Maxim MAX5022EVKIT Operating and maintenance instructions

General Description
The MAX5022 evaluation kit (EV kit) is a fully assembled
and tested 5W flyback-converter circuit board. The
power supply is configured for an isolated +5VDC out-
put voltage that can supply up to 1A of current. The line
input voltage range is from 85VAC to 265VAC or
120VDC to 375VDC.
The MAX5022 EV kit demonstrates high efficiency up to
80% at 262kHz switching frequency. This high efficiency
is achieved by using a single transistor (MOSFET),
flyback-converter topology providing output power up to
5W. The surface-mount transformer has a tertiary wind-
ing to power the MAX5022 IC after startup. An optocou-
pler along with the transformer provide input-to-output
isolation up to 4500VDC.
Warning: The MAX5022 EV kit is designed to operate
with high voltages. Dangerous voltages are present on
this EV kit and on equipment connected to it. Users
who power up this EV kit or the power sources connect-
ed to it must be careful to follow safety procedures
appropriate for working with high-voltage electrical
equipment.
Under severe fault or failure conditions, this EV kit may
dissipate large amounts of power, which could result in
the mechanical ejection of a component or component
debris at high velocity. Operate this kit with care to
avoid possible personal injury.
Features
♦85VAC to 265VAC or 120VDC to 375VDC Input
Range
♦Isolated Output Voltage: +5VDC at 1A
♦Input-to-Output Isolation Up to 4500VDC
♦Fully Assembled and Tested
♦Efficiency Up to 80%
♦2% Output Voltage Regulation Over Line and
Load
Evaluates: MAX5022
MAX5022 Evaluation Kit
________________________________________________________________ Maxim Integrated Products 1
19-2073; Rev 3; 4/05
For pricing, delivery, and ordering information, please contact Maxim/Dallas Direct! at
1-888-629-4642, or visit Maxim’s website at www.maxim-ic.com.
Ordering Information
PART TEMP RANGE IC PACKAGE
MAX5022EVKIT 0°C to +70°C 6 SOT23-6
Component List
DESIGNATION QTY DESCRIPTION
C1, C9 2
10.0µF ±20%, 400V aluminum
electrolytic capacitors (12.5mm x
13.5mm)
Sanyo 400CV10FS
C2, C3 2
0.22µF ±20%, 50V X7R ceramic
capacitors (1206)
TDK C3216X7R1H224M
C4, C10 2
47µF ±20%, 6.3V aluminum organic
capacitors (case V)
Kemet A700V476M006AT018
C5, C12 2
0.01µF ±10%, 16V X7R ceramic
capacitors (0402)
TDK C1005X7R1C103K
C6 1
0.1µF ±10%, 50V X7R ceramic
capacitor (0603)
TDK C1608X7R1H104K
DESIGNATION QTY DESCRIPTION
C7 1 1000pF ±20%, 4KVAC (DE0910)
Murata DE1E3KX102MA5BA01
C8 1
8200pF ±10%, 50V X7R ceramic
capacitor (0603)
TDK C1608X7R1H822K
C11 1
1000pF ±10%, 630V X7R ceramic
capacitor (1206)
TDK C3216X7R2J102K
C13 1
2200pF ±10%, 50V X7R ceramic
capacitor (0402)
TDK C1005X7R1H222K
D1 1
250mA, 75V high-speed switching
diode (SOT-23)
Central Semiconductor CMPD914

Evaluates: MAX5022
MAX5022 Evaluation Kit
2 _______________________________________________________________________________________
DESIGNATION QTY DESCRIPTION
D2 1
3A, 40V Schottky power rectifier
(SMC)
Central Semiconductor CMSH3-40
D3 1
1000V, 1A full-wave diode bridge
(SMDIP)
Central Semiconductor CBR1-D100S
D4 1 600V, 1A ultra-fast rectifier (SMA)
Central Semiconductor CMR1U-06M
D5 1
100V, 200mA small-signal diode
(SOD-123)
Fairchild Semiconductor MMSD4148
F1 2 2AG and 5mm fuse clips
Keystone 3519
F1 1 1/4A 250V SLO-BLO fuse
Littelfuse 229.250H
L1, L3 2
Ferrite beads 220Ωat 100MHz, 2A
DCR = 0.050Ω(0805)
Murata BLM21PG221SN1
L2 1 470µH, 240mA inductor
Sumida CDRH73-471
N1 1
1.8A, 600V, n-channel MOSFET
(DPAK)
Fairchild Semiconductor SSR2N60B
R1, R2 2 360kΩ±5% resistors (1206)
DESIGNATION QTY DESCRIPTION
R3 1 1.00kΩ±1% resistor (0805)
R4 1 24.9kΩ±1% resistor (0805)
R5 1 8.06kΩ±1% resistor (0805)
R6 1 10Ω±5% resistor (0603)
R7 1 1.78Ω±1% resistor (1206)
R8 1 1.2kΩ±5% resistor (1206)
R9 1 240kΩ±5% resistor (0805)
R10 1 10Ω±5% resistor (0805)
R11 1 1.5kΩ±1% resistor (0603)
R12 1 100kΩ±5% resistor (1206)
R13 1 100Ω±5% resistor (0603)
TB1 1 2-point terminal block (0.2in center)
T1 1
480µH (primary:secondary:tertiary
turns ratio 60:3:8) 5W transformer
Cooper Electronic Technologies
CTX03-15256
U1 1 MAX5022EUT-T (6-pin SOT23)
U2 1
70V, 100% to 200% CRT
phototransistor (0.4in lead spacing)
Fairchild CNY17-3.W
U3 1
1.24V precision shunt regulator
(SOT23-5L)
Texas Instruments TLV431AIDBV
— 4 Rubber bumpers
— 1 MAX5022 EV kit PC board
Component List (continued)

Evaluates: MAX5022
MAX5022 Evaluation Kit
_______________________________________________________________________________________ 3
Quick Start
The MAX5022 EV kit is fully assembled and tested.
Follow these steps to verify board operation.
Warning: Exercise CAUTION when connecting and
measuring off-line voltages.
• Voltage at the primary side may be as high as
700VDC.
• Do not turn on the power supply until all connec-
tions are completed.
• Wear protective eye gear at all times.
• Do not touch any part of the circuit with bare hands
or conductive materials while power is applied.
• Make sure all high-voltage capacitors are fully dis-
charged before handling.
Recommended Equipment
• Isolation transformer
• Variac
• Voltmeter
VOUT Setup Procedure
1) Connect the positive lead of a DC voltmeter to the
VOUT pad.
2) Connect the negative lead of a DC voltmeter to the
GND pad.
3) Make sure that the isolation transformer is not pow-
ered up. Connect the variac to the output of the iso-
lation transformer.
4) Connect one lead of an AC voltmeter to the wiper
terminal of the variac.
5) Connect the other lead of the AC voltmeter to the
“common” terminal of the variac.
6) Set the output voltage of the variac to 0VAC.
7) Connect the wiper terminal of the variac to the L ter-
minal of TB1.
8) Connect the “common” terminal of the variac to the
N terminal of TB1.
9) Connect a 50Ω1W resistor across the output.
10) Power up the isolation transformer, and gradually
increase the voltage of the variac to 85VAC and up
to 265VAC.
11) Verify that VOUT is +5V throughout the input volt-
age range of 85VAC to 265VAC.
SUPPLIER PHONE FAX WEBSITE
Central Semiconductor 631-435-1110 631-435-1824 www.centralsemi.com
Cooper-Coiltronics 561-752-5000 561-742-1178 www.cooperet.com
Fairchild Semiconductor 888-522-5372 Local rep only www.fairchildsemi.com
Kemet 864-963-6300 864-963-6322 www.kemet.com
Keystone Electronics 800-221-5510 718-956-9040 www.keyelco.com
Littelfuse 847-824-1188 847-391-0894 www.littelfuse.com
Murata 770-436-1300 770-436-3030 www.murata.com
Sanyo Electronic Device 619-661-6835 619-661-1055 www.sanyodevice.com
Sumida USA 847-545-6700 847-545-6720 www.sumida.com
TDK 847-803-6100 847-390-4405 www.component.tdk.com
Note: Indicate that you are using the MAX5022 when contacting these component suppliers.
Component Suppliers

Evaluates: MAX5022
MAX5022 Evaluation Kit
4 _______________________________________________________________________________________
MAX5022 EFFICIENCY
90
80
70
60
50
40
30
20
10
0
0100 200 300 400 500 600 700 800 900 1000
EFFICIENCY (%)
OUTPUT CURRENT (mA)
VIN = 85VAC
VIN = 120VAC
VIN = 265VAC
Figure 1. Efficiency Graph
Detailed Description
The MAX5022 EV kit is an off-line 5W flyback converter,
configured for +5VDC/1A output. A tertiary winding
from the transformer is used to power the device during
normal operation. The secondary winding provides the
+5VDC output and can supply up to 1A.
This EV kit uses the MAX5022, a SOT23, current-mode,
pulse width modulating (PWM) controller. This PWM
controller varies the duty cycle to compensate for the
variation in VIN and the output load to maintain a con-
stant output voltage. The duty cycle determines the
on/off duration of the MOSFET (N1). The n-channel
MOSFET is used as a switch to control the current
through the primary winding of the transformer (T1).
The duty cycle is controlled by the feedback loop con-
sisting of voltage-divider resistors (R4, R5), a shunt regu-
lator (U3), an optocoupler (U2), and the PWM compara-
tor inside the MAX5022. This network provides the isolat-
ed feedback, regulating the output voltage to 5V ±2%
with up to 4500VDC input-to-output isolation.
The MAX5022 senses the current going through the
transformer’s primary winding with a current-sense
resistor (R7), and shuts down the output when the out-
put current exceeds the current limit of 1.6A. The
MAX5022 EV kit is protected against catastrophic fail-
ure with the fuse (F1).

Evaluates: MAX5022
MAX5022 Evaluation Kit
_______________________________________________________________________________________ 5
6
3 5
TERMINAL BLOCK
TB-1
TB-2
F1
3
21
4
AC
AC
D3
L2
470µH
R8
1.2kΩ
C1
10µF
400V
C9
10µF
400V
R1
360kΩ
R12
100kΩ
C11 1000pF
R2 360kΩ
C2 0.22µF
L3
D4
D1
1
789
C7
1000pF
C4
47µF
6.3V
R3 1kΩ 1%
1
R10
10Ω
C5
0.01µF
34
5
U3
2
R5
8.06kΩ
1%
R4
24.9kΩ
1%
C6 0.1µF
C10 47µF 6.3V
+5V VOUT
GND
L1
D2
10 1112
T1
CTX03_15256
N1
R6
10ΩR7
1.78Ω 1%
C8
8200pF
1
CS
3
NDRV
5
VIN
VCC
4 6
2
R11 1.5kΩ 1%
C12
0.01µF
C3
0.22µF
5 4
6
U2-B
R9
240kΩ
OPTO
GND
MAX5022
U1
SECONDARY GROUND
PRIMARY GROUND
NOTE: ALL RESISTORS ARE 5% UNLESS OTHERWISE SPECIFIED
100Ω
D5
12 56
34
U2-A
R13
C13 2200pF
Figure 2. MAX5022 EV Kit Schematic

Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are
implied. Maxim reserves the right to change the circuitry and specifications without notice at any time.
6_____________________Maxim Integrated Products, 120 San Gabriel Drive, Sunnyvale, CA 94086 408-737-7600
© 2005 Maxim Integrated Products Printed USA is a registered trademark of Maxim Integrated Products, Inc.
Evaluates: MAX5022
MAX5022 Evaluation Kit
Figure 3. MAX5022 EV Kit Component Placement Guide—Component Side
Figure 4. MAX5022 EV Kit PC Board Layout—Component Side
Figure 5. MAX5022 EV Kit PC Board Layout—Solder Side

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