The ST7540 reference design has been developed as a useful tool to demonstrate how a
small, high-performance powerline node can be built using the ST7540 FSK transceiver.
With this reference design, it is possible to evaluate the ST7540 features, in particular, its
transmitting and receiving performances through actual communication on the power line.
The ST7540 reference design may be considered to be composed of three main sections:
●Power supply section, specifically tailored to match powerline coupling requirements
and to operate within a wide range of the input mains voltage
●Modem and crystal oscillator section
●Linecoupling interface section
The coupling interface is designed to allow the ST7540 FSK transceiver to transmit and
receive on the mains using 72 kHz carrier frequencies, within the European CENELEC
standard A-band specified for automatic meter reading.
Figure 1.ST7540 reference design board with outline dimensions
52 mm
76 mm
As it can be seen from the picture above, a special effort has been made to obtain a very
compact reference design board, while keeping the focus on transmission and receiving
performances.
Note:The information provided in this application note refers to EVALST7540-2 reference design
Figure 10.Measured frequency response of the Tx active filter (typical curve) . . . . . . . . . . . . . . . . . . 20
Figure 11.Simulated frequency response of the Tx active filter with components tolerance effect. . . 20
Figure 12.Measured frequency response of the Tx active + passive filters connected to the CISPR net-
Transmitting output current limitR6=1.1kΩ – See Figure 2500 mA rms
nd
2
harmonic distortion
at mains output
3rd harmonic distortion
at mains output
exceeds 180 °C device shuts
down
R7 = 47kΩ, R8 = 15kΩ – See
Table 2
Loaded with CISPR 16-1
network
Loaded with CISPR 16-1
network
85 °C
22.25 V rms
-55
-61
Unit
dB
C
50Hz attenuation100 dB
Receiving specifications (Rx mode)
-3
Minimum detectable Rx signalBER<10
Auxiliary supply
5 V regulated voltageST7540 internally generated-5%5.05 +5%V
5 V current capability50 mA
3.3 V regulated voltageST7540 internally generated-5%3.3 +5%V
3.3 V current capability50 mA
Power supply section
AC mains voltage range85 265 V
Mains frequency50-60 Hz
Output voltageGreen led ON-10%12.3 +10%V
Output voltage rippleIout = 500 mA, Vin=85 Vac1%
Peak output current500 mA
Output power5.6 W
Efficiency at Pout=3.5W70 %
Nominal transformer isolation*
Primary to secondary/
secondary to auxiliary
, negligible noise48 dBµV rms
4 kV
Doc ID 12791 Rev 37/55
Electrical characteristicsAN2451
Table 1.Electrical characteristics of the ST7540 reference design (continued)
Val ue
ParameterTest conditions
MinTypMax
Number of holdup cycles0
Input power100 mW
Switching frequencyTransceiver section in Tx mode -10%65 +10%kHz
Switching frequency
Transceiver section in Rx
mode
-10% 21 +10%kHz
Unit
Table 2.Output voltage level setting through V
V(PA_OUT)
[V
]
P-P
V(PA_OUT)
[V
]
RMS
V(PA_OUT)
[dBuV
RMS
]
partitioning - typical values
sense
R
7
[kΩ]
2.8301.0001201615
3.1701.1201212015
3.5601.2601222415
3.9901.4101232715
4.4701.5801243315
5.0301.7801253915
5.6602.0001264715
6.3402.2401275115
7.1002.5101285615
7.9802.8201296815
Figure 2.Typical curve for output current limit vs. RCL value
R
[kΩ]
8
8/55Doc ID 12791 Rev 3
AN2451Safety precautions
2 Safety precautions
The board must be used only by expert technicians. Due to the high voltage (220 V ac)
present on the parts which are not isolated, special care should be taken with regard to
people's safety.
There is no protection against high voltage accidental human contact.
After disconnection of the board from the mains, none of the live parts should be touched
immediately because of the energized capacitors.
It is mandatory to use a mains insulation transformer to perform any tests on the high
voltage sections (see circuit sections highlighted in Figure 7 and Figure 8) in which test
instruments like Spectrum Analyzers or Oscilloscopes are used.
Do not connect any oscilloscope probes to high voltage sections in order to avoid damaging
instruments and demonstration tools.
Warning:ST assumes no responsibility for any consequences which
ST7540 transceiver uses frequency shift keying (FSK) modulation to perform a half-duplex
communication on a powerline network. It operates from a 7.5 to 13.5 V single supply
voltage (Vcc) and integrates a power amplifier (PA), which is able to drive low line
impedance, and two linear regulators providing 5 V and 3.3 V.
Figure 3.ST7540 Transceiver block diagram
The ST7540 can communicate using eight different communication channels (60, 66, 72,
76, 82.05, 86, 110, 132.5 kHz), four baud rates (600, 1200, 2400, 4800) and two deviations
(1 and 0.5). Additional functions are included, such as watchdog, automatic control on PA
output voltage and current, carrier/preamble detection and band-in-use signaling,
transmission time-out, and thermal shutdown.
The transceiver, which is dedicated only to physical communication, operates with a
microcontroller whose aim is to manage the communication protocol stack. A reset output
(RSTO) and a programmable clock (MCLK) can be provided to the microcontroller by the
ST7540 in order to simplify the external logic and circuitry.
The host controller can exchange data with the transceiver through a serial interface,
programmable to operate either in UART (CLR/T data clock not used) or in SPI mode.
Communication on the power line can be either synchronous or asynchronous to the data
clock that is provided by the transceiver at the programmed baud rate.
When in transmission mode (i.e. RxTx line at low level), the ST7540 samples the digital
signal on the TxD line at the programmed baud rate and modulates it in a FSK sinusoidal
output on the Tx_OUT line. This signal is then externally fed into the power amplifier to add
current capability. The power amplifier can also introduce gain and active filtering to the
signal, just using few external passive components. The resulting signal on the PA_OUT line
is coupled to the power line.
When in receiving mode (i.e. RxTx line at high level), an incoming FSK signal on the Rx_IN
line is demodulated and the digital output is available for the microcontroller on the RxD pin.
10/55Doc ID 12791 Rev 3
AN2451Evaluation tools description
The device also recovers the synchronism of the received signal using an internal PLL. The
recovered clock is present on CLR/T output.
The ST7540 operating parameters can be set by means of an internal control register,
accessible only through the SPI host interface.
4 Evaluation tools description
The complete evaluation system for the ST7540 powerline communication consists of:
●a PC using the "ST7540 power line modem demo kit" software tool
●one EVALCOMMBOARD hosting the ST7 microcontroller
The correct procedure for connecting the EVALST7540-2 and the EVALCOMMBOARD is as
follows:
1.Connect the EVALST7540-2 and the EVALCOMMBOARD
2. Connect the ac mains cable to the EVALST7540-2 and the USB cable to the
EVALCOMMBOARD
3. Connect the EVALST7540-2 to the ac mains supply
4. Connect the EVALCOMMBOARD to the PC via the USB cable.
Warning:Follow the connection procedure to avoid damaging the
boards.
Figure 4.Complete evaluation system including a PC, an EVALCOMMBOARD and
the EVALST7540-2 board
B /
UUSSB
RS232
Doc ID 12791 Rev 311/55
Evaluation tools descriptionAN2451
Figure 5.ST7540 powerline modem demonstration kit with control register window
The complete chain, controlled by the ST7540 powerline modem demonstration kit, can set
up real communication at bit level, simply by sending or receiving a user-defined bit stream.
It is possible to establish a half-duplex communication with two of these communication
nodes (two chains) connected to each other. In order to better evaluate communication
between two nodes, the ST7540 powerline modem demonstration kit has some particular
features, including:
●Frame synchronization: a byte synchronization header can be added to the to the
exchanged data to set up a simple protocol, intended to test the capability of the
system to correctly receive the exact transmitted bit sequence. This can be done in two
ways: via the ST7540 control register settings (the internal configuration register of the
modem has a frame header field, in which an 8- or 16-bit header can be set) or via the
Rx panel of the ST7540 powerline modem demonstration kit (setting a synchronization
at SW level). A bit synchronization can be introduced as a simpler feature by enabling
the preamble detection method in the control register panel and then inserting at least
one “0101” or one “1010” sequence at the beginning of the transmitted bit stream.
●Ping session: a master-slave communication with automatic statistics calculation can
be very useful to test a point-to-point or a point-to-multipoint powerline communication
network, thus providing a method to evaluate reachability of each node in the network.
For further details about the ST7540 powerline modem demonstration kit, please refer
to the user manual UM0239 “ST7540 power line modem demo kit graphical user
interface”.
12/55Doc ID 12791 Rev 3
AN2451Board description
5 Board description
The ST7540 reference design is composed of the following sections:
●Power supply section, based on ST’s VIPer12A-E IC
●ST7540 modem and crystal oscillator section
●Line coupling interface section, with three subsections:
–Transmission active filter
–Transmission passive filter
–Receiving passive filter.
The board also has two connectors, which allow the user to plug the mains supply on one
side of it and the I.B.U. communication board on the other side.
Figure 6.Positioning of the various sections of the board
The schematics of the whole reference design appear in Figure 7 and 8. Figure 7 shows
the modem and the coupling Interface circuits, while Figure 8 represents the power supply
circuit. In both the schematics, high voltage regions are highlighted.
Ta bl e 3 lists the components used to develop the reference design board. All parts have
been selected to give optimal performances.
The layout of the printed circuit is given in Appendix A - Figure 49, Figure 50 and Figure 51.
Doc ID 12791 Rev 313/55
Board descriptionAN2451
Figure 7.Modem and coupling interface schematic
HIGH
VOLTAGE
SECTION
14/55Doc ID 12791 Rev 3
AN2451Board description
Figure 8.Power supply schematic
VccVcc
VssVss
Vcc
TEST PADS
L3
470uHL3470uH
T1T1
C4
C4
R2
220kR2220k
Vcc
L4
33 uHL433 uH
D4D4
21
1
470pF 630V
470pF 630V
+
+
C2
C2
10uF 400V
10uF 400V
R5
1k5R51k5
D6
LEDD6LED
C29
C29
47uF 16V
47uF 16V
C9
C9
47uF 16V
47uF 16V
C8
470uF 16V
C8
470uF 16V
+
+
R4
560R4560
8
5
4
3
2
C5
220 pFC5220 pF
23
D2D2
Q1Q1
13
R3
1
D3D3
DC OUTPUT
C10
2.2 nF
C10
2.2 nF
10 KR310 K
12 V dc
1
3
D5
10VD510V
2
13
24
U2U2
R1
F1
D1
D1
4
10R 1WR110R 1W
T - 2AF1T - 2A
BRIDGE
BRIDGE
6
5
CN1CN1
C3
10uF 400V
C3
10uF 400V
+
+
1
3
-+
-+
2
10
L2L2
1
L1
1 mHL11 mH
N
P
C1
1
33nF X2C133nF X2
2
AC INPUT
85 V ac to 256 V ac
U1U1
578
DRAIN
FB
Vdd
36
C6
10 uFC610 uF
S
241
C7
47 nFC747 nF
HIGH
VOLTAGE
SECTION
Doc ID 12791 Rev 315/55
Board descriptionAN2451
Table 3.Bill of materials
Item QtyPartValueDescription
11CN1HEADER 2Mains supply connector
21CN2CON50A50 pins SMT right angle female p=1.27mm
31C133nF X2Murata GA355XR7-GB333K
42C2,C310uF / 400VYageo SE-K / Nichicon VK 20%
51C4470pF / 1kVTDK C4520X7R-3A471K
61C5220pF / 50VTDK C0603C0G-1E220J
74C6,C15,C17,C2410uF / 16VTDK C3216X7R-1C106MT
81C747nF / 25VMurata GRM188R7-1E473K
91C8470uF / 16VRubycon 3M0319 / Yageo SE-K 20%
102C9,C2947uF / 16VMurata GRM32ER6-1C476K
111C102.2nF Y1
122C11,C1233pFTDK C1005C0G-1H330J
132C14,C2710nFMurata GRM188R7-1H103K
144C16,C18,C19,C25100nFTDK C1608X7R-1H104K
152C21,C33150pFMurata GRM1885C-1H151J
161C2210uF
171C23100nF X2EPCOS B32922-A2104K
181C2622nF
191C3015pFMurata GRM1555C-1H150J
201C3122pFMurata GRM1555C-1H220J
211C32390pFMurata GRM1885C-1H391J
221D1DF06S600 V - 1.5 A bridge rectifier
231D2STTH1L06ASMA ultra-fast Schottky diode
241D3BAS16 / BAS21SOT23
251D4STPS1H100SMA Schottky diode
TDK CD12-E2GA222MYNS /
Murata DE1E3-KX222M
Murata GRM21BR6-1A106K /
TDK C2012X5R-0J106K
Murata GRM21B5C-1H223J /
TDK C3216C0G1H223J
261D5BZX84C10SOT23 10V zener diode
271D6LEDGreen LED
282D8, D10BAT54SSOT23 low drop Schottky diode
291D9SM6T12CA12V bidirectional transil diode
301F12A - TTime-lag fuse
311JP4CLOSE
321J1CONNECTOR
16/55Doc ID 12791 Rev 3
AN2451Board description
Table 3.Bill of materials (continued)
Item QtyPartValueDescription
331L11mHEpcos B82442-H1105K
341L22x10mH 0.3ARadiohm 42V15
351L3470uHEpcos B82442-A1474K
361L433uHEpcos B82462-A4333K
371L547uH
381L6220uH
391Q1BC857BLSOT23
401R110R 1WMetal oxide type - radial
411R2220K0603 1%
421R310K0603 1%
431R45600603 1%
441R51K50603 1%
451R61K10603 1%
461R747K0603 1%
471R815K0603 1%
481R94K70603 1%
491R1012K0603 1%
501R121K0603 1%
511R141K80603 1%
521R174700603 1%
Epcos B82464-A4473K /
WE 744-775-147
Epcos B82462-A4224K /
WE 744-774-222
531R193K90603 1%
541R2056K0603 1%
551R212K70603 1%
561T1
571T2
581U1VIPER12ASSMPS controller / switch
591U2SFH610-AOpto-switch
601U3ST7540Powerline transceiver
611X116 MHz
SMPS
transformer
Line
transformer
Doc ID 12791 Rev 317/55
TDK SRW12.6EF-E07H013 /
WE S06-100-057
VAC T60403-K5024-X044 /
Radiohm 69H14-2101
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