ST STEVAL-ISA096V1 -12 V/150 mA adaptable buck-boost converter User Manual

UM1470
User manual
STEVAL-ISA096V1 -12 V/150 mA adaptable buck-boost converter
Introduction
The purpose of this document is to describe the STEVAL-ISA096V1 switched mode power
supply (SMPS) demonstration board. The STEVAL-ISA096V1 is a non-isolated SMPS
designed in buck-boost topology capable of delivering up to 2 W output over a wide input
voltage range, providing a cost-effective and space-saving solution.
It also offers the user the possibility of adapting the circuit to their needs thanks to the
availability of a free PCB area.
The STEVAL-ISA096V1 SMPS generates a 12 V nominal output voltage. This board is
based on VIPer™06XS - a monolithic converter integrating an 800 V avalanche rugged
MOSFET and PWM controller in one package.
This document contains a basic technical description of the demonstration board (schematic
diagram, PCB details, and bill of material) as well as the most significant parameter
measurements (load regulation, efficiency, standby behavior, EMI and thermal behavior
data).
Figure 1.
May 2012
STEVAL-ISA096V1 demonstration board
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Contents
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Contents
1
Main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2
Board connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3
Board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4
5
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3.1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2
Description of the schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4
Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3
Load characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4
EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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List of figures
List of figures
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
STEVAL-ISA096V1 demonstration board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Input/output connection of SMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEVAL-ISA096V1 circuit schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
The PCB layout - top and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Efficiency at 120 VAC and 230 VAC depending on the output current. . . . . . . . . . . . . . . . 11
Efficiency at full load (150 mA) over input voltage range . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Standby depending on the input voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The 12 V output load characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EMI measurement regarding EN55022 Class 2 - peak detector . . . . . . . . . . . . . . . . . . . . 15
EMI measurement regarding EN55022 Class 2 - AVG detector. . . . . . . . . . . . . . . . . . . . . 16
Thermal map of the board at 265 VAC on the input - left bottom side, right top side . . . . . 17
Thermal map of the board at 85 VAC on the input - left bottom side, right top side . . . . . . 17
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Main characteristics
1
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Main characteristics
The main characteristics of the SMPS are listed below:
●
●
Input:
–
VIN: 85 ~ 264 Vrms
–
f: 45 ~ 66 Hz
Output:
–
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-12 VDC ± 10%, 150 mA
●
Standby < 30 mW at 264 VAC
●
Short-circuit: protected
●
PCB type and size:
–
FR4
–
Single side 35 µm
–
SMPS size 19 x 39 mm, board size 38 x 61 mm
●
Isolation: isolated 4 kV/8 mm
●
EMI: according to EN55022 Class B
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2
Board connection
Board connection
The STEVAL-ISA096V1 demonstration board is shown in Figure 2, with input and output
locations.
Figure 2.
Input/output connection of SMPS
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Board description
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3
Board description
3.1
Schematic
A schematic diagram of the buck-boost converter board based on the VIPer06XS is
provided in Figure 3.
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Figure 3.
5
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Board description
STEVAL-ISA096V1 circuit schematic
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Board description
3.2
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Description of the schematic
The input part of converter consists of an input single-wave rectifier, EMI/EMC filter and bulk
capacitor.
The input rectifier is based on two 1 A/1 kV general purpose diodes (D1, D2). The 2 kV
blocking voltage is selected to increase robustness against input surge pulse.
The EMI filter is based on a π filter (C10, C2, L1) and the possibility to place an input foil
capacitor may also be an option. This capacitor is not mandatory in order to satisfy EMI
limits (see Figure 9), but it can be used in case a wider margin of EMI limits is required.
The input EMC filter is based on the inrush resistor R2 and bulk capacitors C10 and C2.
The buck-boost converter itself uses a standard connection. The VIPer06XS (U1),
containing an active switch and controller, is placed as the high side with floating reference.
After turn-ON of the internal MOSFET the energy is stored in the inductor L3. After U1 is
turned off the energy stored in the L3 is distributed to the output capacitor C5 via diode D4
and in capacitor C3 via diode D3. It can be expected that the voltage drop over capacitor C3
is almost the same as the voltage drop over output capacitor C5. The feedback loop
performs constant voltage regulation and the output voltage is measured across C3 by
a voltage divider (R1 and R3) connected to the FB pin of U1.
3.3
Layout
The layout of the PCB is based on a one-sided FR4 with a 35 μm thickness and is shown in
Figure 4.
The size of the PCB dedicated for the SMPS itself is 39 mm x 19 mm while the size of the
complete PCB is 61 x 38 mm; this extra space (area provided by through-hole connections)
is intended to give the user the possibility of modifying certain board specifications.
It is possible, for example, to apply an output linear regulator generating precisely 3.3 or 5 V
or to realize different types of feedback loop to minimize load regulation.
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Board description
Figure 4.
The PCB layout - top and bottom
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Board description
3.4
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Bill of materials
Table 1.
BOM
Index Quantity
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Ref.
Value / generic part
number
Package / class
1
1
R1
27 kΩ / 1% / 0.1 W
0805
2
1
R2
22 Ω / 2 W / 5%/WW
TH - wire wound
3
1
R3
10 kΩ / 1% / 0.1 W
0805
4
0
R4
N. A.
0805
5
0
R5
N. A.
0805
6
0
C1
N. A.
18 x 6 x RM 15
7
1
C2, C10 3.3 μF / 400 V
R 10 x 13, RM 5 mm
8
1
C3, C4 1 μF / 25 V / X7R
1206
9
2
C5
47 μF / 50 V
R 6.3 x 11 RM 2.5 mm
10
0
C6
N. A.
0805
11
1
C7, C8 1.5 nF / 50 V
0805
12
1
L1
1 mH / 80 mA
13
1
L3
1.5 mH/400 mA,
HV 768 772 152
14
2
D1, D2 1N4007
MELF / SMA
15
2
D3, D4 STTH1L06A
SMA
16
1
D5
17
1
DZ1
18
1
19
20
R 8 x 10, RM 5 mm
1N4148
SOD80
ZD / 15 V / 5%
SOD80
U1
VIPer06XS
SSO10
1
J1
Screw terminal 2 pos. RM 5 mm
1
J2
Screw terminal 3 pos. RM 5 mm
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Manufacturer
Würth Elektronik
STMicroelectronics™
STMicroelectronics
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Measurements
4
Measurements
4.1
Efficiency
The output voltage efficiency depending on the output current of 12 V output is displayed in
Figure 5.
Figure 5.
Efficiency at 120 VAC and 230 VAC depending on the output current
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Measurements
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Figure 6 shows the efficiency of the SMPS at full load applied on the 12 V, depending on the
different input voltage. A drop of efficiency at low input voltage is mainly caused by an
increase in the losses in the input inrush resistor and EMI filter.
Figure 6.
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Efficiency at full load (150 mA) over input voltage range
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4.2
Measurements
Standby
The standby behavior of the board is displayed in Figure 7. This value is for any input
voltage below 30 mW. The measured value could be partly reduced by using a higher value
of resistors R1 and R3. The power loss over these resistors is about 4.5 mW. By using
a higher value voltage divider (5 - 10 times) the standby losses drop by about several mW,
but this action increases load regulation.
Figure 7.
Standby depending on the input voltage
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Measurements
4.3
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Load characteristics
The load characteristics of a 12 V output are displayed in Figure 8. The output voltage is for
any load and any input voltage within a ±10% tolerance.
Figure 8.
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The 12 V output load characteristics
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4.4
Measurements
EMI
The conductive EMI test of the demonstration board is displayed in Figure 9 and 10. The
AVG detector is used in Figure 10, while the peak detector measurement can be seen below
in Figure 9.
Figure 9.
EMI measurement regarding EN55022 Class 2 - peak detector
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Measurements
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Figure 10. EMI measurement regarding EN55022 Class 2 - AVG detector
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4.5
Measurements
Temperature
The thermal map at full load measured at 265 VAC and at 85 VAC is displayed in Figure 11
and Figure 12. The ambient temperature was 25 °C. Regarding the measurements visible
below, it can be estimated that the temperature of the components is below AMR even at
85 °C of ambient temperature. This range can be extended by using a bigger Cu heatsink
area connected to the drain of the VIPer06XS.
Figure 11. Thermal map of the board at 265 VAC on the input - left bottom side, right top side
Figure 12. Thermal map of the board at 85 VAC on the input - left bottom side, right top side
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Revision history
5
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Revision history
Table 2.
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Document revision history
Date
Revision
02-May-2012
1
Changes
Initial release.
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