This is a simple breakout and enhanced security board for the HLK-PM01.

Why?

After a long discussion (links) and following tests the HLK-PM01 was considered at that time (2015-2017) the best AC to DC 5v module option (within reasonable price range). But tests and teardowns concluded that a fuse, MOV and a thermal fuse would be good for extra protection.

What?

The HLK-PM01 module converts 240v AC to 5v DC and this breakout board adds more security.

Safety

This is the main thread: http://forum.mysensors.org/topic/1607/safe-in-wall-ac-to-dc-transfo

Here is the review and teardown of the module: http://lygte-info.dk/review/Power%20Mains%20to%205V%200.6A%20Hi-Link%20HLK-PM01%20UK.html

This is my safety discussion thread: https://forum.mysensors.org/topic/4175/clearance-creepage-and-other-safety-aspects-in-mysensors-pcbs

• AC-DC separation = 6mm minimum
• AC-AC separation (Creepage/clearance) = 3mm (Minimun between the AC pins on the HLK- module).

Note: there has been some fake/pirated HLK components! Read more here.

Disclaimer

If you order or use this you agree to and understand that the author is not liable for any injury or damage howsoever caused and that you use this PCB at your own risk. This is DIY and the author has not made any professional test. This product has not been marked with any certification marks and cant be guaranteed to comply with any standards.

This has been tested in a "lab" environment and works there with normal 240v AC to 5v DC. With a load of a normal MySensors.org module (<200mA) there is no heat building up that could be considered dangerous. The board has not been stress tested with higher voltages than 240v or currents more than 200mA.

Request for future rev.

Includes some additional space for 4x M3 screw holes

Links

• http://forum.mysensors.org/topic/1607/safe-in-wall-ac-to-dc-transformers
• http://forum.mysensors.org/topic/1540/110v-230v-ac-to-mysensors-pcb-board
• Performance test and review of mains to 5V 0.6A Hi-Link HLK-PM01
• https://skippy.org.uk/quick-look-at-the-hlk-pm01/
• https://www.ieee.li/pdf/essay/safety_considerations_in_power_supply_design.pdf

I Want it!

Order 10pcs PCB: Openhardware.io (Recommended!) and support me and MySensors!

Download from this page to get KiCad and Gerber files and upload to your favourite PCB house!

If you want PCBs with a faster shipping time or fewer pieces you can order from me on Ebay.

• 

  koray mascud commented 2 years ago
  

  what the ratings are of the two capacitors used in your circuit? A 1000 uF and a 100 uF?

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  titou4307 commented 2 years ago
  

  @sundberg84
  Hi !!
  Many thanks for your response and your reactivity

  I will try to mod but I don't know this creation pcb but I will try

  Have a good day and nice end of year 2022

  titou4307 (from France)

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  sundberg84 commented 2 years ago
  

  @titou4307 Hello! I dont really work on that project anymore, but its open hardware and all files are there so feel free to modify

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  titou4307 commented 2 years ago
  

  Hello
  I would like to pass order for this PCB....

  Is it possible to have a version more larger for fixations (screw x4) for to fix this PCB on a box ?

  Best regard

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  sundberg84 commented 3 years ago
  

  @RobIII - there is no specific reason why I choose 73dgr, probably it was easy avalible.
  70-85 woudl sure work good.

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  RobIII commented 3 years ago
  

  Hi! I was wondering why you used the 73°C thermal fuse specifically? I’m assuming it’s what you had lying around and any value of, say 70-85°C will do? Or is there a specific reason for that specific value?
  I’m asking since that specific value (+/- 1°C) keeps popping up everywhere:

  https://everythingesp.com/if-youre-like-me-you-constantly-find-that/
  https://forum.arduino.cc/t/hlk-pm01-power-supply/427005
https://easyeda.com/matimoto/HLK_PM01-33b4760fcdff46b6b71784304f89c379

  Thanks in advance!

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  JohanH commented 4 years ago
  

  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:
  

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  JohanH commented 4 years ago
  

  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.

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  Sleipnirr commented 4 years ago
  

  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.

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  sundberg84 commented 5 years ago
  

  @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