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February 2014 DocID025645 Rev 1 1/18
AN4419Application note
VIPER37HE: 15 W wide range single output evaluation board
By Fabio Cacciotto
Introduction
This application note describes a 15 W wide range evaluation board, based on Viper37HE, which is designed as an example of an isolated auxiliary power supply.
The board and the transformer were designed and optimized in order to have a very compact size evaluation board.
www.st.com
Contents AN4419
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Contents
1 Test board: design and evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Output voltage characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Efficiency and light load measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 No-load and light load consumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Typical board waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Conducted noise measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Thermal measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Evaluation tools and documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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18
1 Test board: design and evaluation
Table 1 summarizes the electrical specification of the power supply, Table 2 provides the BOM and Table 4 lists transformer's spec. The electrical schematic is shown in Figure 2 and the PCB layout in Figure 3 and Figure 4.
Figure 1. Electrical schematic
Table 1. VIPer37H evaluation board electrical specification
Parameter Min. Typ. Max. Unit
AC Main Input voltage 100 265 VAC
Mains frequency (fL) 50 60 Hz
Output Voltage 11.7 12 V 12.3 V
Output Current 1.25 A
Output ripple voltage 50 mV
Rated output power 15 W
Input power in standby @ 230VAC 50 mW
Active mode efficiency 78 %
Ambient operating temperature 60 °C
C633uF
D4
BAT41ZFILM
L2
3.3uH
R430k
16NTC
C41nF
GND
12V-1.25A
OPTOSFH610A-2
OPTOSFH610A-2
C1210nF
C10100uF
IC2TS432
BR
CONT
DRAIN
GND
CONTROL
VDD
FB
IC1VIPER37HE
-+ BR
RMB6S
R71k
T1
F1
2A
D2BAT41ZFILM
AC IN AC IN
D6
STPS5H100UF
D3
BAT41ZFILM
R647k
R24.7
21
34
CM2X20mH
C833nF
R812k
C72.2nF
R3133K
C9470uF
D518V
R1115k
R982k
C315uF
R10130k
R5220
D1STTH1L06A
C13
2.2nF
R1220k
RV
320V
R122.2M
1mH
L1
C5220pF
C215uF
C111uF
C1
220nF - X2
AM18323v1
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Figure 2. Evaluation board (30 x 72 mm) max
AM18336v1
Table 2. VIPer37H evaluation board: bill of material
Reference Part Description Note
R1 220 kΩ 0.33 W – 200 V
R2 4.7 Ω 1% tolerance
R3 133 kΩ 1% tolerance
R4 30 kΩ 1% tolerance
R5 220 Ω 0.25 W
R6 47 kΩ 1% tolerance
R7 1 kΩ
R8 12 kΩ
R9 82 kΩ 1% tolerance
R10 130 kΩ 1% tolerance
R11 15 kΩ 1% tolerance
R12 2.2 MΩ 1% tolerance
C1 BFC233920224 220 nF - 275 V x 2 Vishay
C2, C3 450BXF15M10X20 15 μF - 450 V electrolytic Rubycon
C4 C3216C0G2J102JT 1 nF - 630 V MLCC TDK
C5 GRM188R71H221KA01D 220 pF - 16 V MLCC Murata
C6 35YXM33MEFC5X11 33 μF - 35 V electrolytic Rubycon
C7 GRM1885C1H222FA01D 2.2 nF - 50 V MLCC Murata
C8 GRM188R71H333KA61D 33 nF -16 V MLCC Murata
C9 25ZLJ470M10X12.5 470 μF - 25 V electrolytic Rubycon
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Note: If not otherwise specified, all resistors are ± 5%, 0.1 .
C10 25YXJ100M5X11 100 μF - 25 V electrolytic Rubycon
C11 GRM188C81E105KAADD 1 μF - 25 V MLCC Murata
C12 GRM188R71H103KA01D 10 nF - 50 V MLCC Murata
C13 DE2E3KY222MA2BM01 2.2 nF - 250 V X1/Y1 CAP Murata
D1 STTH1L06A Ultra-fast diode 600 V - 1 A STMicroelectronics
D2, D3, D4 BAT41ZFILM Signal Schottky diode STMicroelectronics
D5 MMSZ5248B-V-GS08 18 V Zener diode Vishay
D6 STPS5H100B Power Schottky 100 V - 5 A STMicroelectronics
L1 B82144A2105J 1 mH Axial inductor Epcos
L2 SD43-332ML 3.3 μH Power inductor Coilcraft
CM 744821120 20 mH CM choke Wurth Elektronik
IC1 VIPer37LE Offline HV converter STMicroelectronics
IC2 TS432ILT 1.24 V Shunt voltage reference STMicroelectronics
OPTO SFH610A-2 Optocoupler Vishay
TF YJ-310V600210 Flyback transformer Yujing Technology
BR RMB6S Bridge 600 V - 1 A Taiwan Semiconductor
NTC B57236S160M NTC Inrush current limiter Epcos
Fs 0461002.ER 2 A fuse Littlefuse
Table 2. VIPer37H evaluation board: bill of material (continued)
Reference Part Description Note
Table 3. Transformer characteristic
Reference Description
Manifacturer Yujing Technology CO. LTD.
Part number YJ-310V600210
Core EEE - 13 V
Ferrite 3C94 Ferroxcube
Primary Inductance 0.85 mH ±10%.
Leakage inductance 40 µH max
Primary turns (N1+N3) 75
Secondary turns (N2) 12
Auxiliary turns (N4) 14
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Figure 3. Electrical scheme
Figure 4. Drawing transformer (mm.)
AM18338v1
AM18337v1
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18
1.1 Output voltage characteristics
The output voltage of the board is measured in different line and load conditions. Figure 5 shows the results: the output voltage variation range is a few tens mV for all the tested conditions.
All output voltages have been measured on the output connector of the board.
Figure 5. Line and load regulation
1.2 Efficiency and light load measurements
Any external power supply (EPS) must be capable to meet the international regulation agency limits. The European code of conduct (EC CoC) and US department of energy (DoEUS EISA 2007) limits are taken as reference. EPS limits are fixed up to 77.76%, when the average efficiency is measured. The average efficiency measures the average value at 25%, 50%, 75% and 100% of the rated output power, at both 115 VAC and 230 VAC. Figure 6 shows the results.
0.00 0.25 0.50 0.75 1.00 1.25 1.5011.8
11.9
12.0
12.1
12.2
12.3
115 Vac 230 VacO
utpu
t vol
tage
[V]
Output current [mA]
AM18324v1
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Figure 6. Efficiency vs. output power
1.3 No-load and light load consumptions
No-load consumptions and light load consumption are two important parameters that must be considered when selecting the IC controller and very often they are the key parameters of choice.
The presented board was optimized in order to provide an extremely low consumption at zero load but also in order to meet EµP Lot 6 energy saving regulation, which requires that the efficiency of the converter must be higher than 50% when the output is loaded with 250 mW.
In Figure 7 and Figure 8 the consumption in the said condition are shown.
Figure 7. No load consumption vs. input voltage
AM18325v1
0 2 4 6 8 10 12 14 1670
72
74
76
78
80
82
84
86
88
EC Code of Conduct
115 Vac 230 Vac average @ 115 Vac average @ 230 Vac
Effic
ienc
y [%
]
Output power [W]
AM18326v1
50 100 150 200 250 30010
15
20
25
30
35
40
45
50
55
60
65
Inpu
t pow
er [m
W]
Input voltage [Vac]
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Figure 8. Light load consumptions at 250 mW O/P
1.4 Typical board waveforms
In this section, typical waveforms are reported.
Drain voltage and current waveforms were reported at nominal input voltages and full load in Figure 9 and Figure 10.
The startup phase is shown in Figure 11 and Figure 12: the IC starts with very clean waveforms and no overshoot/undershoot appear on the output.
Finally also the output voltage when the converter is submitted to dynamic load variations is measured, in order to be sure that good stability is ensured and no overvoltage on undervoltage occurs
The board was submitted to dynamic load variations from 0% to 100% load (Figure 13 and Figure 14): no abnormal oscillations were noticed on the output and the over/under shoot were well within acceptable values.
AM18327v1
50 100 150 200 250 300200
250
300
350
400
450
500
250 mWIn
put p
ower
[mW
]
Input voltage [Vac]
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Figure 9. Drain current and voltage at full load 115 VAC
Figure 10. Drain current and voltage at full load 230 VAC
AM18328v1
Ch1 (Max): 340 VCh2 (Max): 596.mA
IDS
VDS
M: 4.0 µs/div
AM18329v1
Ch1 (Max): 517 VCh2 (Max): 612 mA
M: 4.0 µs/div
IDS
VDS
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Figure 11. Startup at full load and 115 VAC
Figure 12. Startup at full load and 230 VAC
AM18330v1
Ch3 (Max): 12.04 V M: 40 ms/div
VDD
VD S
VOUT
AM18331v1
Ch3 (Max): 12.06 V M: 40 ms/div
VDD
VD S
VOUT
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Figure 13. Step load at 115 VAC
Figure 14. Step load at 230 VAC
AM18332v1
Ch1 (Max): 0 ACh1 (Min): 1.26 A
Ch2 (Max): 12.07 VCh2 (Min): 11.73 V M: 20 .0 ms/div
VOUT
IOUT
AM18333v1
Ch1 (Max): 0 ACh1 (Min): 1.26 A
Ch2 (Max): 12. 06 VCh2 (Min): 11.7 4 V M: 20 .0 ms/div
VOUT
IOUT
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AN4419 Conducted noise measurements
18
2 Conducted noise measurements
A pre-compliance test for EN55022 (Class B) European normative was performed using peak measurements detector of the conducted noise emissions at full load and nominal mains voltages. Figure 15 and Figure 16 show the results. As seen in the diagrams, in all test conditions there is a good margin for the measurements with respect to the AV and QP limits, also using the peak detector with max-hold function.
Figure 15. CE average measurement at 115 VAC and full load
Figure 16. CE average measurement at 230 VAC and full load: Peak measurement
AM18334v1
AM18335v1
Thermal measurements AN4419
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3 Thermal measurements
A thermal analysis of the board was performed using an IR camera.
The board was submitted to full load at nominal input voltage and the thermal map was taken 30 min. after the power on at ambient temperature (25 °C).
Figure 17, Figure 18, Figure 19 and Figure 20 show the results.
Figure 17. Thermal map at 115 VAC and full load top side
Figure 18. Thermal map at 115 VAC and full load bottom side
Figure 19. Thermal map at 230 VAC and full load top side
Figure 20. Thermal map at 230 VAC and full load bottom side
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AN4419 Conclusions
18
4 Conclusions
A 15 W wide range single output flyback converter using the new VIPer37HE has been introduced and the results are presented.
The transformer arrangement and the very compact sizes make the PSU suitable as external adapter or as an auxiliary power supply in all the applications where performances and dimensions are the main constrains.
The efficiency performances were compared with requirements of the most important international regulation agencies for external AC-DC adapters, resulting in a wide margin respect the minimum required.
Evaluation tools and documentation AN4419
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5 Evaluation tools and documentation
The VIPer37LE evaluation board order code is: STEVAL-ISA140V1.
Further information about this product are available in the VIPer37 datasheet at www.st.com.
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AN4419 Revision history
18
6 Revision history
Table 4. Document revision history
Date Revision Changes
24-Feb-2014 1 Initial release.
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