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Rev 1.0November 2005 1/15
15
IntroductionThis application note describes a power supply that can be used as a wall transformer replacement or asa power module for a small consumer appliance. The design objectives are:
■ The outside case dimensions (in inches) are 2L x 2W x 1H, with smaller inside dimensions,
■ the Line and Neutral pins (of equal size and 8mm from the end of the assembly) are attached to the case,
■ the input voltage ranges are 95VAC to 135VAC; and 190VAC to 270VAC,
■ the output voltage is 15V (max) at 1mA (min) and is 12V (min) at 500mA (max), with a 50% duty cycle,
■ the ambient temperature range is –5°C to 55°C, and
■ the Electromagnetic Interference (EMI) is measured for all loads.
The power supply for the wall transformer replacement application consists primarily of a re-packagedVIPer12 Demonstration Board (12V, single output voltage, see Application Note AN1734 for details).
Figure 1. VIPer12-based Power Supply Assembly, Top View
AN2173APPLICATION NOTE
Using a VIPer12-based Power Supplyto Replace a Wall Transformer
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AN2173 - APPLICATION NOTE
2/15
Table of Contents
1 VIPer12-based Power Supply Features and Assembly . . . . . . . . . . . . . . . 4
1.1 Layout and Component Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Heat Sink Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Operation Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Transformer Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Transformer Mechanical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Appendix A. Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Appendix B. KIDDE VIPer12 Demo Board BOM . . . . . . . . . . . . . . . . . . . . 13
5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AN2173 - APPLICATION NOTE
3/15
List of Figures
Figure 1. VIPer12-based Power Supply Assembly, Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Figure 2. PCB Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Figure 3. PCB Component Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Figure 4. EMI Measurements (EMI EN5502, Class B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 5. Heat Sink Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Figure 6. Drain to Source Voltage (Vds) and Drain Current (Id) Waveforms . . . . . . . . . . . . . . . . . . . . 8Figure 7. Power Supply Efficiency with Line Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Figure 8. Line Regulation: Power Supply Output Voltage vs. Varied Input Line Voltage. . . . . . . . . . . 9Figure 9. Load Regulation: Power Supply Output Voltage vs. Varied Load . . . . . . . . . . . . . . . . . . . . 9Figure 10. Transformer Winding Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Figure 11. Transformer Mechanical Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Figure 12. VIPer12-based Power Supply Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 VIPer12-based Power Supply Features and Assembly AN2173 - APPLICATION NOTE
4/15
1 VIPer12-based Power Supply Features and Assembly
● Fixed 60kHz Switching Frequency
● Switch mode General Purpose Power Supply
● Burst Mode Operation in Standby for Blue Angel operation
● Current Mode Control
● Typical 75% Efficiency at Full Load
● Auxiliary Undervoltage Lockout with Hysteresis
● Output Short Circuit Protection
● Thermal Shutdown Protection
● Meets EN55022 Class B EMI specification
1.1 Layout and Component Placement
To meet Printed Circuit Board (PCB) space requirements, both sides of the PCB are used for either low or high voltage power supply mains by selecting the appropriate voltage rating for the bulk capacitors and the Metal Oxide Varistor (MOV). Surface-mount components should be used wherever possible to reduce the size of the assembly. The remaining axial lead devices (e.g., resistors, diode, and “pigtail” fuse) are mounted vertically to save PCB space.
The line and neutral pins are molded into the bottom of the case and pass through two holes in the top of the case, and a line cord attachment is on the side opposite the line and neutral pins (see Figure 2 on page 5 and Figure 3 on page 5). The PCB size is determined by the overall dimensions and the side wall thicknesses of the case (1.78in x 1.78in, with rectangular mounting slots in each side). A 0.118in mounting hole is provided. Additional support using 0.75in PCB standoffs is recommended, with the component leads trimmed to 0.65in (max).
See Appendix A. Schematics on page 12 and Appendix B. KIDDE VIPer12 Demo Board BOM on page 13 for details.
AN2173 - APPLICATION NOTE 1 VIPer12-based Power Supply Features and Assembly
5/15
1.2 Assembly
The initial PCBs and power supply assemblies were routed, built, and tested in the lab. An assembly fits into the case with the attached output wire cable that is connected from the flange to the end. If a Pollution Degree 1 rating is desired, the assembly should be in a sealed case, since the cable runs from the secondary (across the transformer) to the primary. Additionally, the transformer can be smaller if the case is sealed. If a sealed case is not used, then thicker insulation or triple-insulated wire may be required.
Assembly EMI (EN5502, Class B) measurements are shown in Figure 4 on page 6.
Figure 2. PCB Layout
Figure 3. PCB Component Placement
1 VIPer12-based Power Supply Features and Assembly AN2173 - APPLICATION NOTE
6/15
Figure 4. EMI Measurements (EMI EN5502, Class B)
AN2173 - APPLICATION NOTE 1 VIPer12-based Power Supply Features and Assembly
7/15
1.3 Heat Sink Enhancement
The smaller layout, though useful for PCB space savings, is also prone to heat sink area reduction. To enhance the cooling capacity for the VIPer12, mounting a small heat sink directly in the holes with the 4 DRAIN pins in the VIPer12’s DIP package is recommended (see Figure 5).
Figure 5. Heat Sink Configuration
2 Operation Characteristics AN2173 - APPLICATION NOTE
8/15
2 Operation Characteristics
Figure 6. Drain to Source Voltage (Vds) and Drain Current (Id) Waveforms
Note: Measured during normal operation with an input line of 115VAC and the output at full load.
Figure 7. Power Supply Efficiency with Line Variation
Note: Measured at full load, when the line is varied from 85VAC to 137VAC.
72
73
74
75
76
77
78
80 90 100 110 120 130 140
Input Line Voltage (VAC)
Eff
icie
ncy
(%
)
AI11834
AN2173 - APPLICATION NOTE 2 Operation Characteristics
9/15
Figure 8. Line Regulation: Power Supply Output Voltage vs. Varied Input Line Voltage
Note: Power supply output voltage is monitored while running at full load, and the line is varied from 85VAC to 134VAC.
Figure 9. Load Regulation: Power Supply Output Voltage vs. Varied Load
Note: Power supply output voltage is monitored while running at 115VAC, and the load is varied from 0.01A to 0.51A.
12.1
12.12
12.14
12.16
12.18
12.2
80 90 100 110 120 130 140
Input Line Voltage (VAC)
Ou
tpu
t V
olt
age
(VO
)
AI11835
12.1
12.12
12.14
12.16
12.18
12.2
0.00 0.10 0.20 0.30 0.40 0.50 0.60
Load (A)
Ou
tpu
t V
olt
age
(VO
)
AI11836
3 Transformer Electrical Specifications AN2173 - APPLICATION NOTE
10/15
3 Transformer Electrical Specifications
When the VIPer12A (U4) is ON, energy is stored in the primary winding of transformer (10-8), TR1. This energy is transferred to the auxiliary winding (5-6), and to the output (1-2) when the VIPer12A is OFF. The auxiliary winding provides the bias voltage for the VIPer12A at pin 4 (VDD).
Figure 10. Transformer Winding Schematic
Table 1. Winding Inductance RatingsParameter Value Units
Primary Inductance (Lp) 3.25 ± 10% mH
Primary Leakage Inductance (Llp) 34 (typ) µH
N1 N212V @ 0.50A
N4
N315V @ 0.02A
1
2
8
9
6
105
120 - 400V@ 60kHz,50% DC
1/2 Primary
1/2 PrimarySecondaryAuxiliary
AI11837
TR1
AN2173 - APPLICATION NOTE 4 Transformer Mechanical Information
11/15
4 Transformer Mechanical Information
Figure 11. Transformer Mechanical Drawing
0.71 (max)
0.71 (max)
0.48 ± 0.02
1 4
10 5
0.65 (max)
0.19 REF
0.055 REF
0.022 (typ)
0.13 ± 0.02 (3x)
0.10 ± 0.02 (5x)AI11838
Appendix A. Schematics AN2173 - APPLICATION NOTE
12/15
Appendix A. Schematics
Figure 12. VIPer12-based Power Supply Schematics
R4
220
C4
22µF
/25V
C2
10µF
/250
V
C7
330µ
F/2
5VC8
330µ
F/2
5V
C11
0.04
7µF
DR
AIN
DR
AIN
DR
AIN
DR
AIN
SO
UR
CE
SO
UR
CE
Fb
3
VD
D4
U4
VIP
er12
A
1 2
4 3
U2
H11
A81
7A
R7
3.40
k
R5
1k C9
0.01
µF
21
D3
ST
TH
102
32
41
L1H
JC03
08Q
R2
2k 1
/2W
C3
47pF
88
1010
55
66
11
22
CV
P11
-021
4 3
21
BR
1S
M
C6
47nF
R8
4.7
D2
BA
V20
WS
*For
190
to 2
70V
AC
:
C1
= 1
.0µF
/400
VC
2 =
10µ
F/4
00V
R1
= 4
.7Ω
1/4
W C
CM
OV
= 4
40V
Line
Neu
tral
C5
3.3n
F25
0V Y1
R1
1%
1%
C1
4.7µ
F/2
50V
HS
F1
5.1Ω
Fus
able
Res
isto
r
Jum
per
1kV
TR
1
21
MO
V22
0V
R3
9.1k
21
3U3
TL4
31
95 to
135
VA
C
VIN
*
R6
13.3
k
R9
12.1
V
RT
N
3.3k
8 67 5 1 2
AI11184
AN2173 - APPLICATION NOTE Appendix B. KIDDE VIPer12 Demo Board BOM
13/15
Appendix B. KIDDE VIPer12 Demo Board BOM
Table 2. Domestic Bill of MaterialsQty Reference Part Description Manufacturer Manufacturer Part Number
1 BR1 SM Bridge 600V 1.5A Diodes, Inc. DF1506S-T
1 C1 4.7uF/250V Electro Panasonic ECA-2EHG4R7
1 C2 10uF/250V Electro Panasonic ECA-2EHG100
1 C3 47pF 1kV Ceramic Panasonic ECC-D3A470JGE
1 C4 22uF/25V Electro Panasonic ECA-1EM220
1 C5 3.3nF 250V Y1 Panasonic ECK-ATS332ME
1 C6 47nF SMD 1206
2 C7, C8 330uF/25V Electro Panasonic EEU-FC1E331L
1 C9 0.01uF 0805 Panasonic ECJ-2VB1H103K
1 C11 0.047uF 250V Box Panasonic ECQ-U2A473ML
1 D2 200V .2A Micro Commercial BAV20WS-TP
1 D3 200V 1A STMicroelectronics STTH102
1 F1 5.1 Ohm Fusable Resistor
1 L1 Common Mode Hua Jung Comp. HJC0308Q
1 R1 JUMPER
1 R2 2K 5% 1/2W
1 R3 9.1K 5% 1206
1 R4 220 5% 805
1 R5 1K 5% 0805
1 R6 13.3K 1% SMD 0805 Panasonic ERJ-6ENF1332V
1 R7 3.40K 1% SMD 0805 Panasonic ERJ-6ENF3401V
1 R8 4.7 5% 1206
1 R9 3.3K 5% 1206
1 TR1 Output transformer Cramer Coil CVP11-021
1 U2 H11A817A Fairchild H11A817A
1 U3 TL431 STMicroelectronics TL431AIZ
1 U4 VIPer12A Dip STMicroelectronic VIPer12ADIP
1 MOV 220V Varistor
1 HS U4 Heat Sink
2 AC Wires
1 Output cable assembly
5 Revision History AN2173 - APPLICATION NOTE
14/15
5 Revision History
Date Revision Changes
11-November-2005 1.0 First edition
AN2173 - APPLICATION NOTE 5 Revision History
15/15
Information furnished is believed to be accurate and reliable. However, STMicroelectronics assumes no responsibility for the consequencesof use of such information nor for any infringement of patents or other rights of third parties which may result from its use. No license is grantedby implication or otherwise under any patent or patent rights of STMicroelectronics. Specifications mentioned in this publication are subjectto change without notice. This publication supersedes and replaces all information previously supplied. STMicroelectronics products are notauthorized for use as critical components in life support devices or systems without express written approval of STMicroelectronics.
The ST logo is a registered trademark of STMicroelectronics.All other names are the property of their respective owners
© 2005 STMicroelectronics - All rights reserved
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Figure 1. VIPer12-based Power Supply Assembly, Top View1 VIPer12-based Power Supply Features and Assembly1.1 Layout and Component Placement1.2 AssemblyFigure 2. PCB LayoutFigure 3. PCB Component PlacementFigure 4. EMI Measurements (EMI EN5502, Class B)
1.3 Heat Sink EnhancementFigure 5. Heat Sink Configuration
2 Operation CharacteristicsFigure 6. Drain to Source Voltage (Vds) and Drain Current (Id) WaveformsFigure 7. Power Supply Efficiency with Line VariationFigure 8. Line Regulation: Power Supply Output Voltage vs. Varied Input Line VoltageFigure 9. Load Regulation: Power Supply Output Voltage vs. Varied Load
3 Transformer Electrical SpecificationsFigure 10. Transformer Winding SchematicTable 1. Winding Inductance Ratings
4 Transformer Mechanical InformationFigure 11. Transformer Mechanical Drawing
Appendix A. SchematicsFigure 12. VIPer12-based Power Supply Schematics
Appendix B. KIDDE VIPer12 Demo Board BOMTable 2. Domestic Bill of Materials
5 Revision History