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ST AN3290 Application Note Design Reference for Dual Output SMPS Applied to Power Line Modem Utilizing ALTAIR04-900 Primary Controller

Summary

This application note provides a detailed design and technical evaluation for building a double-output Switched-Mode Power Supply (SMPS) specifically for power line communication systems. The solution utilizes the ALTAIR04-900 controller, featuring primary sensing to simplify circuit design by eliminating secondary voltage references or optocouplers. The document covers comprehensive testing data, including efficiency measurements, operational waveforms across various mains voltages, and detailed reports on protection features like overload and brownout detection. This resource is ideal for engineers designing robust, high-reliability low-voltage power supplies used in modem applications.

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AN3290

Application Note

Reference design for double output SMPS for power line modem applications using ALTAIR04-900 primary controller

Introduction This application note introduces a new “all-primary sensing” switching regulator ALTAIR04- 900, used to build an innovative solution to supply a power line communication. A demonstration board, implementing a wide-range double-output power supply, has been developed and the results of its bench evaluation are reported in this document. The board uses the new ALTAIR04-900, a quasi-resonant (QR) current-mode controller IC specifically designed for QR ZVS (zero voltage switching at switch turn-on) flyback converters, which combines a high-performance low-voltage PWM controller chip and a typical 16 RDSon, 900 V, avalanche-rugged power MOSFET in the same package. The device is capable of providing constant output voltage regulation using primary-sensing constant voltage loop (CV loop). This eliminates the need for the optocoupler and the secondary voltage reference while still maintaining quite accurate regulation. Also, using the primary constant current loop (CC loop), it is possible to set the maximum deliverable output current without any secondary components or current sensor.

April 2011 Doc ID 18038 Rev 1 1/34

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Page Summary Contents For ST AN3290 Application Note Design Reference for Dual Output SMPS Applied to Power Line Modem Utilizing ALTAIR04-900 Primary Controller

Page 1 AN3290 Application Note Reference design for double output SMPS for power line modem applications using ALTAIR04-900 primary controller Introduction This application note introduces a new “all-primary...
Page 2 Contents AN3290 Contents Test board design and evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Output voltage characteristics . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 3 AN3290 List of Tables List of Tables Table 1. ALTAIR04-900 power supply: electrical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 2. ALTAIR04-900 power supply - bil...
Page 4 List of figures AN3290 List of figures Figure 1. Electrical schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Figure 2. PCB: com...
Page 5 AN3290 Test board design and evaluation 1 Test board design and evaluation As a reference design, a 7.48 W nameplate output power SMPS has been specifically designed and developed according to the spe...
Page 6 Test board design and evaluation AN3290 Figure 1. Electrical schematic Figure 2. PCB: component side (not to scale) 6/34 Doc ID 18038 Rev 1
Page 7 AN3290 Test board design and evaluation Figure 3. Demonstration board image: power supply board Doc ID 18038 Rev 1 7/34
Page 8 Test board design and evaluation AN3290 Figure 4. Demonstration board image: complete (power supply and PLM boards) Table 2. ALTAIR04-900 power supply - bill of material Reference Part Description Not...
Page 9 AN3290 Test board design and evaluation Table 2. ALTAIR04-900 power supply - bill of material (continued) Reference Part Description Note C6 B32922C3224M 220 n F - X2 EPCOS C7 2.2 n F - Y-CAP C8 470 n...
Page 10 Test board design and evaluation AN3290 Table 3. ALTAIR04-900 power supply: transformer characteristics Core E16 Primary inductance 2 m H Leakage inductance 1.42% nom. Primary winding 7.68 ± 5% Np1 11...
Page 11 AN3290 Output voltage characteristics 2 Output voltage characteristics Figure 6 and 7 show the load and the line regulation of the output 1 when the other output is charged with 40 m A and 80 m A resp...
Page 12 Efficiency and no load measurements AN3290 3 Efficiency and no load measurements In this section the converter efficiency has been measured at different output current levels on VOUT1 and VOUT2 fixed ...
Page 13 AN3290 Typical board waveforms 4 Typical board waveforms Typical waveforms during TX mode and different input voltages are shown in this section. In this condition the load on output 1 changes from 35...
Page 14 Typical board waveforms AN3290 Figure 11. Normal operations in TX mode at 115 VAC Figure 12. Normal operations in TX mode at 230 VAC 14/34 Doc ID 18038 Rev 1
Page 15 AN3290 Typical board waveforms Figure 13. Normal operations in TX mode at 264 VAC Figure 14. Normal operation in TX mode at 85 VAC and IOUT2=40 m A Doc ID 18038 Rev 1 15/34
Page 16 Typical board waveforms AN3290 Figure 15. Normal operation in TX mode at 85 VAC and IOUT2=80 m A Figure 16. Normal operation in TX mode at 115 VAC and IOUT2=40 m A 16/34 Doc ID 18038 Rev 1
Page 17 AN3290 Typical board waveforms Figure 17. Normal operation in TX mode at 115 VAC and IOUT2=80 m A Figure 18. Normal operation in TX mode at 230 VAC and IOUT2=40 m A Doc ID 18038 Rev 1 17/34
Page 18 Typical board waveforms AN3290 Figure 19. Normal operation in TX mode at 230 VAC and IOUT2=80 m A Figure 20. Normal operation in TX mode at 264 VAC and IOUT2=40 m A 18/34 Doc ID 18038 Rev 1
Page 19 AN3290 Typical board waveforms Figure 21. Normal operation in TX mode at 264 VAC and IOUT2=80 m A Doc ID 18038 Rev 1 19/34
Page 20 Protection features AN3290 5 Protection features The ALTAIR04-900 has several protection features that considerably increase end-product safety and reliability: auxiliary winding disconnection (or bro...
Page 21 AN3290 Protection features Figure 23. Short-circuit mode: 13 V shorted at 230 VAC Doc ID 18038 Rev 1 21/34
Page 22 Protection features AN3290 5.2 Auxiliary winding disconnection (brownout) At any switching cycle, the current sourced from the ZCD pin during turn-on is sensed and compared with an internal reference,...
Page 23 AN3290 Protection features 5.3 Secondary winding short-circuit and transformer saturation protection The ALTAIR04-900 is equipped with a hiccup mode overcurrent protection level. If the voltage on the...
Page 24 Protection features AN3290 Figure 26. Hiccup mode OCP: protection tripping at VIN=230 VAC and full load Figure 27. Hiccup mode OCP: operating condition at VIN=115 VAC 24/34 Doc ID 18038 Rev 1
Page 25 AN3290 Protection features Figure 28. Hiccup mode OCP: operating condition at VIN=230 VAC Doc ID 18038 Rev 1 25/34
Page 26 Conducted noise measurements AN3290 6 Conducted noise measurements One of the main benefits of the quasi-resonant mode of operation concerns conducted EMI emissions. In mains operated applications, du...
Page 27 AN3290 Conducted noise measurements Figure 30. CE average measurement at 115 VAC and full load: neutral Figure 31. CE average measurement at 230 VAC and full load: line Doc ID 18038 Rev 1 27/34
Page 28 Conducted noise measurements AN3290 Figure 32. CE average measurement at 230 VAC and full load: neutral 28/34 Doc ID 18038 Rev 1
Page 29 AN3290 Modifications for ultra wide-range operations 7 Modifications for ultra wide-range operations Although the board has been developed in wide-range up to 264 VAC, it can be easily modified in ord...
Page 30 Modifications for ultra wide-range operations AN3290 Table 4. ALTAIR04-900 power supply: bill of material for 440 VAC input voltage option Reference Part Description Note R10, R11 6.8 MΩ C3, C18 47 µF...
Page 31 AN3290 Conclusions 8 Conclusions A double-output flyback converter using the new ALTAIR04-900, specifically designed for power line modem systems based on ST7580 (by STMicroelectronics), has been intr...
Page 32 Demonstration tools and documentation AN3290 9 Demonstration tools and documentation The ALTAIR04-900 demonstration board order code is: EVLALTAIR900-M1. In order to get a complete PLM system, the pow...
Page 33 AN3290 Revision history 10 Revision history Table 5. Document revision history Date Revision Changes 26-Apr-2011 Initial release Doc ID 18038 Rev 1 33/34
Page 34 AN3290 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, corre...

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Brand Dual
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Published June 01, 2026
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Frequently Asked Questions

What primary benefit does using primary sensing offer?

It uses a constant voltage loop (CV loop) for regulation, eliminating the need for optocouplers and secondary voltage references.

What protective features are included in this design board?

Protection includes overload/short-circuit protection, auxiliary winding disconnection (brownout), and secondary winding short-circuit detection.

How can I set a maximum output current limit?

The primary constant current loop (CC loop) allows setting the limit without requiring external current sensors or components.

Does this converter support wide input voltage ranges?

Yes, performance measurements are provided covering operation across various VAC inputs, such as 85 VAC to 264 VAC.