Application note VIPower: VIPer22A dual output reference board 90 to 264 VAC input, 10W output Introduction This is an off-line wide range VIPer22A dual outputs power supply at a switching frequency of 60kHz and is set up for secondary regulation with an optocoupler. One output delivers 5V at 1A and while a second output delivers12v at 0.42A, making up the total output power of 10W. Switch mode general purpose power supply Single-sided board 75% efficiency Output short circuit protection Thermal shutdown protection Meets EN55022 class B EMI specification Meets Blue Angel Operating conditions Parameter Input voltage range Input Frequency Range Output voltages Output current Output power Efficiency Line regulation Load regulation Output ripple voltage EMI Limits 90 to 264Vac 50/60 Hz V1= 5V; V2=12V I=0.84A 10W 75% typical +/- 0% for 5V output +/- 0.3% for 5V output 20mVpp EN55022 Class B July 2006 Rev 4 1/20 www.st.com
Contents Contents 1 PCB lay-out................................................ 5 2 Line regulation.............................................. 6 3 Load regulation............................................. 7 4 Efficiency.................................................. 8 5 Line frequency ripple........................................ 9 6 Switching frequency ripple.................................. 10 7 Transient load response..................................... 11 8 EMI results................................................ 12 9 Blue Angel................................................ 13 9.1 Stand-by input power........................................ 13 10 Transformer specification................................... 14 11 Output current and voltage capability.......................... 15 12 Thermal considerations..................................... 16 13 Component list............................................ 17 14 Revision history........................................... 19 2/20
List of figures List of figures Figure 1. Board lay-out............................................................ 5 Figure 2. Board top legend (not in scale)............................................... 5 Figure 3. Board bottom foil (not in scale)............................................... 5 Figure 4. Line regulation........................................................... 6 Figure 5. Load regulation for 5V output................................................ 7 Figure 6. Load regulation for 12V output............................................... 7 Figure 7. Efficiency vs. input voltage.................................................. 8 Figure 8. Efficiency vs. Pout........................................................ 8 Figure 9. Line ripple for 5V output.................................................... 9 Figure 10. Line ripple for 12V output................................................... 9 Figure 11. Switching ripple for 5V output............................................... 10 Figure 12. Switching ripple for 12V output.............................................. 10 Figure 13. Transient load response................................................... 11 Figure 14. EMI.................................................................. 12 Figure 15. Mechanical drawings of the transformer....................................... 14 Figure 16. Schematic diagram....................................................... 18 3/20
List of tables List of tables Table 1. Input power in no load condition at different input voltage......................... 13 Table 2. Change in output voltage and current......................................... 15 Table 3. Bill of material........................................................... 17 Table 4. Revision history......................................................... 19 4/20
PCB lay-out 1 PCB lay-out Figure 1. Board lay-out Figure 2. Board top legend (not in scale) Figure 3. Board bottom foil (not in scale) 5/20
Line regulation 2 Line regulation Figure 4. shows the line regulation of both the +5V and the +12V output. The output voltages are measured for the input voltage range of 85 to 264VAC at the maximum output power of 10W. The +5V output shows a 0% line regulation while the +12V output has a line regulation of 0.25%. Figure 4. Line regulation Output Voltage (Vdc) 14 12 10 8 6 4 2 50 100 150 200 250 300 Input Voltage (Vac) 5V 12V 6/20
Load regulation 3 Load regulation The load regulation measurements are taken at the input voltage of 120Vac. Here, the load regulation measured for the +5V output is ±0.3% while the +12V output shows a load regulation of ±0.46%. See Figure 5. and Figure 6. Figure 5. Load regulation for 5V output Output Voltage (V) 5.5 5.25 5 4.75 4.5 4.25 4 0 0.2 0.4 0.6 0.8 1 1.2 Output Current (A) V1 Figure 6. Load regulation for 12V output Ouput Voltage (V) 12.5 12.4 12.3 12.2 12.1 12 11.9 11.8 11.7 11.6 11.5 0 0.1 0.2 0.3 0.4 Output Current (A) V2 7/20
Efficiency 4 Efficiency Figure 7. shows the efficiency curve of the reference board when the input voltage is varied from 90 to 264Vac at the maximum output power of 10W. Here, the typical efficiency value is measured to be 75%. Meanwhile, Figure 8. shows the efficiency measurement taken at 120Vac while the output power is varied from 1W to the maximum 10W. The typical efficiency measured is also around 75%. Figure 7. Efficiency vs. input voltage Efficiency (%) 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00% 74.00% 73.00% 72.00% 50 100 150 200 250 300 Efficiency Vin (Vac) Figure 8. Efficiency vs. Pout Efficiency (%) 85.00% 80.00% 75.00% 70.00% 65.00% 60.00% 55.00% 50.00% 45.00% 40.00% 0.00 5.00 10.00 15.00 Pout (W) Efficiency 8/20
Line frequency ripple 5 Line frequency ripple Figure 9. Line ripple for 5V output Figure 10. Line ripple for 12V output Figure 9. and Figure 10. show the line frequency ripple waveforms of the +5V and +12V output respectively taken at 90Vac input. The line frequency ripple for +5V is 10mVpp while for the +12V output; it is 50mVpp. 9/20
Switching frequency ripple 6 Switching frequency ripple Figure 11. Switching ripple for 5V output Figure 12. Switching ripple for 12V output The switching ripple for the +5V output measured is 12mVpp while this ripple measured for the +12V output is 200mVpp. The low ripple for the +5V output is obtained using the low pass LC (PI) filter configuration of L2 and C10. The waveforms are taken at the input voltage of 90Vac. 10/20
Transient load response 7 Transient load response Figure 13. Transient load response The transient load response is measured at the input voltage of 90Vac where the +5V output load is varied from 50% load (0.5A) to 100% load (1A) while the +12V is kept at the nominal load value of 0.21A. The dynamic response measured is 140mV or 2.8% while the settling time is 500ms. See Figure 13. 11/20
EMI results 8 EMI results Figure 14. EMI The unit passes the European Norm, EN55022 Class B EMI. 12/20
Blue Angel 9 Blue Angel The reference board meets the Blue Angel Norm, consuming less than 1W total when working in stand-by mode. The board operates in burst mode when both the output loads are reduced to zero and the output voltages still remain regulated. 9.1 Stand-by input power Table 1. Input power in no load condition at different input voltage Input Voltage Input Wattage at No Load 115Vac 230Vac 210.38mW 331.85mW At the input voltage of 120Vac, a minimum load of 100mA is needed to keep the total input power consumption to be less than 1W. 13/20
Transformer specification 10 Transformer specification Figure 15. Mechanical drawings of the transformer Meets Construction for: UL 1310, 1950,1411, IEC 61558-1,2-17, EN60950 www.cramercoil.com 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 winding provides the bias voltage for the VIPer22A at pin 4 (Vdd). The electrical specifications of the transformer are as follow: Primary Inductance 2.25mH±15% Primary Leakage Inductance 22µH typical Turns Ratio (N1/N5:N2) 1:0.053 Turns Ratio (N1/N5:N3) 1:0.127 Turns Ratio (N1/N5:N4) 1:0.167 The transformer is designed and manufactured by Cramer Coil and Transformer. 14/20
Output current and voltage capability 11 Output current and voltage capability The standard voltage and current values for the reference board can be changed to deliver a different voltage and current value, with changes to the following components as detailed in Table 2. Table 2. Change in output voltage and current Output Voltages T1 C9 5 and 12V CVP32-002 220µF/25V 5 and 15V CVP32-003 220µF/35V 5 and 24V CVP32-004 220µF/50V 15/20
Thermal considerations 12 Thermal considerations The reference board is single-sided and utilizes a wide area of two ounces copper pad to act as a heat sink for the VIPer22ADIP. All other traces utilize one-ounce copper. 16/20
Component list 13 Component list Table 3. Bill of material Quantity Reference Description 1 BR1 KBP210GDI 1 C1 0.047µF/250V boxcap 1 C2 22µF/400V electrolytic 1 C3 100pF 1kV ceramic 1 C4 22µF/25V electrolytic 1 C5 680µF/25V electrolytic 1 C6 22nF/50V ceramic 1 C7 100µF/25V electrolytic 1 C8 4.7nF/250V Y cap 1 C9 210µF/25V electrolytic 1 C11 0.01µF/50V ceramic 1 C12 10µF/400V electrolytic 1 D1 1N4148 1 D2 1N5821 1 D3 STMicroelectronics BYW100-200 1 F1 0.5A 250V Fuse 2 J1, J2 Connectors 1 L1 Compostar 2x30mH common-mode line choke 1 L2 Coilcraft 10µH inductor 1 R1 5Ω 5% 1W Wire wound 1 R2 2KΩ 5% 1/2W 1 R4 68Ω 5% 1/4W 1 R5 2.438KΩ 1% 1/4W 1 R6 470Ω 5% 1/4W 1 R7 9.1kΩ 5% 1/4W 1 R8 2.49KΩ 1% 1/4W 1 R9 15KΩ 5% 1/2W 1 T1 Cramer coil transformer CVP32-002 1 U1 STMicroelectronics VIPer22ADIP 1 U2 H11A817A or LTV817 optocoupler 1 U3 STMicroelectronics TL431 2 W1, W2 Jumper wire 17/20
Component list Figure 16. Schematic diagram J1 FUSE 0.5A 5X20mm R1 250V 5 ohms 1W F1 CON2 85 to 264Vac L1 30mH 2 X 30mH C2 22uF 400V C4 22uF 25V C3 100pF 1kV R2 2k 0.5W C6 22nF 50V C5 680uF 25V 1 2 3 4 2 1 L C1 0.047uF 4 3 BR1 KBP210GDI N All resistors are 1/4 W 5% unless specified. All capacitors are in uf and 50 V unless specified. C12 10uF 400V D1 1N4148 Drain 6 Drain Vd d 4 Drain Drain Source Source Fb 3 U1 VIPer22 A R7 9.1k T1 CVP32-002 W1 C8 4.7nF Y1 cap D2 1N5821 L2 5 V @ 1.0A 10uH C7 100uF 25V 5V GND D3 12V @ 0.42A BYW100-200 C9 R9 220uF 15k 25V 0.5W 12V Rtn R4 68 U2 H11A817A R6 470 R8 2.49k 1% U3 TL431 ST C11 0.01uF 50V R5 2.43k 1% STMicroelectronics 1375 East Woodfield Road, Suite 400 Schaumburg, IL 60173 Title VIPer22A Dual Outputs Reference Design Size Document N umber Rev B Tuesday, August 30, 2005 Date: Sheet of 1 1 C J2 CON4 0 8 7 5 1 2 0 0 1 2 3 4.... 0.... 5 6 8 7 1 23 4 2 1 18/20
Revision history 14 Revision history Table 4. Revision history Date Revision Changes 16-Jul-2003 1 First issue 13-Jun-2005 2 - Schematic changed - Component list table modified 09-Sep-2005 3 Schematic modified 31-Jul-2006 4 - New template - Component list value modified 19/20
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