ST AN1735 Application note VIPer22A Single Output Reference Board 90 to 264 VAC input 10W output
Contents
1. JE Jp lo alala PO a TAE ET NS 7 Trensiem Load Response a alter tts AINA f i gt i j HIE Pham sec alen kadak tihi 1 bag muo pi IHT E are all 20000 m 2 4 Line and load regulation The output voltages are measured over the entire input voltage range that is between 90 and 264 Vac This gives the line regulation as shown in Figure 9 As can be seen from the graph the output voltage remained at a constant 12V output The line regulation therefore is 096 Figure 9 Line regulation 13 N On Output Voltage V nm 8 11 70 120 170 220 Input Voltage Vac 270 7 15 Test results AN1735 The output voltage has also been measured in a range of loads as shown in Figure 10 at a nominal input voltage of 120 Vac The load regulation is approximately 0 125 when tested from 10 to 100 of full load on the output Figure 10 Load regulation 13 2 125 v FI 5 115 O 11 0 0 2 0 4 0 6 0 8 1 Output Load A 2 5 EMI emissions Figure 11 EMI conducted emissions Mkrl 1 696 MHz Ref 75 dBpy Atten 16 dB 22 59 dBHV Span 2 MHz VBH 38 kHz Sweep 56 29 ms C401 pts The results shown in Figure 11 indicate that the unit passes EN55022 Class B EMI conducted emission tests 8 15 OI AN1735 Waveforms 3 Waveforms Figure 12 shows the drain current IpRain and2. SZ AN1735 Application note VIPer22A Single Output Reference Board 90 to 264 VAC input 10W output July 2006 Introduction This Application Note deals with an off line wide range single output power supply using a VIPer22A off line SMPS primary switcher manufactured by STMicroelectronics The VIPer22A combines a dedicated current mode PWM controller with a high voltage Power MOSFET on the same silicon chip and its switching frequency is internally fixed at 60 kHz The feedback path of the power supply includes an optocoupler for secondary regulation and galvanic isolation between primary and secondary sides The output voltage is regulated at 12V with a maximum output current of 0 84A resulting in a maximum output power of 10W Product highlights Switch mode General Purpose Power Supply Single sided Board 75 Typical Efficiency Output Short Circuit Protection Thermal Shutdown Protection Complies with EN55022 Class B EMI specifications Complies with Blue Angel standards Rev 2 1 15 www st com Contents AN1735 Contents 1 Summary description a EK dae een m nl 3 1 1 Boardlayout ka 1280 a RAANG KATAWA AK k et a dama s NAWA 4 2 TEST Reef ss ENNEN js e E oaa eek et E EN ap 5 2 1 Frequency ripple ssa os sat K siss K i k k PAA 5 2 2 Efficiency results ssa ass sp SsT Sa K AY 6 2 3 Load response vert die KAG BEA KG AE EE EE S SE Ew bo 6 2 4 Line and load Geleet GATA RD 8550083 K EEN 7 2 5 EMILE
3. at the full load of 0 84A Figure 4 Line frequency ripple J Jp JET a e ViPer22A Single Cutput dE KA Full Los i i 90Vac EE EE a 3 Figure 5 Switching frequency ripple w VIPer 24Single Output LOW E a Nang i Ki va no Maida Mia IN NN Iti d Full Loori i i 90Var E eje dg Ma i way uu 5 15 Test results AN1735 2 2 2 3 6 15 Efficiency results Figure 6 Efficiency vs Pour 80 0 75 0 70 0 65 0 Efficiency 60 0 55 0 0 2 4 6 8 10 12 Pout W The typical efficiency of the board is about 75 The efficiency measurements are taken at a nominal input voltage of 120 Vac Figure 6 shows the efficiency measurements that are taken when the output power is varied from 1W to 10W Figure 7 meanwhile shows the efficiency measurement taken when the input voltage is varied from 90 to 264 Vac at the maximum output power rating of 10W The average measured efficiency is 75 Figure 7 Efficiency vs Vum 84 0 82 0 80 0 78 0 76 0 74 0 72 0 70 0 50 100 150 200 250 300 Vin Vac Efficiency Load response At an input voltage of 120 Vac the output load is stepped from 50 to 100 load 0 42A to 0 84A The settling time is found to be 400ys and the dynamic regulation is 120mV or 1 The resulting waveforms are shown in Figure 8 AN1735 Test results Figure 8 Transient load response
4. drain voltage Vps during normal operation at full load The converter works in the Discontinuous mode as illustrated by the waveforms Figure 12 Vps and drain current stopp 10 0 12 0Voc Jeev ju 4 Output current and voltage capability The output voltage and current can be set to a different value by changing components as shown in Table 2 Table 2 Changes in output voltage and current Vout T1 R8 R5 C9 C10 5 0V 2 0A CVP32 006 2 49KQ 1 2 49KQ 1 2X1000uF 25V 100uF 25V 12V 0 84A CVP32 001 13 3KQ 1 3 48KQ 1 1000uF 25V 100uF 25V 15V 0 67A CVP32 005 14 7KQ 1 2 94KQ 1 680 F 35V 100yuF 35V 24V 0 42A CVP32 007 13 0KQ 1 1 50KQ 1 220uF 50V 100uF 50V ky 9 15 Thermal considerations AN1735 5 Thermal considerations The VIPer22A is a single sided reference board that uses a wide two ounce copper pad area to act as a heat sink for the VIPer22ADIP All other traces use one ounce copper At 65 C the measured case temperature is 90 C therefore making the junction temperature 123 7 C 6 Blue angel standard The Blue Angel standard is a German certification for products and services that have environmentally friendly aspects It requires that the power supply consumes less than 1W of power when in Standby mode The total power consumption of this reference board is less than 1W when working in Standby Burst mode Table 3 lists the input power cons
5. winding provides the bias voltage for the VIPer22A at pin 4 Non 11 15 Component list AN1735 8 12 15 Component list Table 5 Component list Quantity Reference Description 1 BR1 KBP210GDI 1 C1 0 047 F 250V boxcap 1 C2 22uF 400V electrolytic 1 C3 100pF 1kV ceramic 1 C4 22uF 25V electrolytic 1 C6 0 01uF 50V ceramic 1 C8 4 7nF 250V Y cap 1 C9 1500uF 25V electrolytic 1 C10 100uF 25V electrolytic 1 C11 0 01 F 50V ceramic 1 C12 10uF 400V electrolytic 1 D1 1N4148 1 D2 STMicroelectronics BYW98 200 1 F1 0 5A Fuse 2 J1 J2 Connectors 1 L1 2x30mH common mode line choke 1 L2 Coilcraft 10uH inductor 1 R1 5095 1W wire wound 1 R2 2KQ2 5 1 2W 1 R4 680 5 1 4W 1 R5 3 48KQ 196 1 4W 1 R6 4702596 1 4W 1 R7 9 1kQ5 1 4W 1 R8 13 3KQ 1 1 4W 1 T1 Cramer coil transformer CVP32 001 1 U1 STMicroelectronics VIPer22A 1 U2 H11A817A or LTV817 optocoupler 1 U3 STMicroelectronics TL431 1 W1 W2 Jumper wire lt Component list AN1735 Figure 14 Schematic diagram 99012094 bug peiyoeds ssaun ADS pue JN UI ase ssoyoedeo yy paiioeds sein 9 5 Mp L SE SIOISISSI Y 13 15 Revision history AN1735 9 14 15 Revision history Table 6 Revision history Date Revision Changes Jul 2003 1 Initial release 17 Jul 2006 2 Converted to new corporate t
6. E AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION OR INFRINGEMENT OF ANY PATENT COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED ST REPRESENTATIVE ST PRODUCTS ARE NOT RECOMMENDED AUTHORIZED OR WARRANTED FOR USE IN MILITARY AIR CRAFT SPACE LIFE SAVING OR LIFE SUSTAINING APPLICATIONS NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR MALFUNCTION MAY RESULT IN PERSONAL INJURY DEATH OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE ST PRODUCTS WHICH ARE NOT SPECIFIED AS AUTOMOTIVE GRADE MAY ONLY BE USED IN AUTOMOTIVE APPLICATIONS AT USER S OWN RISK Resale of ST products with provisions different from the statements and or technical features set forth in this document shall immediately void any warranty granted by ST for the ST product or service described herein and shall not create or extend in any manner whatsoever any liability of ST ST and the ST logo are trademarks or registered trademarks of ST in various countries Information in this document supersedes and replaces all information previously supplied The ST logo is a registered trademark of STMicroelectronics All other names are the property of their respective owners 2006 STMicroelectronics All rights reserved STMicroelectronics group of companies Australia Belgium Brazil Canada China Czech Republic Finland France Germany Hong Kong India Israel Italy Japan Malaysia Malta Morocco Singa
7. MISSIONS aa 22000 Ka Ka pelea eines Dea TRA 8 3 WAVGIONNGS EE 9 4 Output current and voltage capability 2000e eee eee eee 9 5 Thermal considerations 0200 0c k knn nn nn nn n 10 6 Blue angel standard an nn nan 10 7 Transformer specifications kkk knn nn n eee 11 8 Component list ad d dag deed Eeer KT ANG HA ed Cae EKKE SN s 12 9 REVISION history dE ER BRENNEN e KG Ee in 14 2 15 ky AN1735 Summary description 1 Summary description Table 7 lists the main parameters of the converter while a prototype of the board is shown in Figure 1 Table 1 Operating conditions Parameter Limits Input voltage range 90 to 264 Vac Input frequency range 50 60 Hz Output Voltage V 12V Output current 0 84A Output power 10W Efficiency 75 typical Line regulation 0 Load regulation 0 2 Output voltage ripple 20m Vpp EMI EN55022 class B Figure 1 Board prototype FEITT H H YI J E Viper22 IA 2 wf eet 3 01 3 15 Summary description AN1735 1 1 Board layout Figure 2 Board top legend not to scale Figure 3 Board bottom foil not to scale 4 15 ky AN1735 Test results 2 2 1 Test results Frequency ripple Figure 4 presents the line frequency ripple taken with an input voltage of 90 Vac A 10mVpp amplitude is measured at the output Figure 5 shows the switching ripple on the output
8. emplate Minor editing changes AN1735 Please Read Carefully Information in this document is provided solely in connection with ST products STMicroelectronics NV and its subsidiaries ST reserve the right to make changes corrections modifications or improvements to this document and the products and services described herein at any time without notice All ST products are sold pursuant to ST s terms and conditions of sale Purchasers are solely responsible for the choice selection and use of the ST products and services described herein and ST assumes no liability whatsoever relating to the choice selection or use of the ST products and services described herein No license express or implied by estoppel or otherwise to any intellectual property rights is granted under this document If any part of this document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products or services or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein UNLESS OTHERWISE SET FORTH IN ST S TERMS AND CONDITIONS OF SALE ST DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO THE USE AND OR SALE OF ST PRODUCTS INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOS
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10. umption Du values at different input voltages when measured with zero loads at the output Table 3 Input power consumption in No Load conditions Input voltage Input Wattage at No Load 115 Vac 200 mw 230 Vac 366 mW In order to keep the total input power to be less than 1W total a minimum load of 40 mA is needed when using a 120 Vac input supply Therefore the reference board complies with the Blue Angel standard 10 15 ky AN1735 Transformer specifications 7 Transformer specifications Figure 13 Mechanical drawings of the transformer O GHZ Nina II nztwee Sunde a N3 Ev 024 NOTE POLARITY SHOWN FOR Tr TRANSFORMER FOR CORRE FLYBACK OPERATION CONNEC B TO PIN The transformer is designed and manufactured by Cramer Coil and Transformer Co Table 4 lists the electrical characteristics of the transformer Table 4 Electrical characteristics of the transformer Parameter Values Primary inductance 2 25MH 10 Primary leakage inductance 19 9uH typical HIPOT N1 N3 N4 to N2 5500VAC 1Sec DCR N1 N4 2 87Q typical DCR N2 0 07Q typical DCR N3 1 26Q typical Turns ratio N1 N4 N2 1 0 127 Turns ratio N1 N4 N3 1 0 167 When the VIPer22A U1 is on energy is stored in the primary winding of transformer 1 2 TX1 This energy is transferred to the auxiliary winding 3 4 and to the output 5 6 when the VIPer22A is off The auxiliary
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ST AN1735 Application note VIPer22A Single Output Reference Board 90 to 264 VAC input 10W output