Thanks,
We want to produce a (400W peak) offline power supply for a product in EU. (+ elsewhere)
OK.
Thing is, power supplies for household items must be in totally enclosed plastic cases for safety reasons.........
Says who?
There are plenty of metal-housed devices, including ones with power supplies inside, with or without an earth pin.
if you have that, then you need to have an internal metal foil inside the plastic enclosure, otherwise you will not pass radiated EMC regulatory compliance testing.
Says who? There are plenty of plastic-housed devices, including ones with power supplies inside, which do not use internal shielding. (What I mean is that internal shielding isn't a requirement
per se. It is, however, often a sensible way to achieve EMC compliance.)
...And if you have a metal foil surrounding the SMPS, then its best to connect it to earth...
Not necessarily. (Bearing in mind that I'm at the limits of my knowledge on this point -- I just know there are name-brand devices out there that have completely floating shields.)
but if the two pin socket doesnt have an earth, then how can this be done?
Obviously it can't -- sorta.
Look at what SMPSs do to reduce EMI. EMI noise is AC, mostly at frequencies well above 50/60Hz. So what you do is to capacitively couple the secondary-side ground to the AC input using a small Class Y safety cap. The small value of the cap makes it high-impedance at 50/60Hz, but low-impedance at the high frequencies you want to arrest. Since the neutral side of mains is tied to earth somewhere, that's your path to earth. Since you don't know which AC wire will be neutral, you use another safety capacitor between secondary-side ground and the other AC wire. (This is why devices with unearthed SMPSs often tingle when you touch them: their ground is floating at 1/2 mains voltage, albeit at minuscule current.)
The end result is that no matter which way the plug is inserted, the secondary ground, to which your shielding is tied, is tied to earth
as far as high frequency AC is concerned.
Lots of AC-powered home AV gear is Class II, with the double square symbol, but is in a metal case with ventilation slits, using no earth
Thanks, may i ask what this metal case is connected to....or is it just "floating"?
It's either truly floating or (often) connected to secondary ground.
With all this said, I'm no expert on this, and you would be remiss to not engage the services of an EMC consultant.
Also, when you say "offline", do you mean non-isolated? (There seem to be multiple competing meanings of what the term indicates...) Or what exactly do you mean?