November 2014 DocID10637 Rev 3 1/16
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AN2001Application note
VIPower™: the VIPer53-E single output reference board with 90 to 264 Vac input, 24 W output
IntroductionThe VIPer53-E combines an enhanced current mode PWM controller with a high voltage MDMesh™ Power MOSFET in the same package. The VIPer53-E is available in two different packages, DIP8 and PowerSO-10.The reference board is an offline wide range power supply including the VIPer53-E and is set for secondary regulation by driving the PWM controller through an optocoupler. The switching frequency is 100 kHz and the total output power is 24 W.
Here below the main features:
• Switch mode general purpose power supply
• Current mode control with adjustable limitation
• 75% efficiency
• Output short-circuit and overload protection
• Thermal shutdown protection
• EN55022 Class B EMI specification
• Blue Angel compliant
Table 1. Operating conditions
Parameter Limits
Input voltage range From 90 to 264 Vac
Input frequency 100 kHz
Output voltage V = 12 V
Output power 24 W
Efficiency 75% typical
Line regulation +/- 0
Load regulation +/- 0.2%
Output ripple voltage 15 mVpp
EMI EN55022 Class B
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Contents AN2001
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Contents
1 PCB layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Load regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Line regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Transient response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 Line and switching frequency ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Blue Angel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9 EMI results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 Transformer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11 Different output current and voltage capability . . . . . . . . . . . . . . . . . . 11
12 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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AN2001 List of figures
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List of figures
Figure 1. Board layout (not in scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Figure 2. Efficiency vs. IOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Figure 3. Efficiency vs. VIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Figure 4. Load regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 5. Line regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 6. Transient response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 7. Line frequency ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Figure 8. Switching frequency ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Figure 9. VDS and drain current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Figure 10. EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Figure 11. Transformer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Figure 12. PC board top legend (not in scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Figure 13. PC board bottom copper (not in scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Figure 14. Schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PCB layout AN2001
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1 PCB layout
Figure 1. Board layout (not in scale)
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AN2001 Efficiency
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2 Efficiency
Figure 2 and Figure 3 show the two efficiency curves of the reference board. In Figure 2 the input voltage is 120 Vac while the output load varies from 0 A to the full load 2 A. Figure 3 shows the efficiency where the input voltage varies from 90 to 264 Vac and the output load is fixed at 2 A.
3 Load regulation
VOUT is measured while the output load varies from 0 A to 2 A at the nominal input voltage 120 Vac. Figure 4 shows the load regulation at 0.2%.
Figure 2. Efficiency vs. IOUT Figure 3. Efficiency vs. VIN
0%10%20%30%40%50%60%70%80%90%
0 0.5 1 1.5 2
Iout (A)
Eff
icie
ncy
(%
)
Efficiency
77.00%
77.50%
78.00%
78.50%
79.00%
79.50%
80.00%
80.50%
81.00%
80 130 180 230 280
Vin (Vac)
Eff
icie
ncy
(%
)
Efficiency
Line regulation AN2001
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4 Line regulation
The line regulation has to be 0%. The output load is at full load 2 A, the input voltage varies from 90 to 264 V and the output voltage for the reference board remains regulated.
5 Transient response
Figure 6. Transient response
Figure 6 shows the transient load response as the output load goes from 1 A to 2 A (50% to 100% load) at the input voltage 120 Vac. The dynamic response is 80 mV or 0.7% while the settling time is 420 µs.
Figure 4. Load regulation Figure 5. Line regulation
10
10.5
11
11.5
12
12.5
0 0.5 1 1.5 2
Iout (A)
Vo
ut
(V)
11.8
12
12.2
12.4
90 140 190 240 290
Input Voltage (Vac)
Ou
tpu
t Vol
tag
e (V
)
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6 Line and switching frequency ripple
Figure 7 and Figure 8 show the line and switching frequency ripple of the reference board with an input voltage of 120 Vac and the output current is fixed at 2 A.
Both waveforms show a line frequency and switching frequency ripple of 10 mVpp each.
Figure 7. Line frequency ripple Figure 8. Switching frequency ripple
Waveforms AN2001
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7 Waveforms
Figure 9 displays the drain current and VDS at 230 Vac full load. The converter works in discontinuous mode as shown by the waveforms.
Figure 9. VDS and drain current
8 Blue Angel
The reference board consumes less than 1 W total when it works in standby burst mode at the input voltage of 120 Vac. The measured input power consumption is 569 mW with zero load on the output. The board meets the Blue Angel certification.
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9 EMI results
Figure 10. EMI
The reference board passes the EN55022 Class B EMI test as shown in Figure 10.
Transformer specifications AN2001
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10 Transformer specifications
Figure 11. Transformer specifications
The transformer is designed and manufactured by Cramer Coil and Transformer Co., Inc. Below the electrical specifications of the transformer:
• Primary inductance 1.10 mH±10%
• Primary leakage inductance 6.4 μH typical
• HIPOT (N1, N3, N4 tro N2) 4000 Vac, 1 second
• DCR (N1/N4) 0.905 Ω typical
• DCR (N2) 0.020 Ω typical
• DCR (N3) 0.112 Ω typical
• Turn ratio (N1/N4:N2) 1:0.121±3%
• Turn ratio (N1/N4:N3) 1:0.121±3%
When the VIPer53-E is on, the energy is stored in the primary winding of the transformer (pins from 3 to 5). This energy is transferred to the auxiliary winding (pins 1 and 2), and to the output (6, from 7 to 10, 11) when the VIPer53-E is off. The auxiliary winding provides the bias voltage for the VIPer53-E on pin 7 (VDD).
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11 Different 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, as shown in Table 1.
Figure 12. PC board top legend (not in scale)
Figure 13. PC board bottom copper (not in scale)
Table 2. Secondary component value to obtain different output voltage and current
VOUT and IOUT T1 R6 R9 C8, C16 D4
5.0 V 4.8 A CVP53-003 2.49 kΩ 1% 2.49 kΩ 1% 3300 µF 10 V STPS1045
12 V 2.0 A CVP53-001 3.48 kΩ 1% 13.3 kΩ 1% 1000 µF 25 V BYW98-200
15 V 1.6 A CVP53-004 2.94 kΩ 1% 14.7 kΩ 1% 1000 µF 35 V BYW98-200
24 V 1.0 A CVP53-005 1.50 kΩ 1% 13.0 kΩ 1% 470 µF 50 V BYW98-200
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Table 3. Component list
Quantity Reference Description
1 BR1 KBP210GDI bridge rectifier
1 C1 0.047 µF 250 V
1 C2 68 µF/400 V electrolytic
1 C3 4700 pF 1 k V ceramic
1 C4 100 µF/25 V electrolytic
1 C5 4.7 nF 50 V polyester
2 C6, C7 470 nF 50 V ceramic
2 C8, C16 1000 µF/25 V electrolytic
1 C9 220 µF/25 V electrolytic
1 C10 4.7 nF/250 V Y1 cap
2 C11, C12 0.01 µF 50 V ceramic
1 C13 470 pF/1 k V ceramic
1 C14 100 pF/1 k V ceramic
1 C15 Not used
2 C17, C18 0.33 µF/250 V
1 L1 Panasonic 35 mH common-mode line choke
1 L2 Coilcraft 2.2 µH inductor
1 T1 Cramer Coil CVP53-001
1 R1 4 Ω 5% 3 W wire wound
1 R2 22 kΩ 5% 2 W resistor
1 R3 3 kΩ 5% 0.5 W resistor
1 R4 15 Ω 5% 0.25 W resistor
1 R5 3.3 kΩ 5% 0.25 W resistor
1 R6 3.48 kΩ 1% 0.25 W resistor
1 R7 1 kΩ 5% 0.25 W resistor
1 R8 68 Ω 5% 0.25 W resistor
1 R9 13.3 kΩ1% 0.25 W resistor
1 R10 22 Ω 5% 0.5 W resistor
1 R12 1 kΩ 5% 2 W resistor
1 R13 Not used
1 D1 1N4148
2 D2, D3 STTH1R06
1 D4 BYW98-200
1 D5 1.5KE220A transil
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1 U2 H11A817A or LTV817A optocoupler
1 U3 TL431
1 U4 VIPer53DIP-E
2 W1, W2 Jumper wire
2 J1, J2 Connectors
Table 3. Component list (continued)
Quantity Reference Description
Different output current and voltage capability AN2001
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Figure 14. Schematic diagram
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12 Revision history
Table 4. Revision history
Date Revision Changes
16-Jul-2004 1 First issue
12-Sep-2006 2
- New template
- Component list value modified- Schematic diagram modified
12-Nov-2014 3Updated title in cover page.Content reworked to improve readability, no technical changes.
AN2001
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