ST AN2067 Application note

AN2067
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APPLICATION NOTE
VIPower: DIMMABLE WHITE LEDS
POWER SUPPLY WITH VIPer53
In the same way that LED manufacturers succeed to realize blue LEDs, they now propose white LEDs inside a monolithic chip, or so called “single­chip white ” LED s . A current source is the mo re appropriate way to drive LEDs. For a maximum of flexibility, a large voltage range must be supported at the output due to the large threshold of these white LEDs, and the possible serial arrangement of them. Furthermore, if these LEDs h av e to be dimmable, they must be driven with a PWM (current generator). As a consequence, key features for this off-line power supply is a current generator, which can work as a Pulses Width M odulated mode, with a wide output voltage range, and must also suite any input voltage standard, and a galvanic isolation.
1. VIPer53 DESCRI PTION
VIPer53, the first multichip device of the VIPer family has been chosen to fulfill the requirements. It f eatures very l ow R a typical power of 35W in wide range in a standard DIP-8 package without a heatsink, answering the
of 1 allowing to deliver
dson
need for higher efficiency and reduced space thanks to a lower power dissipation.
1.1. General features
The block diagram is given on Figure 1. An adjustable oscillator is driving a current controlled PWM at a fixed switching frequency. The peak drain current is set for each cycle by the voltage present on the COMP pin. The useful range of the COMP pin extends from 0.5V to 4.5V, with a corresponding drain current range from 0A to 2A. This COMP pin can be either used as an input when working in secondary feedback configuration, or as an output when the internal error amplifier connected on the VDD pin is operating in primary feedback to regulate the VDD voltage to 15V. The VDD under voltage comparator drives a h igh voltage startup current source, which is switched off during the normal operation of the device. This feature together with the burst mode capability allows to reach very low level of input power in standby mode, when the converter is lightly loaded.
Table 1. White LEDs Power Supply Specification
Parameter Name Conditions Min Typ Max Unit
V
Output current I Output voltage V Output Power P Input Voltage V
OUT
OUT
OUT
IN
= 20V 200 1000 mA
OUT
I
= 1A 5 40 V
OUT
40 W
82 265 V
AC
Rev. 1
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Figure 1. VIPer 5 3 bl oc k diagram
ON/OFF
OVERTEMP.
DETECTOR
OSC DRAIN
OSCILLATOR
PWM
LATCH
S
R1
FF
R2
R3 R4 R5
Q
BLANKING TIME
SELECTION
1V
H
COMP
CURRENT
AMPLIFIER
VDD
8.4/
11.5V
15V
18V
UVLO
COMPAR ATOR
ERROR
AMPLIFIER
OVERVOL TAGE
COMPAR ATOR
0.5V
4.35V
STANDBY
COMPAR ATOR
OVERLOAD
COMPAR ATOR
150/400ns BLANKING
4V
4.5V
0.5V
PWM
COMPAR ATOR
8V
125k
TOVL COMP SOURCE
converter, the output power is first limited by the
1.2. Overload protection
A threshold of 4.35V typical has been implemented on the COMP pin. This overload threshold is 150mV below the clamping voltage of
4.5V which corresponds to the current limitation of the device. In case of a COMP v oltage exc eedi ng the overload threshold, the pull up resistor on the TOVL pin is released and the external capacitor connected on this pin begins to charge. When reaching a value of 4V typical, the device stops switching and remains in this state until the VDD voltage reaches V
, or resumes normal
DDoff
operation if the COM P voltage returns t o a value below the overload threshold. The drain current that the device is able to deliver without triggering the overload threshold is called “current capability”, specified as I
in the data
Dmax
sheet. This value must be used to size correctly the converter versus its max imum output power. When an overload occurs on secondary side of the
current limitation of the device. If this overload is lasting for more than a time constant defined by a capacitor connected on the TOVL pin, the device is reset, and a new restarting sequence is initiated by turning on the startup current source. The capacitors on the VDD pin and on the TOVL pin will be defined together in order to insure a correct startup and a low res tart d uty cycle in ov erload or short circuit operation. Here are the typical corresponding formulas:
C
C
C
Where t
OVL
VDD
VDD
12.56–×10 tss⋅>
1

84×10
I

>
--------------------------

V

and D
ss
---------------- 1–

D
RST
DD1tss
DDhyst
are respectively the time
RST
C
OVLIDDch2
-------------------------------------------⋅⋅>
V
DDhyst
needed for the output voltages to pass from 0V to
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their nominal values at startup, and the restart duty cycle in overload or short circuit condition. A typical value of 10 % is generally set for this last parameter, as it insures that the output diodes and the transformer don’t overheat. The other parameters can be found in the data sheet of the device. As the VDD capacitor has to respect two condition s, the max imu m valu e will b e ret ained to define its value.
1.3. Stand-by operation
On the opposite load config uration, the converter is lightly loaded and the COMP voltage is decreasing until reaching the shutdown threshold at typically 0.5V. At this point, the switching is disabled and no more energy is passed on secondary side. So, the output voltage is decreasing and the regulation loop is rising again above the shutdown threshold, thus resuming the normal switching operation. A burst mode with pulse skipping is taking place, as long as the output power is below t he one corresponding to the minimum turn on of the device. As the COMP voltage is working around 0.5V, the peak drain current is very low (it is actually defined by the minimum turn on time of the d evice, and by the primary winding of the transformer) and no audible noise is generated. In addition, the minimum turn on time depends on the COMP voltage. Below 1V (V blanking time increases to 400ns, whereas it is 150ns for higher voltages. The minimum turn on time resulting from these values are respectively 600ns and 350ns, when taking into account the internal propagation time. This feature brings the following benefit:
• This brutal change induces an hysteresis between normal operation and burs t mode which is reached sooner when the output power is decreased.
• A short value in normal operation insures a good drain current control in case of short circuit on secondary side.
• A long value in standby operation reinforces the burst mode by skipping more switching cycles, thus decreasing switching losses. More details regarding the stan dby operation c an be found in the data sheet. See also the prac tical
COMPbl
), the
results obtained in the corresponding section of this document.
2. WHITE LEDS POWER SUPPLY
2.1. Schematic
The power topology is an off-line fly-back, working at a fixed frequency of 66KHz. The overall schematic is presented on Figure 2.
2.1.1. Primary section
On the left hand side of the schematic, there is the fuse F1, inrush current limiter CTN1, input filter T1, followed by the rectifier BR1 and its bulk capacitance C3. R4, C4 and D4 built the RCD clamper, for discharging the leakage inductance of the transformer. D2, R2 and C5 is the rectifier and filtering of the primary auxiliary winding, used in forward mode (refer to Section 3). This generates a voltage supply from 21 V up to 80 V, proportional to turns ratio between main primary winding and au xiliary primary winding, and versus input voltage range (110 V A serial voltage regulator is required to supply the VIPer 53 with the correct voltage (around 12 V). It is built with R14, DZ14, Q1 and C12. Notice that the V 80 V. This transistor may also dissipate 0.7 W when input voltage is 250 V The COMP pin filter is done using C8, R9 and C9.
2.1.2. Transformer
By definition, a current generator may have a large output voltage variation, according to the output load. Then, if auxiliary winding is used in fly-back mode, there could be a large voltage variation on auxiliary winding as it is proportional to the reflected voltage. So, it will be used in forward mode in order to limit the voltage variation for supplying the VIPer53. In order to guaranty the functionality even with low output voltage load, an auxiliary winding at secondary side has been added, instead using the main secondary output to supply the regulation loop and the voltage limitation (using the TSM 101). For similar reasons, this auxiliary winding will be also used in forward mode.
up to 250 VAC).
AC
of this transistor must be higher than
CE0
.
AC
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Figure 2. Current Generator Schem at i c
1A OUTPUT
J107
VREF INPUT
P101
1KA
2.2K
R103
0
R107
R131
2.2K
C131
10nF
R101
12K
0.25
R100
6.8K
R107
C113
22nF
C111
100nF
C110
10uF/63V
L101
10µH
C112
220uF/63V
D101
STTH302
R102
680
U2A
C114
100nF
PC817
R108
100K
R106
10K
3.3
R122
D122
BAS21
1K
R109
1
2
345
8
Vref
VCC
GND
6
TSM101
U103
C121
22uF/40V
7
330
R105
U2B
PC817
C_YCAP
2.2nF/2KV
T2
DRAIN
SOURCECOMP
D2
BAS21
D4
EBR44-600
R4
47K/4W
R2
10
C4
1nF/250V
R14
3.3K/0.5W
VIPER53
TOVL
VDD
15V
OSC
C11
4.7nF
R5
5.1K
Q1
2N5550
C12
22uF/25V
DZ14
12V/0.5W
C9
470nF
R9
6.8K
C8
4.7nF
C10
100nF
C5
C3
100uF/400V
1uF/100V
BR1
1A/600V
C2
100nF/400V
T1
COMMON
MODE
F1
0.5A
FILTER
C1
<0
T
C
100nF/400V
CTN1
AC INPUT
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2.1.3. Secondary section
On the right hand side of the schematic, the secondary winding is used in fly-back mode. D101, C112 are respec tively the rectifying di ode and its filtering. L101 and C110 bui ld another low pass filter.
The auxiliary sec ondary winding used in forw ard mode (refer to Section 3) in association with R122, D122 and C121 built the rectifier and filtering for the supply of the regulation loop, using a dedicated component (TSM101). This supply is independent from the load voltage.
TSM 101 has been design for voltage and current controller, which can be used for the control of a current generator, in association with a voltage limitation. It includes its own reference voltage (bandgap), and two operational amplifiers.
2.1.4. Current regulation loop
The output current is sensed through the shunt resistor R100. The shunt voltage is amplified using R101 and R107 in association with one OPamp of the TSM 101, building the error amplifier. The current target is set through the trimmer P101. R103 and P101 provide a fraction of the reference voltage provided by the TSM 101 (U103).
There is also another way to set the current target, using the connector J107 for dimming (see Section 2.2).
C113 with R107 is the integrator network of this amplifier, in order to cancel the static error of the regulation loop.
Then, the regulation loop continue with the opt o­coupler U2 (diode and transistor). This set the level of the COMP pin filter, which set the peak drain current VIPer53’s power cell (current control mode). Thus, the energy stored inside the transformer during each cycles is transferred on the secondary side, which supply the output current.
R131 and C131 is a phase lead net work in order to compensate the phase delay due to L101/C110 filter, for whole loop stability purpose.
2.2. Dimming
2.2.1. Dimming purpose
The main purpose of this application is to supply “single-chip white LEDs”, and to dim the brightness of these LEDs.
Because the white color is obtained from two peaks in the spectrum (a blue ray and a yellow ray), there is a dependency between the driving current and the white color spectrum.
2.2.2. Dimming in the application
This application do not propose any PW M and its oscillator circuitry, which can be easily found in dedicated literature. The way to proceed is to apply an external PWM signal on the node VREF_INPUT.
Provided that output impedance of the generator is not higher than 50 , the input voltage is forced by the external generator instead of the DC reference voltage of the TSM 101.
The low level voltage of this PWM signal must be 0V, and high level voltage must be around 1 V.
Then, the peak current of the PWM generator can be set using the trimmer P101, a s in DC mode, from 0 up to 1 A.
The maximum frequency allowed is limited by dynamic behavior of the PWM current generator (refer to Section 2.2.4). The best way to use this power supply, is to set the lowest frequency convenient for human eye versus flicker. The highest the period, the highest the dimming range.
2.2.3. Audible noise
When using the power supply with a P WM signal, some audible noise may be heard, especially if the frequency of the external signal is inside the audible range.
This noise is emitted by the core of the transformer, and is a normal way to work. This noise is proportional to the output power transferred through it.
This noise can be reduced by optimiz ation of the transformer.
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2.2.4. Dynamic behavior of the current regulation loop
As explain above, the power supply must be ab le to generates a PWM current, at a sufficient frequency in order to avoid flicker, with the possibility to adjust the duty cycle. The shortest the time response of the regulation loop, the more linear will be the 0 % up to 100 % characteristics of the dimming range.
Thanks to the threshold of LED, it is possible to pulse its current instead to pulse its voltage. Then, the voltage can be maintained, it a void to charge and discharged the output capacitances. This helps a lot for dynamic behavior of the current generator, since the output filtering capacitance are quite large.
The dynamic behavior of this current generator is limited by several root causes in the whole schematic.
First origin of limitation is the RC couple R101 + R107 / C113. When the reference level is changing on the error amplifier (TSM 101-pin 5), the OPamp must move to this new operating point, by charging the node TSM 101-pin 3. This is limited by the charging of the capacitor C113 through the resistor R101 + R107.
Secondly, the filtering c apacitance C121 must be large enough in order to properly sustain the supply voltage of the OPamp and the resistor R102. Effectively, during a transient, the OPamp has to compensate its output level for loop stabilization. Then, the dynamic behavior is limited by the (dis)charging of the capacitor C113 through the resistor R102, once t he supply voltage of the amplifier is stable during that transient.
Third, the serial resistance of the load, plus the shunt resistance R100, and t he serial resistor of the capacitor C112 are limiting the time res ponse of the current generator. When switching the output current from O FF (low current le vel) t o ON (high current level), the output voltage has to increase of:
Vout I
But, the output current capability will be limited for a while, until the charging of the capacitance C112 is not completed. When this capacitor is charged, then the current capability is then available for the load itself.
outRsloadRshunt
+()=
2.2.5. Voltage limitation
The output voltage limitation is built around R106, R105, R108, C114 and the corresponding OPamp of the TSM 101.
R 106, R 105 create a bridge divider of the output voltage, in order to compare that fraction to the reference voltage of the TSM 101. The voltage limit is set by the formula:
R105 R106+

-------------------------------- -
Vout Vref
If the voltage limit is reached, the cable AND of the TSM 101 allow the voltage limitation circuit to force the whole loop to reduce the output power.
The stability of the voltage limitation loop i s done with R108 and C114.
For human body protection against electrical shocks, this limit has been set to around 40 V, as advise in safety standards.
2.3. No load operation
The design of the VIPer53 is intended to enter into burst mode when output see a low load. The application designer must avoid to en ter in hiccup mode (or bad burst mode) when no load is connected.
The resistors R106 and R105 has been designed in the application in order to have the VIPer53 in burst mode when no load is connected. A sufficient current is drawn into R106 and R105, dissipating the few power transferred to the secondary side of the transformer during the burst mode, using the minimum turn-on time (see Figure 7, Figure 9 and Section 4.8, Figure 17 for measurements).
2.4. Short circuit operatio n
Due to current generator structure, there is no malfunction or damage when used in short circuit condition. The current is by definition lim ited. The output power is low in that condition (refer to Section 4.8 and Figure 18 for measurements).
2.5. Low Voltage Load
When using very low voltage load (less than 4 volts at output), some instability problem may appears, depending of t he load ty pe (inductive or capacitive load, etc.).
=

R105
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Poles and zeros vary too much, which lead to make instable the whole transfer function.
This instability may be associated with audible noise due to some low frequency oscillations. The user must avoid using loads which have a voltage below than 4V, in order to ensure a correct operation of the power supply.
3. Transformer des ign
3.1. Primary Inductance
The primary inductance has been set to 0.5mH, according to the output power required, and the (minimum specification of) current capability of the VIPer53.
The VIPer software helps to define the number of turns of the primary inductance. It provides a result of 52 turns, in 2 wires. A diameter of 0.4mm has been chosen.
3.2. Primary Auxiliary winding
The VIPer53 must be supplied with at least 12.8 V, for a correct operation. This winding is also used in forward mode. The turn rat io between primary winding and primary auxiliary winding according to the minimum input voltage (100 V
A value of 0.21 will be used with 11 turns on auxiliary. At maximum input voltage (400 V auxiliary supply then will be 85 V. This will provide constraint on the voltage regulator for the VIPer53.
) is 0.18.
DC
DC
), the
3.4. Summary of transformer
Table 2 summarise the spec ification of the power supply transformer.
4. Measurements
The measurements done on the application board has been performed at room temperature (27° C), using an open application board, in still air condition.
Static measurements have been performed us ing a programmable electronic load, used as a voltage generator (so called “static load”).
In order to be as close as possible of the LEDs load, dynamic measurements have been done using a discrete voltage generator, as described in Figure 3 (so called “dynamic load”). This present a similar load as LEDs according to serial resistance and parasitic capacitance.
Figure 3. Discrete Voltage Load
3.2.1. Secondary wind in g
The output voltage may vary from 4 V up to 40 V, and the reflected voltage must n ot exceed 100 V. The turn ratio should be 0.5 (26 turns) in order to avoid current mode instability.
A diameter of 0.7mm is provided by VIPer software.
3.3. Secondary Auxiliary winding
This secondary auxiliary output must guaranty a voltage from minimum 6 V up to m aximum 32 V (supply voltage range of the TSM 101). The turn ratio is 0.077 (4 turns). This provide a supply voltage from 7.7V up to 30.8 V, which is in line with the specification of the TSM 101.
4.1. Switching cycle
Figure 4 and Figure 5 show the drain voltage and drain current respectively in discontinuous mode and continuous mode, with a 40 Watts static load, and input voltage respectively at 400 V and 100 V.
Figure 7 and Figure 9 present Drain voltage, Drain current, V The output (static) load is 4 Watts (40 Volts, 100 mA), and input voltage is respectively at 100 V and 400 V .
COMP
and V
voltage in burst mode.
OUT
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Table 2. Transformer specification
Parameter
Primary inductance Lprim: 0.5mH
Primary auxiliary winding 0.211 11 1 ~0.2 <0.1 Secondary winding 0.5 26 1 0.7 1 Secondary auxiliary winding 0.077 4 1 ~0.2 <0.1
Figure 4. Discontinuous mode (40W/V
Prim. Induct.
or Turn Rati o
Lleak < 4µH (0.8%)
Core: E25H
=400V)
IN
Number
of Turns
52 2 0.4 2.3
Figure 6. Burst mode (P
Number
of Wires
Wire diam.
(mm)
=4W; VIN=100V)
load
Max Current
(A)
Figure 5. Con t in uo us m od e (40 W /V
=100V)
IN
Figure 7. Burst mode (P
=4W; VIN=400V)
load
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Figure 8. Dynamic response 50% duty cycle at 100Hz
4.2. Dynamic response
4.2.1. Discrete load
An external signal has been applie d on c onne ctor J107 (node VREF_IN), in order to replace the static internal reference voltage of the TSM101 with a PWM signal.
The amplitude of this signal is 0 V (low level) - 1 V (high level) in order to get the full range 0 up to 1 A.
The frequency of this signal is around 100 Hz. The generator allow to adjust the duty cycle of this (PWM) signal from 10% up to 90%.
The load used during these measurements is a discrete load (dynamic load).
Figure 9. Dynamic response 10% duty cycle at
100Hz
Figure 8, Figure 9 and Figure 10 show the dynamic response of the current generator, when used in PWM mode, respectively with 50%, 10% and 90% of duty cycle.
10% and 90% of duty cycle at 100 Hz, is roughly the minimum and maximum du ty c ycle allowed to get an acceptable shape for the current pulse.
The minimum turn on/off time is around 1 ms. This provide a maximum frequency of 500 Hz (2 ms period).
Figure 10. Dynamic response 90% duty cycle
at 100Hz
4.2.2. LEDs load
Figure 11 and Figure 12 represent the dynamic response on real load, respectively on 4 white LEDs, and 1 white LED.
The dynamic response is worst than using discrete load. It is also worst using 4 LEDs than using 1 LED. This typically shows the LED serial resistance limitation, as explain below in Section
2.2.4. The poor dynamic response on LEDs load is
because it has been o ptimized u sing the discrete load, which have different serial resistance.
There is a room for im provement on LEDs load, until the signal V maximum value (4.5V). Poles and zeros may be tune in order to improve the dynamic response of
COMP
, and then I
V
still do not reach its
COMP
.
OUT
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Figure 11. Dynamic response on 4 White LEDs
Figure 12. Dynamic response on 1 White LED
4.4. Load regulation
The regulation versus the load is represented in Figure 14. The regulation is around 0.4 %.
Figure 14. Lo ad R egulation
1050 1040 1030 1020 1010 1000
990
Iout (mA)
980 970 960 950
010203040
Vout ( V)
4.5. Voltage limitation
Figure 15 is the extension of the load regulation in Figure 14 (up to the voltage limit). Then, the voltage limitation act on the output power through the whole regulation l oop, and the output curren t then decrease down to 0.
Note: Since the bridge divider has been slightly tune, the voltage limit may be different than these measures according to R10 5 and R106 standard values.
Figure 15. Voltage Limitation
1200
1000
4.3. Line regul a tio n
Figure 13 presents the output current variation versus AC line input voltage. It shows a variation of 0.4 %.
Figure 13. AC Li ne R egulation
1050 1040 1030 1020 1010 1000
Iout (mA)
990 980 970 960 950
100 150 200 250 300 350 400
Vin ( V)
800
600
Iout (mA)
400
200
0
0 10203040
Vout (V)
4.6. Power Supply Efficiency
Figure 16 shows the efficiency of the power supply when output power increases from 0 up to 40 Watts, using several input voltage. Output voltage vary while output current is 1A.
The efficiency is lower than what could have been expect for an off line converter. This is mainly due
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to the current generator structure of this application, which impose to have the supply of the VIPer53 connected on a fo rward windi ng, and because of its associated serial voltage regulator.
Figure 16. Efficiency (I
100.0
90.0
80.0
70.0
n (%)
60.0
50.0
40.0
5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0
Pout (W )
4.7. Efficiency Vs. output power (V
OUT
=1A)
=100V)
IN
Vin=100V Vin=200V Vin=300V Vin=400V
Main contributors in the power budget are the transformer, the inrush current limiter, primary and secondary rectifier, and the clamper.
When output load increase, the ratio between the dissipated power of these main contributors and the output power decrease. This is because power of main contributors is quite cons tant versus the output load.
Figure 18. In put power in Shor t Circuit mode
3.0
2.5
2.0
1.5
Pin (W)
1.0
0.5
0.0 100 150 200 250 300 350 400
Vin (V)
Figure 19 presents Drain, COMP pin, Output voltage and Drain current during short circuit condition. Notice that the converter is in continuous mode (V
Figure 19. Short circuit con di tio n ( V
=100V).
IN
=100V)
IN
4.8. Extreme load conditions
Figure 17 and Figure 18 show the po wer supply consumption respectively when no load is connected at the output and in short circuit condition.
5. Boa rd description
Figure 17. Input power in No Load mode
1.2
1.0
0.8
0.6
Pin (W)
0.4
0.2
0.0 100 150 200 250 300 350 400
Vin (V)
5.1. Printe d Circuit Board
Figure 20 to Figure 22 present the PCB of the application. They respectively show all the layers of the PCB, the BOTTOM layer of the PCB, and then the TOP OVERLAY layer of the PCB.
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Figure 20. All layers (not in scale)
Figure 21. Bottom layer (not in scale)
Figure 22. Top Overlay layer (not in scale)
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6. Bill of material
The Table 3 presents the bill of material of the application.
Table 3. Bill Of Material
Symbol Description Quantity
BR1 1A/500V 1 C1 100n/400V 1 C2 100n/400V 1 C3 100u/400V/159 PUL-SI 1 C4 1nF/250V 1 C5 1µF/100V/RLI135 1 C8 4.7nF 1 C9 470nF 1 C10 100nF 1 C11 4.7nF 1 C12 22µF/25V 1 C104 NC 1 C105 NC 1 C107 NC 1 C110 10uF/63V 1 C111 100nF 1 C1 12 220uF/63V/RLI 135 1 C113 22nF 1 C114 100nF 1 C121 22uF/40V 1 C131 10nF 1 COR1 CORNER 1 COR2 CORNER 1 COR3 CORNER 1 COR4 CORNER 1 COR5 CORNER 1 COR6 CORNER 1 CTN1 1 C_YCAP 2.2n/2KV 1 D2 BAS21 1 D4 EBR44-600 1 D101 STTH302 1 D122 BAS21 1 DZ14 12V/0.5W 1
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F1 FUSE 1 J1 1 J2 1 J3 1 J101 1 J102 1 J103 1 J107 Vref_in 1 L101 10uH 1 P101 1K 1 P1011 1K 1 Q1 BC546/VCEO=100V/1W 1 R2 10 1 R4
R5 R9 R14 R100 R101 R102 R103 R104 R105 R106 R107 R108 R109 R122 R131 TR1 LN_FILTER 1
TR2 E25 1 U1 STMicroelectronics VIPer53DIP 1 U2 PC817 1 U101 STMicroelectronics TSM1 01A 1
47K/4W
5.1K
6.8K
3.3K/0.5W
0.25 12K 680
2.2K 1
1.8K 56K
6.8K 100K 1K
3.3
1.8K
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