4 with naked wire. 3. n sec1 and n sec2 are with triple insulation wire. winding diagram figure 5?winding diagram
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 8 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. winding order winding no. tape layer number start & end magnet wire (mm) turns n p 1 3 1 0.15mm * 1 127 n p_au 1 5 4 0.18mm * 1 18 n c 1 4 nc 0.18mm * 3 7 n sec1 1 10 6 0.6mm * 1 tiw 4 n sec2 1 7 9 0.6mm * 1 tiw 4 electrical specifications 60 second, 60hz, from pri. to sec. 3000vac 60 second, 60hz, from pri. to core. 500vac electrical strength 60 second, 60hz, from sec. to core. 3000vac primary inductance pins 1 - 3, all other windings open, measured at 60khz, 0.1 vrms 1.6mh10% primary leakage inductance pins 1 - 3 with all other pins shorted, measured at 60khz. 0.1 vrms 50 h10% materials item description 1 core: ee16, ui=230025%, al=73.2.4nh/n 2 3% gapped, or equivalent 2 bobbin: ee16, 5+5pin 1 sect th, ul94v-0 3 wire: 0.15mm,, 2uew, class b 4 wire: 0.18mm,, 2uew, class b 5 triple insulation wire: 0.60mm tiw 6 tape: 8.0mm(w)0.06mm(th) 7 varnish: john c. dolph co, bc-346a or equivalent 8 solder bar: chen nan: sn99.5/cu0.5 or equivalent
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 9 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. evb test results performance data t a =25 , unless otherwise noted. 64 66 68 70 72 74 76 78 80 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 14 16 18 20 22 24 26 28 30 50 100 150 200 250 300 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 60 80 100120140160180 200 220240260 280 300 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 10 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. 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 220 l to n 90 pass -1000 220 l to n 270 pass 1000 220 l to pe 90 pass -1000 220 l to pe 270 pass 1000 220 n to pe 90 pass -1000 220 n to pe 270 pass
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 11 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. conducted emi test test with 230vac input and full load condition clrwr 2 av sgl tds 6db 1 mhz 10 mhz 0 10 20 30 40 50 60 70 80 90 100 110 120 en55022a en55022q 1 pk clrwr att 10 db rbw 120 khz mt 100 ms preamp off 150 khz 30 mhz 230vac, 50hz, maximum load, l line, output gnd floats, en55022 limits sgl tds 6db 1 mhz 10 mhz 0 10 20 30 40 50 60 70 80 90 100 110 120 en55022a en55022q clrwr 2 av 1 pk clrwr att 10 db rbw 9 khz mt 20 ms preamp off 150 khz 30 mhz 230vac, 50hz, maximum load, n line, output gnd floats, en55022 limits
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 12 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. conducted emi test (continued) clrwr 2 av sgl tds 6db 1 mhz 10 mhz 0 10 20 30 40 50 60 70 80 90 100 110 120 en55022a en55022q 1 pk clrwr att 10 db rbw 9 khz mt 1 s preamp off 150 khz 30 mhz 230vac, 50hz, maximum load, l line, output gnd connects to earth, en55022 limits sgl tds 6db 1 mhz 10 mhz 0 10 20 30 40 50 60 70 80 90 100 110 120 en55022a en55022q clrwr 2 av 1 pk clrwr att 10 db rbw 9 khz mt 1 s preamp off 150 khz 30 mhz 230vac, 50hz, maximum load, n line, output gnd connects to earth, en55022 limits
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 13 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. thermal test test with 85vac input and full load condition. pcb la yout is with 1oz copper. ambient temperature is 25c. top layer output diode d3 bottom layer
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 14 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. evb test results performance waveforms are tested on the evaluation board. v in =115vac/60hz, v out =5v, i out =1a, l p =1.6mh, n p :n p_au :n sec1 :n sec2 =127:18:4:4, t a =25 , unless otherwise noted.
EV020-5-S-00A ? universal inpu t, 5w cell phone charger EV020-5-S-00A rev.1.02 www.monolithicpower.com 15 11/28/2013 mps proprietary information. patent protec ted. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. evb test results (continued) performance waveforms are tested on the evaluation board. v in =230vac/50hz, v out =5v, i out =1a, l p =1.6mh, n p :n p_au :n sec1 :n sec2 =127:18:4:4, t a =25 , unless otherwise noted.
EV020-5-S-00A ? universal inpu t, 5w cell phone charger notice: the information in this document is subject to change wi thout notice. please contact m ps for current specifications. users should warrant and guarantee that third party intellectual property rights ar e not infringed upon when integrating mps products into any application. mps will not assume any legal responsibility for any said applications. EV020-5-S-00A rev.1.02 www.monolithicpower.com 16 11/28/2013 mps proprietary information. patent protect ed. unauthorized photocopy and duplication prohibited. ? 2013 mps. all rights reserved. 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 load to: a. positive (+): vout b. negative (?): gnd 5. turn power supply on after making connections.

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