AN2000

Application note
VIPower: VIPer53A dual output reference
board 90 to 264 VAC input, 24W output

Introduction
This is an off-line wide range VIPer53 dual output reference board that is set up for
secondary regulation through an optocoupler. This design is geared towards any general
purpose off-line switch mode power supply needs. The total output power is 24W and is
delivered through two output, +5V and +12V.
The VIPer53 combines in the same package an enhanced current mode PWM controller
with a high voltage MDMesh Power Mosfet. It is available in two packages: DIP-8 and
PowerSO-10.
Complete switch mode general purpose power supply
● Single-sided board
● Over 74% efficiency
● Output short circuit protection
● Thermal shutdown protection
● Meets EN55022 class B EMI specification
● Meets Blue Angel

Operating conditions
Parameter Limits

Input voltage range 90 to 264Vac

Input frequency range 47 to 63kHz
Temperature range 0 to 80 °C
Output voltages V1= 5V; V2=12V
Output power (peak) 24W
Line regulation +/- 0%
Load regulation +/- 0.4% for 5V output
Efficiency 78% typical
Output ripple voltage 1% ripple; less than 10mV if π filter is used at output
Safety Short circuit protection
EMI EN55022 class B

August 2006 Rev 2 1/23

www.st.com
Contents AN2000

Contents

1 General circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Transformer specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Line frequency ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Transient response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Line regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Load regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8 Switching frequency ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9 Components list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10 Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11 Blue Angel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

12 Output voltage and current capability . . . . . . . . . . . . . . . . . . . . . . . . . . 18

13 Tovl function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

14 EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

15 PCB layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

16 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2/23
AN2000 List of figures

List of figures

Figure 1. Transformer specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2. Line frequency ripple (5V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3. Line frequency ripple (12V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 4. Efficiency vs. Vin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 5. Efficiency vs. Pout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6. Transient response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7. Line regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 8. Schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 9. Load regulation for 5V output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 10. Load regulation for 12V output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11. Switching ripple for 5V output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12. Switching ripple for 12V output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 13. Vds and drain current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 14. Short condition at 90Vac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 15. Short condition at 264Vac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 16. EMI result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 17. Board top legend (not in scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 18. Board bottom foil (not in scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 19. Board prototype (not in scale). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3/23
List of tables AN2000

List of tables

Table 1. Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 2. Stand-by input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 3. Secondary side value components to obtain different output voltage . . . . . . . . . . . . . . . . 18
Table 4. Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4/23
AN2000 General circuit description

1 General circuit description

The reference design operates from 90 to 264Vac input with an output power peak of 24W
through two output voltages of +5V and +12V. The AC input is rectified and filtered by the
bridge BR1 and the bulk capacitor C2 to generate the high voltage DC bus applied to the
primary winding of the transformer, T1. The switching frequency can be set to any value
through the choice of R3 and C5 and here, it is set at 100kHz.
Secondary regulation is provided by an optocoupler and TL431, U2 and U3 respectively.
The optocoupler is connected in parallel with the compensation network on the COMP pin.
Vdd voltage should be kept lower than the internal 15V reference and the auxiliary winding
of the transformers have been designed to ensure that. The compensation resistor, R5, sets
the dynamic behavior of the converter. It can be adjusted to provide the best compromise
between stability and recovering time with fast load changes.
It is possible to modify the output voltages by changing the transformer turns ratio and
modifying the resistance values of R6 and R9 in the feedback loop. For output filtering, the
components used are C8, C15, C16, and C19. An additional LC (PI) filter is added to the
5Vdc output, L2-C9 configuration, for further effective ripple and noise rejection.

5/23
Transformer specification AN2000

2 Transformer specification

Figure 1. Transformer specification

Primary Inductance 1.10mH ± 10%

Primary Leakage Inductance 6.96µH typical

When the VIPer53 (U4) is on, energy is stored in the primary winding of transformer (3-5),
T1. This energy is transferred to the auxiliary winding (1-2), and to the +5V output (6,7-8,9),
and the +12V output (10-11) when the VIPer53 is off. The auxiliary winding provides the bias
voltage for the VIPer53 at pin 7 (Vdd).
The transformer is designed and manufactured by Cramer Coil and Transformer Company,
Inc.

6/23
AN2000 Line frequency ripple

3 Line frequency ripple

Figure 2. Line frequency ripple (5V) Figure 3. Line frequency ripple (12V)

The line frequency ripple measurements are made at the input voltage of 120Vac. Here, the
measured ripple is 10mVpp for +5V while it is 20mVpp for the +12V.

7/23
Efficiency AN2000

4 Efficiency

Figure 4. Efficiency vs. Vin Figure 5. Efficiency vs. Pout

79.00% 90.00%
80.00%
78.50%

Efficiency (%)
Efficiency (%)

70.00%
78.00%
60.00%
77.50% 50.00%
77.00% 40.00%

76.50% 30.00%
20.00%
76.00%
0.00 10.00 20.00 30.00
80 130 180 230 280
Efficiency Vin (Vac) Efficiency Pout (W)

Efficiency is the ratio of the output power to the input power. Figure 4. shows the efficiency
measurement vs. varying input voltage at maximum output power while Figure 5. shows
efficiency vs. output power measurements, taken at the nominal line input of 120VAC. This
reference board has an efficiency of 78% at 115VAC at full load for both outputs.

8/23
AN2000 Transient response

5 Transient response

Figure 6. Transient response

The 5Vdc output current is stepped from 50% (1.2A) to 100% (2.4A) load, at a line input of
120Vac while the 12Vdc output is kept at the nominal value of 0.5A. The settling time is 400
µs. There is a 1.5% dynamic regulation or 75µV. This is shown in Figure 6.

9/23
Line regulation AN2000

6 Line regulation

The change in the DC output voltage for a given change in the AC input voltage is referred to
as line regulation. Both the 5V and the 12V outputs show a line regulation of 0% and 0.75%
respectively.

Figure 7. Line regulation

14

12

10
5V
Vout (V)

8
12V
6
4

2
0
90 140 190 240 290
Vin (Vac)

10/23
Line regulation

11/23
R10 C13
22 470pF
D3 D6
STTH1R06 Cramer Coil STPS5L40
STTA106 L2 5V @ 2.4A
TR1
. 10uH
C14
1

100pF C8 C19 C9
FUSE BR1 C3 R2 1kV 2700uF 2700uF 330uF
2A 5X20mm D5 4700pF 22k 16V 25V J2
250V 1.5KE220A 1kV 2W 16V
gnd 1
R1 R12 2
Line 4
5ohms F2 4 3 1k 3
2W 4
. D4
3W .
D2 12V @ 1A CON4
STTH1R06
STTA106 BYW98-200
C16 C15
J1 1000uF 1000uF
1

.
1 600V, 2A R4 25V 25V
2

2 C1 BRIDGE 15
0.047uF C17 C18
0.33uF 0.33uF W1 12V rtn
CON2 250V 250V D1 C10
85 to 264Vac 1N4148
2

0
4.7nF
0 Y1 cap
C2
68uF R3
400V 3k
AC in L1 U4
1 8
2 X 35mH Comp TOVL
2 7
C4 Osc Vdd R8
100uF 68
3 6
Source nc
25V C6
4
Source Drain
5
470nF R7
1k

1
4
VIPer53DIP R9
U2 2.49k
C5 LTV817 1%
Schematic diagram

4.7nF

2
3
R5
3.3k C12
0.01uF
50V
C7 U3 C11

1
470nF TL431 0.01uF
ST
3

2
R6
2.49k
1%
0
All resistors are 1/4 W 5% unless specified.
All capacitors are in uF and 50 V unless
specified.
Figure 8.
AN2000
Load regulation AN2000

7 Load regulation

The change in the DC output voltage for a given change in the output load is referred to as
load regulation. The 5Vdc output stays within ± 0.4% while the 12Vdc output shows a ± 1%
load regulation.

Figure 9. Load regulation for 5V output Figure 10. Load regulation for 12V output

8 13

7 12.5
6 12

Vout (V)
Vout (V)

5 11.5
4
11
3
10.5
2
10
1 0 0.2 0.4 0.6 0.8 1 1.2
0 0.5 1 1.5 2 2.5 3 Iout (A)
Iout(5V) Iout (A) Iout (12V)

12/23
AN2000 Switching frequency ripple

8 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 10mVpp. The low ripple for the +5V
output is obtained using the low pass LC (PI) filter configuration of L2 and C10. The
waveform is taken at the input voltage of 120Vac.
The switching ripple measured for the +12V output, meanwhile, is 100mVpp.

13/23
Components list AN2000

9 Components list

Table 1. Bill of material

Quantity Reference Description

1 BR1 600V, 1A bridge

1 C1 0.047µF/250V boxcap
1 C2 68µF/400V electrolytic
1 C3 4.7nF 1kVceramic
1 C4 100µF/25V electrolytic
1 C5 4.7nF 50V ceramic
2 C6, C7 470nF 50V ceramic
1 C8, C19 2700µF/16V electrolytic
1 C9 330µF/25V electrolytic
1 C10 4.7nF/250V Y cap
2 C11, C12 0.01µF 50V ceramic
1 C13 470pF 1kV ceramic
1 C14 100pF 1kV ceramic
2 C15, C16 1000µF/35V electrolytic
2 C17, C18 0.33µF 275V boxcap
1 D1 1N4148
2 D2, D3 STMicroelectronics STTH1R06
1 D4 STMicroelectronics BYW98-200
1 D5 STMicroelectronics 1.5KE220A
1 D6 STMicroelectronics STPS5L40
1 F1 2A Fuse
2 J1, J2 Connectors
1 L1 Panasonic 2x35mH common-mode line choke
1 L2 Coilcraft 2.2µH inductor
1 R1 4Ω 5% 3W Wire wound
1 R2 22kΩ 5% 2W
1 R3 3kΩ 5% 0.5W
1 R4 15Ω 5% 0.25W
1 R5 3.3kΩ 5% 0.25W
2 R6, R9 2.49kΩ 1% 0.25W
1 R7 1kΩ 5% 0.25W
1 R8 68Ω 5% 0.25W

14/23
AN2000 Components list

Table 1. Bill of material

1 R10 22Ω 5% 0.5W
1 R12 1kΩ 5% 2W
1 T1 Cramer Coil CVP53-002
1 U2 H11A817A or LTV817A optocoupler
1 U3 STMicroelectronics TL431
1 U4 STMicroelectronics VIPer53
2 W1, W2 Jumper wire

15/23
Waveforms AN2000

10 Waveforms

Figure 13. shows the drain current and Vds at 230Vac full load. The converter is working in
discontinuous mode as can be seen from the waveforms.

Figure 13. Vds and drain current

16/23
AN2000 Blue Angel

11 Blue Angel

The reference board consumes less than 1W total power consumption when working in the
burst mode during standby operation and therefore, meets Blue Angel. Table 2. below
outlines the total power consumption measured on the reference board at different line
voltages with zero loads at both the outputs. The output voltages remain regulated when
operating in the burst mode condition.

Table 2. Stand-by input power

Input Voltage (Vac) Input Wattage at No Load (mW)

115 602
230 790

17/23
Output voltage and current capability AN2000

12 Output voltage and current capability

Different output voltages and currents can be obtained by making the following changes:

Table 3. Secondary side value components to obtain different output voltage

Output Voltages T1 C15 and C16 D4

5V and 12V CVP53-002 1000µF/35V BYW98-200

5V and 15V CVP53-006 1000µF/35V BYW98-200
5V and 24V CVP53-007 560µF/50V BYW98-200

18/23
AN2000 Tovl function

13 Tovl function

Figure 14. Short condition at 90Vac Figure 15. Short condition at 264Vac

There is a threshold of 4.35V set on the COMP pin of VIPer53. When Vcomp goes above this
level, the capacitor connected to the Tovl pin will begin to charge. The internal MOSFET
driver will be disabled and the device will stop switching when Vtovl reaches 4V as shown in
both figures 14 and 15.
At this point, Vdd stops receiving any energy from the auxiliary winding, and therefore its
voltage will drop until it reaches Vddoff and the device is reset. The Vdd capacitor will then
be recharged for a new restart cycle. There will be an endless restart sequence if the
overload or short circuit condition is maintained.

19/23
EMI AN2000

14 EMI

The unit passes EN55022 Class B EMI as shown in Figure 16.

Figure 16. EMI result

20/23
AN2000 PCB layout

15 PCB layout

Figure 17. Board top legend (not in scale)

Figure 18. Board bottom foil (not in scale)

Figure 19. Board prototype (not in scale)

21/23
Revision history AN2000

16 Revision history

Table 4. Revision history

Date Revision Changes

Jul. 2004 1 First issue

- New template
07-Aug-2006 2 - Component list value modified
- Schematic diagram modified

22/23
AN2000

Please Read Carefully:

Information in this document is provided solely in connection with ST products. STMicroelectronics NV and its subsidiaries (“ST”) reserve the
right to make changes, corrections, modifications or improvements, to this document, and the products and services described herein at any
time, without notice.
All ST products are sold pursuant to ST’s terms and conditions of sale.
Purchasers are solely responsible for the choice, selection and use of the ST products and services described herein, and ST assumes no
liability whatsoever relating to the choice, selection or use of the ST products and services described herein.
No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. If any part of this
document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products
or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such
third party products or services or any intellectual property contained therein.

UNLESS OTHERWISE SET FORTH IN ST’S TERMS AND CONDITIONS OF SALE ST DISCLAIMS ANY EXPRESS OR IMPLIED
WARRANTY WITH RESPECT TO THE USE AND/OR SALE OF ST PRODUCTS INCLUDING WITHOUT LIMITATION IMPLIED
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS
OF ANY JURISDICTION), OR INFRINGEMENT OF ANY PATENT, COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT.
UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED ST REPRESENTATIVE, ST PRODUCTS ARE NOT
RECOMMENDED, AUTHORIZED OR WARRANTED FOR USE IN MILITARY, AIR CRAFT, SPACE, LIFE SAVING, OR LIFE SUSTAINING
APPLICATIONS, NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR MALFUNCTION MAY RESULT IN PERSONAL INJURY,
DEATH, OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE. ST PRODUCTS WHICH ARE NOT SPECIFIED AS "AUTOMOTIVE
GRADE" MAY ONLY BE USED IN AUTOMOTIVE APPLICATIONS AT USER’S OWN RISK.

Resale of ST products with provisions different from the statements and/or technical features set forth in this document shall immediately void
any warranty granted by ST for the ST product or service described herein and shall not create or extend in any manner whatsoever, any
liability of ST.

ST and the ST logo are trademarks or registered trademarks of ST in various countries.

Information in this document supersedes and replaces all information previously supplied.

The ST logo is a registered trademark of STMicroelectronics. All other names are the property of their respective owners.

© 2006 STMicroelectronics - All rights reserved

STMicroelectronics group of 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 of America
www.st.com

23/23