Rohm BM2P0161-EVK-003 User manual

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© 2018 ROHM Co., Ltd. No. 60UG092E Rev.00
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JULY.
2018
User’s Guide
AC/DC Converter
Isolation Fly-back Converter PWM method Output 24W 12V
BM2P0161 Reference Board
BM2P0161-EVK-003
ROHM BM2P0161-EVK-003 is from wide input voltage (90Vac 〜 264Vac) to output 12V 2A max. Constant Voltage Reference board. It used to
PWMmethodDC/DC ConverterIC BM2P0161.
BM2P0161 is including 650V High voltage power MOSFET and starter. The starter realize low Stand-by Power.Output voltage control method is
usedcurrent moderegulation, therefore it can used cycle bycycle currentlimit.Quick response in dynamic load changing is achieved.
Switching frequency is fixed 65 kHz. Light load situation has frequency decrease function for higher efficiency. Switching frequency jitter function
enables lower EMI operation. Various functions areincluded for safety, Softstart,Frequency Burst Mode, VCCOVP, Output OLP and thermalshut
down.
Electronics Characteristics
Not guarantee the characteristics, is representative value. Unless otherwise noted: V
IN
= 230Vac, I
OUT
= 500mA, Ta: 25°C
Table 1. Evaluation Board Specification
Description Min Typ Max Units Conditions
Input Voltage Range 90 - 264 Vac
Input Frequency Range 47 50/60 63 Hz
Output Voltage 10.8 12.0 13.2 V
Output Maximum Power - - 24 W I
OUT
=2A
Output Current Range 0.0 1.5 2.0 A (Note 1)
No Load Power Consumption - 73 - mW I
OUT
= 0A
Efficiency 80.0 86.0 - % Output:24V 1.5A
Output Ripple Voltage - 190 - mV BW=20MHz, (note 2)
(NOTE1) Please adjust operating time, within any parts surface temperature under 105°C
(NOTE2) Not include spike noise

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Operation Procedure
1. Operation Equipment
(1) AC Power supply 90Vac ～ 264Vac, over 100W
(2) Electronic Load capacity 2A
(3) Multi meter
2. Connect method
(1) AC power supply presetting range 90~264Vac, Output switch is off.
(2) Load setting under 2A. Load switch is off.
(3) AC power supply N terminal connect to the boardAC (N) of CN1, and L terminal connect to AC (L).
(4) Load + terminal connect to VOUT, GND terminal connect to GND terminal
(5) AC power meter connect between AC power supply and board.
(6) Output test equipment connects to output terminal
(7) AC power supply switch ON.
(8) Check that output voltage is 12V.
(9) Electronic load switch ON
(10) Check output voltage drop by load connect wire resistance
Figure 1. Connection Circuit
Deleting
Maximum Output Power Po of this reference board is 24W. The derating curve is shown on the right. Please adjust load
continuous time by over 105°C of any parts surface temperature within the operating temperature range (-10~65°C).
Figure 2. Temperature Deleting curve
Ta[℃]
Po[W]
-10℃ 25℃ 50℃ 65℃
30W
24W
-
+
DC Multi Meter
V
Electric
LOAD
Power
Meter
AC power
Supply
24W
30W

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Schematics
VIN = 90～264Vac, VOUT = 12V
Figure 3. BM2P0161-EVK-003 Schematics
Bill of Materials Table 2. BoM of BM2P0161-EVK-003
C1
0.1μF
X1
LF1
13mH
F1
1.6A
AC300V
DB1
R4
0.43
±1%
2W
C9
1000pF
100V
C10
10μF
35V
R5
5.6
0.25W
T1
EE25
1
2
3
5
4
7
GND
D3
SBD 10A/150V
RB088BGE150
(TO-252)
C5
47μF
450V
SGND
IC2
TLP431B
C11
0.1μF
100V
R12
10k
±1%
R15
27k
R14
1k
R13
2.2k
R10
33k
±1%
R11
5.6k
±1%
VOUT
GND
PC1
C7
47pF
1kV
L
N
CN1-3
CN1-2
IC1
BM2P0161
VCC
1
N.C N.C. DRAIN
FB
GND_IC
FADJ
SOURCE
2 3 4
8
7 6 5
9
C13
1000μF
25V
Low-Z
C15
0.1μF
100V
C6
1000pF
1kV
R7
100k
2W
C11
2200pF
Y1
ZNR1 C2 0.1μF
X1
R6
0
C8
NC.
8
6
12V/2A
D1
FRD
0.8A/700V
RFN1LAM7S
(PMDTM)
D2
SBD
0.2A/400V
RRE02VSM4S
(TUMD2SM)
Part
Reference
Qty. Type Value Description Part Number Manufacture Configuration
mm (inch)
C1,C2 2 X2 Capacitor 0.1μF 300Vac, ±20% 890324023023CS Wurth -
C5 1 Electrolytic 47μF 450V, ±20% 450BXW47MEFR16X25 Rubycon 16mmΦX25mm
C6 1 Ceramic 2200pF 1000V, X7R, ±10% GRM31BR73A222KW01 Murata 3216 (1206)
C7 1 Ceramic 47pF 1000V, X7R, ±10% RDE5C3A470J2K1H03B Murata -
C8 0 Ceramic NC - - - 1608 (0603)
C9 1 Ceramic 1000pF 100V, X7R, ±10% HMK107B7102KA-T Taiyo Yuden 1608 (0603)
C10 1 Ceramic 10μF 35V, ±10% GMK316AB7106KL-TR Taiyo Yuden 3216 (1206)
C11 1 Y1 Capacitor 2200pF Y1 capacitor DE1E3KX222MB4BP01F Murata -
C13 1 Electrolytic 1000uF 25V , ±20% 25ZLJ1000M10X20 Rubycon 10mmΦX20mm
C15,C16 2 Ceramic 0.1μF 100V, X7R, ±10% HMK107B7104KA-T Taiyo Yuden 1608 (0603)
D1 1 FRD 0.8A 700V RFN1LAM7S ROHM PMDTM
D2 1 REC Di 0.2A 400V RRE02VSM4S ROHM TUMD2SM
D3 1 SBD 10A 150V RB088BGE150 ROHM TO-252
DB1 1 Bridge 1A 800V D1UBA80 Shindengen SOP-4
F1 1 Fuse 1.6A 1.6A 300V 36911600000 Littelfuse -
IC1 1 AC/DC Converter - 650V BM2P0161 ROHM DIP7
IC2 1 Shunt Regulator - ±0.5% TL431BIDBZT TI SOT-23-3
LF1 1 Line Filter 13mH 1A XF1482Y Alpha Trans -
PC1 1 Optocoupler - 5kV LTV-817-B LiteON DIP4
T1 1 Transformer - Bobin:EI-2506,
Core:EE25/20 XE2181A Alpha Trans -
R4 1 Resistor 0.43Ω 2W, ±1% LTR100JZPFLR430 ROHM 3264 (1225)
R5 1 Resistor 5.6Ω 0.25W, ±5% MCR18EZPJ5R6 ROHM 3216 (1206)
R6 1 Resistor 0Ω 0.25W MCR18EZPJ000 ROHM 3216 (1206)
R7 1 Resistor 100kΩ 2W, 700V, ±2% ERG2SJ104E Panasonic -
R10 1 Resistor 33kΩ 0.1W, ±1% MCR03EZPFX3302 ROHM 1608 (0603)
R11 1 Resistor 5.6kΩ 0.1W, ±1% MCR03EZPFX5601 ROHM 1608 (0603)
R12 1 Resistor 10kΩ 0.1W, ±1% MCR03EZPFX1002 ROHM 1608 (0603)
R13 1 Resistor 2.2kΩ 0.1W, ±5% MCR03EZPF222 ROHM 1608 (0603)
R14 1 Resistor 1kΩ 0.1W, ±5% MCR03EZPJ102 ROHM 1608 (0603)
R15 1 Resistor 27kΩ 0.1W, ±5% MCR03EZPJ273 ROHM 1608 (0603)
ZNR1 1 Varistor - 300Vac, 423Vmin, 400A V470ZA05P Littelfuse 5mmΦ Disc

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Design reference of transformer
Manufacturer ：Alfatrans Co., LTD.
〒541-0059 2-7-1 bakurou-cho, chu-o ku, osaka
http://www.alphatrans.jp/
Product: XE2145AAlphaTrans Corp.
Bobin: EI-2506 10PIN
Core: EE25/20 JSF
Figure 4. Connection Diagram Figure 5. Winding structure diagram
Table 3. Alpha Trans XE2145A Winding Specification
Inductance (Lp) 830µH±15% (100kHz,1V)
Leakage Inductance 25µH MAX
Withstand Voltage Pri – Sec AC3000V
Pri - Core AC1500V
Sec – Core AC1500V
Insulation resistance 100MΩover (DC500V)

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PCB
Size : 55 mm x 91 mm
Figure 4. Top Silkscreen (Top view)
Figure 5. Bottom Layout (Top view)

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BM2P0161 Overview
Feature
 PWM Frequency=65kHz
 PWM current Mode Control
 Switching frequency jitter
 Burst function around light load
 Burst frequency control adjust （ FADJ ）
 650 V Starter
 650 V Power MOSFET
 VCC OVP, UVLO
 SOURCE Comparator Leading-Edge-Blanking
 Cycle by cycle current limiter
 Current limiter AC Voltage compensation circuit
 Soft Start function
 OLP 、 Thermal shut down
Key specifications
■ Operation Voltage Range:
VCC: 8.9 V 〜 26.0 V
DRAIN: 650 V(Max)
■ Circuit Current(ON) :
BM2P0161: 0.90 mA(Typ)
BM2P0361: 0.65 mA(Typ)
■ Circuit Current (Burst mode) : 0.30 mA(Typ)
■ Operating Temperature: -40 °C 〜 +105 °C
■ Maximum Junction Temperature : +150 °C
■ MOSFET R-ON : BM2P0161 : 1.0 Ω (Typ)
BM2P0361 : 3.0  (Typ)
Dimension W(Typ) x D(Typ) x H(Max)
DIP7K 9.20 mm x 6.35 mm x 4.30 mm
Pitch 2.54 mm
Figure 8. Block Diagram
Figure 9. DIP7K Package
Table 4. BM2P0161 PIN description
NO. Name I/O Function ESD Diode
VCC
GND
1 SOURCE I/O MOSFET SOURCE
✔ ✔
2 FADJ I Max Burst Frequency Setting pin
✔ ✔
3 GND I/O GND
✔ -
4 FB I Feedback signal input
✔ ✔
5 VCC I Vcc -
✔
6 DRAIN I/O MOSEFET DRAIN - -
7 DRAIN I/O MOSEFET DRAIN - -
GND
DRAIN DRAIN VCC
SOURCE
7 6 5
1 2 3 4
FADJ FB
TOP VIEW

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Design Overview
1. Important parameter
Input Voltage Spec AC90V to AC264V (DC 100V to 380V)
MOSFET Voltage max 650V
1-1．Determination of fly-back voltage VOR
Turns-ratio Np:Ns and duty-ratio is determined along with Fly-back voltage VOR

  

* 1.3: Safety margin. Please check yourself.

 
!"#$ 
%
&'(
Figure 10. MOSFET Drain-Source Voltage (Vds)
Confirmation of Np/Ns and Duty (max)
)&'(
VIN (MIN) =100V, VOR=70V, Vf=1V

   *%) (%'
（＊） VOR should be set to keep margin from input Max voltage plus VOR and MOSFET maximum ratings.
And VOR setting also keep MOSFET on duty within 0.5 at input voltage minimum.


  *%) (%'
!"#$
+,% ) %)-(
VIN→
GND→
VOR

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1-2 ． Selecting operation mode
Flyback converter of fixed frequency PWM switching send power from primary side to secondary side using
Transformer. Transformer operation mode are blow three modes.
 CCM （ Continuous Current Mode ） Primary MOSFET turn ON before secondary coil discharge complete.
 BCM （ Boundary Current Mode ） Primary MOSFET turn ON timing is just secondary coil discharge. Mode
name from looks like bounding ball, secondary current wave form touch to GND at the same time primary coil
current grow-up from GND.
 DCM （ Dis-continuous Current Mode ） Primary MOSFET turn ON timing has some interval after secondary coil
discharge. Coil current is dis-continue.
BM2P0161 can be operate CCM, BCM and DCM.
This reference board transformer design target is BCM point at input DC260V (185V) and LOAD 12V/2A.
Figure 11. Switching waveform (MOSFET Vds,Ids)
Figure 12. Operation mode – Input Voltage and Peak current (MOSFET Drain, Diode)
BCM
BCMBCM
BCM
DCM
DCMDCM
DCM
Operating wave form of MOSFET
Drain voltage and current.
Primary
MOSFET Drain
Peak Current
Input
Voltage
CCM DCM
BCM
Point
Vds
Ids
Vds
Ids
Vds
Ids
Secondary
Diode
Peak Current
Input
Voltage
CCM
DCM
BCM
Point

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1-3. Design of transformer inductances
Assuming condition BCM point is 260VDC 、 65kHz 12V/2A load.
Calculation for secondary and primary inductance, peak current.
Vo=12V 、 secondary rectifier diode VF ＝ 1V
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23 /4*5
6

(7(%((
6
((89(':;
2<23

6
(':;'
6
'=;
>3<?@(A
B7 8
><<?@(A
B7 C'(0
><D><<?4*5
EC'((( E(8
1-4 ． Selecting transformer core size
Accordingly Po (max) =26W, Core is selected EE25.
Table 5. Output Power vs transformer core size
（＊） above table is one of reference, please confirmation to transformer manufacturer.
1-5 ． Calculate of primary wiring turn : Np
The maximum rating of magnetic flux density of standard ferrite core is
0.4T@100 ℃ . Accordingly Bsat=0.266T.
F<GB9
8HIJ':;C'(8 -==
6
(K)#"L,3
Np makes 77 turns.
Prevent form Magnetic saturation.
Check transformer AL-Value － NI value table 。
When Np=77 turns,
02M"N 

6
':;
))*O
6
C;P*O
6
F>F<><<?))#"L,3C'(0)(0Q#"L,3
Confirm by core specification whether or not it falls into this saturation region.
Output Power Po(W) Core Size Core Area Ae
（ mm
2）
~30 EI25/EE25 41
~60 EI28/EE28/EER28 84
~80
EI33/EER35
107
Figure 13. TDK PC47EE25/19
AL-Value to NI Limit

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1-6．Calculate of secondary wiring turn : Ns

'R )) '-*O
Ns wiring is 14 turns.
Secondary wiring average current is output current.
1-7．Calculation of VCC wiring turn ; Nd
Accumulation VCC=16V、Vf_vcc diode =1V
FSF3TT%UVWW
*% -*O%
(%'#"L,3
Nd wiring is 18 turns.
(＊) Please consider secondary capacitor voltage ratings and VCC OVP voltage.
Transformer parameter of this section result.
Table 6. Transformer parameter table
Core PC47EE25/19 compatible
Lp 830µH
Np 77 turns
Ns 14 turns
Nd 18 turns
2．Selection of important components
2-1．Input capacitor；C5
Calculation by using of Table 1-3
Pout=12Vx2.0A=24W, C5：2x24=48  47F
Table 7. Input capacitor selection table
Input Voltage
（Vdc）Cin（µF）
< 300 2 x Pout(W)
300<
1 x Pout(W)
（＊）When selecting, also consider other specifications such as the output retention-time.
Capacitor voltage rating is selected by maximum input voltage.
This time we selected 450V ratings capacitor.