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AN1897 - AN1897
AN1897 APPLICATION NOTE
VIPower: COST UNIVERSAL INPUT SUPPLY WITH VIPer22A
Jun-feng Zhang
INTRODUCTION past years, many consumer products have been provided user, such players. Generally their power supply require multiple outputs supply variety control circuits: MCU, Motor, Amplifier, VFD. VIPer series off-line switch mode power supply regulators combines optimized, high voltage, avalanche rugged Vertical Power MOSFET with current mode control circuitry. result truly innovative conversion that simpler, quicker with component count halved less expensive. VIPer family also represents easiest solution comply with "Blue Angel" "Energy Star" norms, with extremely total power consumption stand-by mode, thanks burst operation. This document would present application player power supply with VIPer22A satisfying specification table below. Table Output Specification INPUT Universal mains line Min: 85Vac Max: 265Vac OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT (See note Imax: 150mA OUTPUT 5Vstb (See note Imax: 100mA
(See note (See note (See note (See note Imin: 20mA Imax: Imax: Imax: Imax: 50mA
Note accuracy +/-5% reached only certain range loads combination. paragraph cross regulation results.
March 2004
1/11
AN1897 APPLICATION NOTE
APPLICATION DESCRIPTION DESIGN Schematics overall schematic shown figure 1.1.1 Start-up Phase member VIPer family, VIPer22A integrated high voltage current source linked Drain pin. startup converter, will charge capacitor until reaches VIPer startup level (14.5V), then VIPer22A starts switching. 1.1.2 Auxiliary Supply VIPer22A wide operating voltage range from 42V, respectively minimum maximum values under-voltage over-voltage protections. This function very useful achieving stand-by total power consumption. During normal working, feedback loop connected output regulate output. mean time, +5Vstb output blocked +5Vstb regulation neglected. When stand-by signal present, provide enough voltage maintain conducted, output blocked, +5Vstb output connected feedback loop. this condition +5Vstb regulated. Thanks transformer structure, other secondary outputs auxiliary voltages pulled down very level, also pulling down total power consumption. these contents summarized following list: normal full load, voltage device must lower than over-voltage protection; short circuit, voltage must lower than shutdown voltage. Actually, this condition leads well known hiccup mode practice; load condition, voltage must higher than shutdown voltage. 1.1.3 Burst Mode Viper22A integrates current mode with Power MOSFET includes leading edge blanking function. burst mode feature which allows VIPer22A skip some switching cycles when energy drained output load goes below E=(Tb*Vin)2 fsw/2Lp (Tb=blanking time, Vin=DC input voltage, sw=Switching frequency, Lp=Primary Inductance). consequence reduce switching losses when working load condition reducing switching frequency. 1.1.4 Feedback Loop output voltage regulated with TL-431 (U3) optocoupler (U2) feedback pin. output voltage high, TL-431 will draw more current through cathode anode current increases optocoupler diode. current optocoupler increases accordingly current into VIPer22A increases. When current increases, VIPer22A will skip some cycles decrease turn time lower output voltage proper level (see figure output voltage regulated thanks reference voltage TL-431 resistive divider
2/11
AN1897 APPLICATION NOTE
Figure VIPer22A internal structure
DRAIN
60kHz OSCILLATOR
+Vdd
LATCH
Secondary feedback
0.23V
SOURCE
1.1.5 Primary Driver fly-back power supply, transformer used energy tank fuelled during time MOSFET. When MOSFET turns off, drain voltage rises from value input voltage plus reflected voltage while secondary diode conducts, transferring secondary side magnetic energy stored transformer. Because primary secondary windings perfectly magnetically coupled, there serial leakage inductance that behaves like open inductor charged that causes voltage spikes MOSFET drain. These voltage spikes must clamped keep VIPer22A Drain voltage below BVdss (730Vmin) rating. peak voltage higher than this value, device will destroyed. most used solution clamp (see figure This very simple cheap solution, impacts efficiency even power dissipation stand-by condition. Also clamping voltage varies with load current. clamp circuits allow drain voltage exceed data sheet breakdown rating VIPer22A during overload operation during turn with high line input voltage. zener clamp recommended (see figure However such solution gives higher power dissipation full load, even clamp voltage exactly defined. Transformer Consideration electrical specification multiple output transformer (cross regulation, leakage inductance), main efforts focused proper coupling between windings. lower leakage inductance transformer will allow lower power clamp reduce input power. will lead lower power dissipation primary side. Auxiliary secondary windings swapped order decrease coupling primary one. secondary windings shielding layer reduce capacitive coupling. Fewer spikes generated auxiliary windings, primary secondary windings have better coupling. Designing transformers leakage inductance involves several considerations: number turns winding build (ratio winding height width) small width windings insulation between windings coupling between windings
3/11
5.1K
TL431
9014
5.1K
100/200
220uF/50V
47pF
CON9
JUMPER JUMPER JUMPER
+5Vstb 0.1A
1N5818
Auxiliary Volt Vmin 3.3Vac 0.15A 0.05A 0.03A 0.03A 5Vstb 0.1A 5Vstb 0.1A 5Vstb 0.1A 1.5A
8550
1000uF/16V EC28-VER3
100uF/10V
LD33V LD33V LD33V
470uF16V
47uF/50V
STPS5L60
3.3V
Vout Vout Vout
VIPER22A
CONTROL
100/200BYW 100/200
9.1K
1.5A
AN1897 APPLICATION NOTE
-26V 0.05A -26V 0.05A -26V 0.05A 470uF/25V
1N4937
220uF/50V
DRAIN
SOURCE
47nF
CON4
100/200
Figure Application schematic
47uF/400V
-12V 0.03A
470uF/25V
FR157 47pF/1KV
1N4007
0.1uF +12V 0.03A
1N4007
100k/1W
2200pF
2.2mH
100uF/10V
CON5
(3.3Vac) 0.15A
1N5818
250V (3.3Vac)
1N4007 1N4007 1N4007
NTC5D-9
CON2
2200pF
CON2
1N4007
4/11
AN1897 APPLICATION NOTE
Figure clamp topology Figure Zener clamp topology
transformer meeting international insulation safety requirements, practical value leakage inductance about 1-3% open circuit primary inductance. high efficiency transformer should have inter-winding capacitance decrease switching losses. Energy stored parasitic capacitance transformer absorbed VIPer cycle cycle during turn-on transition. Excess capacitance will also ring with stray inductance during switch transitions, causing noise problems. Capacitance effects usually most important primary winding, where operating voltage (and consequent energy storage) high. primary winding should first winding transformer. This allows primary winding have mean length turn, reducing internal capacitance. driven primary winding (the connected Drain pin) should beginning winding rather than end. This takes advantage shielding effect second half primary winding reduces capacitive coupling adjacent windings. layer insulation between adjacent primary windings internal capacitance primary winding much factor four, with consequent reduction losses. common technique winding multiple secondaries with same polarity sharing common return, stack secondaries (see figure This arrangement will improve load regulation, reduce total number secondary turns. Commonly clamper based network diode with zener clamp rise drain voltage used. Figure Multiple output winding
5/11
AN1897 APPLICATION NOTE
LAYOUT RECOMMENDATION Since issues strongly related layout, basic rule taken into account high current path routing, i.e. current loop area minimized. heat-sink used connected ground too, order reduce common mode emissions, since close floating drain tab. more consideration made regarding control ground connection: fact order avoid noise interference VIPer logic control ground separated from power ground. EXPERIMENTAL RESULT Efficiency Figure Efficiency 230Vac (Load
+12V/30mA, -12V/30mA, -26V/50mA, 3.3V/0.15A
80.00% 70.00%
Efficiency 80.00% 70.00% 60.00% 50.00% 40.00% 30.00% 20.00% 10.00% 0.00% 0.1A 0.5A 1.5A
Figure Efficiency 260Vac (Load
+12V/30mA, -12V/30mA, -26V/50mA, 3.3V/0.15A
60.00% Efficiency 50.00% 40.00% 30.00% 20.00% 10.00% 0.00% 0.1A 0.5A 1.5A
Efficiency 230Vac Mains Input
Efficiency 260Vac Input
Figure Efficiency 85Vac (Load
+12V/30mA, -12V/30mA, -26V/50mA, 3.3V/0.15A 76.00% 74.00% 72.00% 70.00% 68.00% 66.00% 64.00% 62.00% 60.00% 0.1A 0.5A 1.0A 1.5A 2.0A
Figure Load Regulation (load +5V)
5.20 5.15 5.10 Voltage 5.05 5.00 4.95 4.90 4.85 4.80 0.1A 0.5A 1.5A Load Load Regualtion
Efficiency
Efficiency 85Vac Input
Regulation Table Line regulation Output 0.1A 5Vstb/ 12V/ -12V/ -26V/ 3.3V/
6/11
85Vac 5.15V 5.15V 12.08V -11.98V -25.82V 3.87V
230Vac 5.15V 5.15V 12.11V -11.99V -25.85V 3.87V
260Vac 5.15V 5.15V 12.12V -12.00V -25.86V 3.88V
AN1897 APPLICATION NOTE
Figure Cross regulation
+5V/0.5A 15.00 10.00 5.00 0.00 Voltage -5.00 -10.00 -15.00 -20.00 -25.00 -30.00 Load (mA) +12V -12V -26V 3.3V 10mA 30mA 50mA 100mA 150mA
Table Stand model
Output
5Vstb (100mA) -12V -26V 3.3V Pdis
85Vac 2.05V 5.08V 4.00V 3.99V 9.12V 1.70V 0.8W
230Vac 2.05V 5.11V 3.99V 3.99V 9.10V 1.50V
260Vac 2.07V 5.14V 3.98V 3.98V 9.08V 1.51V 1.1W
Table Full Load Regulation Output
1.5A 5Vstb/ 12V/30mA -12V/30mA -26V/50mA 3.3V/0.15A VIPer Temp
85Vac 5.02V 5.02V 12.03V -12.01V -26.06V 3.77V 53°C
230Vac 5.09V 5.09V 12.06V -12.05V -26.16V 3.80V 47°C
260Vac 5.08V 5.08V 12.05V -12.05V -26.15V 3.78V 45°C
7/11
AN1897 APPLICATION NOTE
TRANSFORMER SPECIFICATION Figure Transformer Structure
Primary inductance: 1KHz, 0.3V Leakage inductance: 28uH Secondary auxiliary winding short (1KHz, 0.3V) Core: EER28L Bobbin: ER28 Pin) Vendor: YuanDongDa electronics Co.,
Table Winding Parameters Layers description
Primary Out1 (5V/1.5A) Out2 (12V/0.03A) Out3 (-12V/0.03A) Out4 (-26V/0.05A) Out5 (5Vstb/0.1A) Out6 (3.3V/0.15A) Auxiliary
Symbol W-12 W-26 Wstb W3v3 Waux
Start Pin2 Pin7 Pin11 Pin12 Pin10 Pin9 Pin14 Pin6
Pin1 Pin12 Pin7 Pin10 Pin13 Pin8 Pin15 Pin5
Number Layer Turns
Wire Size (mm) 2*0.6 0.45
Barrier (3mm) W-12 W-26 W3v3 Wstb Waux
Barrier (3mm)
8/11
AN1897 APPLICATION NOTE
LAYOUT Figure Bottom view demo board (not scale)
Figure Work (not scale)
9/11
AN1897 APPLICATION NOTE
BILL MATERIALS Ref. D11,
10/11 VIPer22A TL431 L4931 ABV33 SS9014 SS8550 1N4007 FR157 STMicroelectronics STMicroelectronics STMicroelectronics
Description
Photocoupler PC817 SHARP
Note
STMicroelectronics STMicroelectronics STMicroelectronics
D10, STTH102
STPS5L60 1N5818 Capacitor 2200pF Capacitor 0.1uF Electrolytic Capacitor 100uF/400V 1nF/1KV Ceramic Capacitor 47nF/50V Electrolytic Capacitor 47uF/50V Electrolytic Capacitor 220uF/50V Ceramic Capacitor 47pF/50V Electrolytic Capacitor 1000uF/16V Electrolytic Capacitor 470uF/16V Electrolytic Capacitor 100uF/10V Electrolytic Capacitor 470uF/25V Electrolytic Capacitor 470uF/25V Electrolytic Capacitor 220uF/50V Electrolytic Capacitor 220uF/16V 9.1K 100K 5.1K 2.2mH Common choke EER28 transformer Fuse 2pin connector 5pin connector 4pin connector 9pin connector
AN1897 APPLICATION NOTE
Information furnished believed accurate reliable. However, STMicroelectronics assumes responsibility consequences such information infringement patents other rights third parties which results from use. license granted implication otherwise under patent patent rights STMicroelectronics. Specifications mentioned this publication subject change without notice. This publication supersedes replaces information previously supplied. STMicroelectronics products authorized critical components life support devices systems without express written approval STMicroelectronics. logo trademark STMicroelectronics. other names property their respective owners 2004 STMicroelectronics Printed ITALY- Rights Reserved. STMicroelectronics GROUP COMPANIES Australia Belgium Brazil Canada China Czech Republic Finland France Germany Hong Kong India Israel Italy Japan Malaysia Malta Morocco Singapore Spain Sweden Switzerland United Kingdom United States http://www.st.com
11/11
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