💬 HLK-PM01 breakout board

[pihome]

Thank you for sharing, what Varistor part number you are using?

[sundberg84]

@pihome im using the recommendations from this thread: https://forum.mysensors.org/topic/1607/safe-in-wall-ac-to-dc-transformers
Make sure you buy the right depending on what AC voltage you have 120/240 or other.

I think these are the ones i bought last time.

[beic]

Dear @sundberg84 can you please read and write here the Varistors exact model/part number from your assembled board, please?

[sundberg84]

@beic hi. Please see the thread above yours

[beic]

@sundberg84 said in 💬 HLK-PM01 breakout board:

@beic hi. Please see the thread above yours

There is no value mentioned there, and how did you calculated the tp peak of the sine for varistor against mains?
You just trow some varistor value in there without calculating anything for RMS and Vpp?!

[sundberg84]

@beic - sorry, I missed your reply :(
I didnt calculate - it depends on your AC, depending on your locations so everyone using this PCB has to get their own MOV.

I have followed the collected recommendations from this thread: https://forum.mysensors.org/topic/1607/safe-in-wall-ac-to-dc-transformers

Im happy to learn more about varistors (haven't got that far in AOE yet :) ) so please inform us if you know more that would be usefull here. You can use the thread above.

The varistor was recommended here: http://lygte-info.dk/review/Power Mains to 5V 0.6A Hi-Link HLK-PM01 UK.html

[ru64]

Hi @sundberg84, did you create custom components for this design? Can you add your library files to the download, please?

[sundberg84]

@ru64 - i tried uploading them but openhardware didnt allow it.
@hek - is it possible to allow these?

.dcm
.lib
.kicad_mod

[hek]

Yes, should be possible to allow those file extensions. I'll take a look at it tonight.

[hek]

@sundberg84

Could you give it another try try uploading the files. They should work now.

[sundberg84]

@hek - worked! Tnx
@ru64 - uploaded!

[ru64]

@sundberg84 - thanks! but still schematic does not open correctly, remapping says:

Warning: No symbol “HLK-PM01” found in symbol library table.
Warning: No symbol “CONN_01X02” found in symbol library table.
Warning: No symbol “CONN_01X02” found in symbol library table.
Warning: No symbol “FUSE” found in symbol library table.
Warning: No symbol “FUSE” found in symbol library table.
Warning: No symbol “FUSE” found in symbol library table.
Warning: No symbol “VR” found in symbol library table.
Warning: No symbol “C” found in symbol library table.
Warning: No symbol “C” found in symbol library table.

Any ideas? Sorry if asking stupid thing, but I am really new with KiCad

[ru64]

Oh, ok, never mind. Apparently, it does not work correctly in the latest KiCad version. When I open it in 4.0.4, it looks fine :)

[ab192]

@sundberg84 can you please tell me what is the type or specifications (other than 600mA) for the output fuse? Could you name a specific fuse as an example?
Thank you.

[sundberg84]

@ab192 - I put that there because that is the limit of the HLK-PM01 output. I never use it though, (i just bridge it) and use the input-fuse... When you choose a fuse its much about what kind if load you are going to have on that circuit.

[Almamater]

Hello, thank you for the good job! Just one question, do you remember what is the size of the 200mA fuse that you put? (5x20mm Fuse? or other?) Thanks

[sundberg84]

@Almamater its a glas fuse with legs, so not a holder and fuse, that took to much space. Search axial lead fuse.

Example:
https://www.ebay.co.uk/itm/112791896665
https://www.ebay.com/itm/174073055432

[Sleipnirr]

Thanks for the great design. I wonder if you could edit the design for new Hi-link 5V products (5V 5W HLK-5M05, 5V 10W HLK-10M05L, and 5V 20W HLK-20M05). They are very similar but different in size. Thank you.

[JohanH]

I've modified the PCB and added support for the 5W module (you can select to use either the 3W or 5W on same PCB). I've also added screw holes. Here is the list of changes:

• Imported to KiCad 5.1.8
• Added M2.5 screw holes
• Added EMI/EMC filter
• Added HLK-5MXX 5W models
• Board size: 72 mm * 42 mm

I've also changed track width to a more proper one for the respective voltages (secondary has larger current). You can leave out the EMI/EMC filter (add jump wires instead of the inductor) as it is not tested. I have not updated the BOM, but e.g. the inductor part id is mentioned in the circuit and the X2 cap is of common size.

You can download the updated design here: https://johanh.net/hlk/HLK-5M12_Breakout_board.zip

Comments are appreciated. I'm new to KiCad, so I might have done some mistakes. The KiCad project should maybe have been named as it was originally, but I renamed it to keep it separate.

[JohanH]

So I actually built one of the boards now. Only tested so far that it outputs 5V (more tests later). Still waiting on the common mode inductor (so jumpered so far). It was hard to find, but the one I designed it for is available at Digikey, part number 817-2151-ND‎ (manufacturer Schaffner RN202-0.3-02-12M‎).

One tricky thing I noticed about the original design by sundberg84 is that he incorporates a thermal fuse. These are really tricky to solder and are normally crimped in production devices, e.g. for fans and such. If you hold the solder iron more than half of a second to the leg you will pop it (you will hear a tiny click when the spring releases) and you have to discard it. Now it isn't absolutely needed on this board, you could just put a jumper in place. But here is a trick if you want to solder a thermal fuse.

Don't solder any other components before the thermal fuse (makes it more easy). Take a small bowl of water and submerge the fuse in water while soldering it. Keep it submerged a while after soldering is ready, to let it cool down completely. This is a 100% reliable way to not destroy the fuse.

Here is a picture of the thermal fuse being soldered: