AN2772 Application note

Offline SMPS for the central units of alarm systems

Introduction
This document describes a 55 W flyback SMPS demonstration board based on the L5991 and STP12NK80Zl, which is available from STMicroelectronics through order code STEVAL-ISA033V1. The board is ideal for use as a power supply for the central units of alarm systems (CUAS) demonstration board, also available from ST (order code: STEVAL-IAC001V1). The circuit is composed of an isolated AC-DC single output converter with an output power capability of approximately 60 W, and non-isolated post-regulators for other output voltage generation by means of switching and linear regulators. The power supply also integrates a battery charger circuit for standard SLA (sealed lead acid) 12 V batteries. Figure 1. Demonstration board STEVAL-ISA033V1

November 2008

Rev 1

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Contents

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Contents
1 2 Power supply specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power supply architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 2.2 2.3 2.4 2.5 AC to DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Flyback transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DC to DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electronic switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 4

Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Experimental results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Conducted EMI measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 6

Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Power supply specification

Power supply specification

The SMPS has the following main characteristics.

Input AC voltage: VIN = 88 300 V, f = 50 60 Hz Output voltages: V1 = 13.8 V V2 = 5 V V3 = 3.8 V AC input check Low battery check I1 = 3 A I2 = 200 mA I3 = 350 mA (1.9 A peak) for GSM module supply

Output diagnostic signals:

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Power supply architecture

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Power supply architecture

Figure 2 shows the block diagram of the considered power supply. The system includes two blocks: an AC-DC converter and a DC-DC section. The first block provides a regulated 13.8 V DC bus, with a 4 A current capability, of which 3 A are dedicated to the supply of three external sirens, while 1 A is dedicated to the battery charger (3.8 V output for the GSM module and 5 V output for logic circuitry). All the DC output voltages are obtained directly from the 13.8 V output by means of two DC-DC converters and a linear regulator. The block diagram also shows two additional blocks consisting of a "switch" and a control logic unit: these two blocks enable the available input supply to be delivered to the output: power from the AC line or from the battery if no AC input is detected.

Figure 2.

Block diagram

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Power supply architecture

2.1

AC to DC converter
The schematics of the converter are shown in Figure 3. The power supply has been designed according to the specifications given above. The converter is based on a flyback topology controlled by the IC L5991 (PWM controller), with a fixed frequency mode (50 kHz). The primary switch of the Flyback converter is a MOSFET, STP12NK80Z (SuperMESH 800 V - 0.75 typical), in a TO-220 package. The voltage spike on the drain due to leakage inductance is clamped by the RCD network R1, C4 and D2 as shown in Figure 3. The L5991 controller is first activated by dropping resistors (R2 + R4) that draw current from the DC bus and charge the supply capacitor C9. Once the voltage on C9 exceeds the turnon threshold, (14 V min.), the IC starts switching. During normal operation, the controller is powered by the auxiliary winding of the transformer, via the D6 diode and R22 resistor. The current flowing in the transformers primary winding is sensed by the R10 resistor, implementing the current mode control scheme. The output rectifier (D7) has been chosen in accordance with the maximum reverse voltage and power dissipation. The rectifier is a Schottky diode (STPS20H100CT in TO-220 package) that can achieve a low forward voltage drop and lower power dissipation, as opposed to a standard PN diode. In order to optimize the switching waveforms, a snubber network (R12 + C21) is connected in parallel to this diode. The regulation feedback is connected to the output and the COMP pin (6) of the L5991 is directly driven by the opto-coupler collector.

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C1 C2 100n 400V 4 R1 C4 10n 600V 3 5 D2 AC_SIGNAL R22 8.2 1N4148 R9 2.7K R21 Q2 BC337 27k
U4

Varistor

100n 400V 1k

L1 15mH 3 4 + 1 T5 TRANSFORMER 2 1n

t t

N 2 C3 220u 450V 20K 6W Cout1 330u 10 6 C37 330u Cout 330u C38 330u

1 2 3 4 5 6 7 8 22 R13 STP12NK80Z 2k2 C7 100p R10 0.20 R14 22 PGND 3 C14 270n C10 680n L5991 TL431 U3 2

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DIODE BRIDGE D1 R12 C21 TRANSIL D8 12

Figure 3.

F1

FUSE

t
STPS8H100

D7

+13.8V

NTC 16 ohm

D5 STTH106 D6

Power supply architecture

1N4148

R46 220R

Flyback converter schematic

R2 15k R4 15k

R5 18k

R3 n.c. M1 PC817 R11 1

R8 1k

R7 15k C23 n.c. 1

C5

C12 2.2nF 12k

R20

16 15 14 13 12 11 10 9

150n

C11 1u

R6 3.9k

C9 PGND 330uF-25V

C13 R15 330k n.c. R18 C6 2.2n

2.7n

R19 47k C8 2.2n

R17 n.c.

C22 n.c.

R16 n.c.

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AN2772

Power supply architecture

2.1.1

Flyback transformer
Figure 4 and Figure 5 show the electrical and mechanical specifications of the transformer.

Figure 4.

Transformer - Schematic diagram and electrical specifications

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Power supply architecture Figure 5. Transformer - Mechanical specifications

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Power supply architecture

2.2

DC to DC converter
The DC-DC section of the power converter consists of two parts: a switching converter based on the L5973D and a standard linear regulator for the 5 V supply. The schematic of this section is shown in Figure 6. The 3.8 V output has a current capability of 350 mA with a peak value of 1.9 A, while the 5 V output has a current capability of 200 mA.

Figure 6.

DC-DC converters
U5

PWR

5 6 7 8

4 3 2 1

L3 15H - 3A

OUT - 3.8V

L5973 C30 R24 4.7k C27 22nF

D3 + COUT2 C29 220pF STPS2L25U R25 6.8K 330F 10V

10F 25V

R26 3.3k

L7805 VIN C31 100nF VOUT GND U2 + COUT3 33F 10V 5V

2.3

Battery charger
The battery charger has been developed using the TSM108, a PWM controller able to regulate the output of a DC-DC converter controlling both the voltage and the current, driving an external p-channel MOSFET (STS5PF30L - 30 V - 5 A - 70 m typ. RON). The schematic of the converter is shown in Figure 7. The "BATTCHRGR-IN" input is connected to the 13.8 V output of the AC-DC converter by means of a jumper in order to easily connect or disconnect the battery charger block from the system. The output of the battery charger, "BATTCHRG-OUT", is connected to the SLA battery by means of a fuse so as to avoid damage to the battery due to an accidental short circuit or over-current condition. The drop between the input and output voltage is such that the duty cycle of the buck converter is too high for the requested current capability, thus making it difficult to use an integrated device. In such a condition, the MOSFET would always be in conduction and the device could over-heat.
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Power supply architecture

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To set a different charging current value, the SW1 jumper can be set to select a relative sensing current "Rsense" and "Rsense1", so as to obtain 0.5 or 1 A respectively of the current limitation.

Figure 7.

Battery charger

BATT CHARGE - IN M2 1 2 3 4 TSM108 1 2 3 4 5 6 7 14 13 12 11 10 9 8 R23 1k C26 220n R31 2.7k 8 7 6 5 L4 470H D4 STPS2L25U R32 12k R40 180k BATT CHRG - OUT

R48 860k

STS5PF30L

C25 220

C28 220

R30 22k C40 220p C36 47n

C32 220n SW1 Rsense1 0.04 Rsense 0.08

2.4

Electronic switch
A dedicated circuit has been used to connect either the AC-DC converter output or the battery to supply the output of the overall power supply. This circuit is identified as "electronic switch" and its schematic is shown in Figure 8. The circuit consists of two highside drivers, VN750, and a logic block with two HCF4011, totalling three inputs and one output. The block is supplied by the battery and controls the ENABLE pin of U30, which enables the connection between the battery and the output. The block also performs under-voltage and over-current protection in order to prevent damage to the battery. The under-voltage and over-current protection threshold can be easily adjusted by changing some resistor values (R35, R36 and R37) and/or voltage reference levels (VREF1 and VREF2).

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Power supply architecture

Figure 8.

Electronic switch
U31 3 2 a k PWR

DC_IN R47 1k2

u29 vn750pt u30 vn750pt 1 2 3 4 5 1 2 3 4 5 1

a1 STPS20L25C

VBATT R35 5.6K VDC_CTRL 3 VREF1 R38 820R R37 3.3k 2 + 4

8 U27A 1 TS912 R39 10k VBATT_CTRL R36 0.1 C35 100n

BATT_OK VBATT

8 U27B VREF2 C34 100n 14 U28A 5 3 2 7 6 HCF4011B HCF4011B 14 U28C 14 10 9 U26A 3 2 7 HCF4011B R45 1.8k VREF2 C33 100n 14 7 HCF4011B 5 4 6 HCF4011B 7 BATT_OK R44 10k U26B VREF1 U16 TL431 8 7 R43 1k 4 R42 1k 14 U28B 5 6 + 4 TS912 7 IBATT_CTRL VBATT_CTRL IBATT_CTRL 1 VDC_CTRL 1

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Power supply architecture

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2.5

Parts list
Table 1 and Table 2 provide the list of parts for the board in accordance with the schematics shown in Figure 3, Figure 6, Figure 7 and Figure 8.

Table 1.

List of parts(1)
Value Fuse Connector Jumper Connector Varistor NTC 10 7.5A 100nF 300 VAC 220 F - 450 V 2.2 nF 1000 V 150 nF - 50 V 2.2 nF - 50 V 100 pF - 50 V 330 F - 35 V 680 nF - 50 V 1 F - 35 V 2.2 nF - Y1 270 nF - 50V 1 nF - 50V Description 3.15 A fuse 2-way connector Wire jumper Double stripline N.M. NTC X2 capacitor Aluminium elcap HV cercap Cercap Cercap Cercap Aluminium elcap Cercap Aluminium elcap Y1 safety cap Cercap Cercap N.M. 330 F - 50V 20 mH 20 k 6 W 5 % 15 k 1/4 W 5 % N.M. 18 k 1/4 W 1 % 3.9 k 1/4 W 1 % 15 k 1/4 W 5 % 1 k 1/4 W 5 % 2.7 k 1/4 W 5 % 0.20 k 15 W 1 % 22 1/4 W 5 % Aluminium elcap Common mode choke Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor RUBYCON - ZL TDK VISHAY RUBYCON - YXF MURATA RUBYCON - YXF ANY EPCOS EPCOS PHOENIX CONTACT Manufacturer

Reference F1 J22 J23 J8 RT1 RT2 C1, C2 C3 C4 C5 C6, C8, C12 C7 C9 C10 C11 C13 C14 C21 C22, C23 C37, C38, Cout1, Cout2 L1 R1 R2, R4 R3 R5 R6 R7 R8 R9 R10 R11, R14

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AN2772 Table 1. List of parts(1) (continued)

Value 1 k 1/4 W 5 % 2.2 k 1/4 W 5 % 330 k 1/4 W 5 % N.M. 47 k 1/4 W 5 % 12 k 1/4 W 5 % 27 k 1/4 W 5 % 8.2 k 1/4 W 5 % 220 2 W 5 % KBU6M STTH106 1N4148 STPS20H100CT N.M. STP12NK80Z BC547B L5991 TL431 PC817B TRANSFORMER 1012.0021 Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Bridge rectifier Fast rec. rectifier General-purpose diode Power schottky rect. Transil Power mosfet Small signal npn bjt Primary controller Shunt regulator Optocoupler Transformer Description

Power supply architecture

Reference R12 R13 R15 R16, R17, R18 R19 R20 R21 R22 R46 D1 D2 D5, D6 D7* D8 M1* Q2 U1 U3 U4 T5

Manufacturer

GENERAL SEMICONDUCTOR STMicroelectronics VISHAY STMicroelectronics

STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics SHARP MAGNETICA

1. Mounted with a heatsink (RTH 9.5C/W).

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Power supply architecture Table 2. AC-DC block - parts list(1)

Value 220 F - 25 V 220 nF 50 V 22 nF 50 V 220 pF - 50 V 10 F - 50 V 100 nF - 50 V 47 nF - 50 V 1 F - 450 V 330 F - 25 V 33 F - 16 V 100 nF - 50 V 1 k 1/4 W 5% 4.7 k 1/4 W 5% 6.8 k 1/4 W 5% 3.3 k 1/4 W 5% 2.2 k 1/4 W 1% 56 k 1/4 W 5% 10 k 1/4 W 5% 22 k 1/4 W 5% 2.7 k 1/4 W 1% 12 k 1/4 W 1% 150 k 2 W 5% 5.6 k 1/4 W 5% 0 820 1/4 W 5% 180 k 1/4 W 5% 1.8 k 1/4 W 5% 1.2 k 1/4 W 5% 860 k 1/4 W 5% 1.2 k 1/4 W 1% 0.1 2 W 5% 0.08 0.04 STPS2L25U STTH1R06 Description Aluminium elcap ZL Cercap Cercap Cercap Aluminium elcap ZL Cercap Cercap Aluminium elcap YK Aluminium elcap ZL Aluminium elcap ZL Cercap Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Wire Jump Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Power schottky diode Fast rec. rectifier RUBYCON RUBYCON RUBYCON RUBYCON

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Reference C25, C28 C26, C32 C27 C29, C40 C30 C31 C36 C39 Cout2 Cout3 C33, C34, C35 R23, R42, R43 R24 R25 R26, R37 R27 R28 R29, R34, R39, R44 R30 R31 R32 R33 R35 R36 R38 R40 R45 R47 R48 R49 R50 Rsense Rsense1 D3, D4 D9 14/22

Manufacturer RUBYCON

SEI-Electronics

STMicroelectronics STMicroelectronics

AN2772 Table 2. AC-DC block - parts list(1) (continued)

Value 15 H 3 A FUSE STS5PF30L BC847A L78M05CV L5973D PC852 TSM108 TL431 HCF4011B TS912 VN750PT STPS20L25C CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR Description SMD power inductor - DO3316P-153 4 A fuse + socket P-channel MOSFET Small signal NPN BJT Linear voltage regulator Stepdown switching regulator Optocoupler

Power supply architecture

Reference L3 F2 M2 Q1 U2** U5 U6 U7 U16 U26, U28 U27 U29, U30 U31 SW1 J9 J10 J21 J19, J20

Manufacturer COILCRAFT

STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics SHARP STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics

Voltage and current stepdown pwm controller Shunt regulator Quad 2 input NAND gate Dual op. amp. High side driver Power Schottky diode Stripline Stripline 2-way connector 8-way connector Double stripline

MOLEX

1. Mounted with a heat-sink (RTH 18C/W)

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Board layout

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Board layout
The board has a double layer substrate with a 35 m copper thickness. Figure 9 shows the top and bottom views of the board. The maximum size of the board is 10.5 x 20.5 cm and the maximum height is 43 mm, given by the transformer.

Figure 9.

Board layout - top and bottom view

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Experimental results

Experimental results
All measurements have been performed at ambient temperature (approximately 25 C), with an input voltage of 88 to 300 VAC. Table 3 lists the output voltage measurements during normal operation at no load and full load.

Table 3.

Output voltages
VIN 13.8 V OUTPUT No load -> 14.09 V 5 V OUTPUT No load -> 5.04 V Full load -> 5.04 V Ripple -> N.I. 3.8 V OUTPUT No load -> 3.76 V Full load -> 3.74 V Ripple -> 60 mV

88300 VAC

Full load -> 13.76 V Ripple -> 74 mV

Figure 10, Figure 11 and Figure 12 show some examples of drain voltages and current waveforms for different input voltages at full load.

Figure 10. Voltage and current - VIN = 110 VAC, full load

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Experimental results

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Figure 11. Drain voltage and current - VIN = 230 VAC, full load

Figure 12. Drain voltage and current - VIN = 300 VAC, full load

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Experimental results

4.1

Conducted EMI measurements

Figure 13 and Figure 14 show the conducted emission measurements, at full load for both US and European nominal input voltages, that is 110 VAC and 230 VAC respectively. The measurements have been performed using a 50 LISN and a spectrum analyzer, using a peak detector. The SMPS is compliant with the standard EN55022 CLASS B.

Figure 13. Conducted EMI - 110 VAC, full load Figure 14. Conducted EMI - 230 VAC, full load
02:21:41 Jul 18, 2007 Ref 75 dBV Peak Log 10 dB/ #Atten 10 dB Mkr1 15.08 MHz 40.5 dB V Ref 75 dBV Peak Log 10 dB/ 02:22:19 Jul 18, 2007 #Atten 10 dB Mkr1 15.08 MHz 33.82 dBV

1 1

W1 S2 S3 FC AA

W1 S2 S3 FC AA

Start 150 kHz Res BW 9 kHz

VBW 30 kHz

Stop 30 MHz Sweep 881.3 ms (1515 pts)

Start 150 kHz Res BW 9 kHz

VBW 30 kHz

Stop 30 MHz Sweep 881.3 ms (1515 pts)

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Conclusion

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Conclusion
A complete SMPS with AC-DC and DC-DC sections for supplying a typical central unit of an alarm system has been designed and fully tested. The power supply has been specifically designed to be connected with the STEVAL-IAC001V1. To order the board online go to http://www.st.com/stonline/domains/buy/buy_dev.htm, and use the order code STEVAL-ISA033V1.

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Revision history

6
Table 4.
Date

Revision history
Document revision history
Revision 1 Initial release. Changes

13-Nov-2008

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