CoolS ET ™ F3R80C C M Fam il y ICE3AR4780CJZ 5V 12W SMPS e val u at ion boar d wit h I CE3AR478 0CJZ ANPS0083 Appl icat ion Not e AN - EVAL- 3AR47 80CJZ V1.0, 2014-03-23 Po wer Manag em ent & Mult im ar k et Edition 2014-03-23 Published by Infineon Technologies AG, 81726 Munich, Germany. © 2014 Infineon Technologies AG All Rights Reserved. LEGAL DISCLAIMER THE INFORMATION GIVEN IN THIS APPLICATION NOTE IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY, CONDITION OR QUALITY OF THE INFINEON TECHNOLOGIES COMPONENT. THE RECIPIENT OF THIS APPLICATION NOTE MUST VERIFY ANY FUNCTION DESCRIBED HEREIN IN THE REAL APPLICATION. INFINEON TECHNOLOGIES HEREBY DISCLAIMS ANY AND ALL WARRANTIES AND LIABILITIES OF ANY KIND (INCLUDING WITHOUT LIMITATION WARRANTIES OF NON-INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF ANY THIRD PARTY) WITH RESPECT TO ANY AND ALL INFORMATION GIVEN IN THIS APPLICATION NOTE. Information For further information on technology, delivery terms and conditions and prices, please contact the nearest Infineon Technologies Office (www.infineon.com). Warnings Due to technical requirements, components may contain dangerous substances. For information on the types in question, please contact the nearest Infineon Technologies Office. Infineon Technologies components may be used in life-support devices or systems only with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered. 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Trademarks of Infineon Technologies AG AURIX™, C166™, CanPAK™, CIPOS™, CIPURSE™, EconoPACK™, CoolMOS™, CoolSET™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, EasyPIM™, EconoBRIDGE™, EconoDUAL™, EconoPIM™, EconoPACK™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, I²RF™, ISOFACE™, IsoPACK™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OptiMOS™, ORIGA™, POWERCODE™; PRIMARION™, PrimePACK™, PrimeSTACK™, PRO-SIL™, PROFET™, RASIC™, ReverSave™, SatRIC™, SIEGET™, SINDRION™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, TEMPFET™, thinQ!™, TRENCHSTOP™, TriCore™. Other Trademarks Advance Design System™ (ADS) of Agilent Technologies, AMBA™, ARM™, MULTI-ICE™, KEIL™, PRIMECELL™, REALVIEW™, THUMB™, µVision™ of ARM Limited, UK. AUTOSAR™ is licensed by AUTOSAR development partnership. Bluetooth™ of Bluetooth SIG Inc. CAT-iq™ of DECT Forum. COLOSSUS™, FirstGPS™ of Trimble Navigation Ltd. EMV™ of EMVCo, LLC (Visa Holdings Inc.). EPCOS™ of Epcos AG. FLEXGO™ of Microsoft Corporation. FlexRay™ is licensed by FlexRay Consortium. HYPERTERMINAL™ of Hilgraeve Incorporated. IEC™ of Commission Electrotechnique Internationale. IrDA™ of Infrared Data Association Corporation. ISO™ of INTERNATIONAL ORGANIZATION FOR STANDARDIZATION. MATLAB™ of MathWorks, Inc. MAXIM™ of Maxim Integrated Products, Inc. MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS Technologies, Inc., USA. muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of Applied Wave Research Inc., OmniVision™ of OmniVision Technologies, Inc. Openwave™ Openwave Systems Inc. RED HAT™ Red Hat, Inc. RFMD™ RF Micro Devices, Inc. SIRIUS™ of Sirius Satellite Radio Inc. SOLARIS™ of Sun Microsystems, Inc. SPANSION™ of Spansion LLC Ltd. Symbian™ of Symbian Software Limited. TAIYO YUDEN™ of Taiyo Yuden Co. TEAKLITE™ of CEVA, Inc. TEKTRONIX™ of Tektronix Inc. TOKO™ of TOKO KABUSHIKI KAISHA TA. UNIX™ of X/Open Company Limited. VERILOG™, PALLADIUM™ of Cadence Design Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™ of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited. Last Trademarks Update 2011-11-11 Application Note AN-EVAL-3AR4780CJZ 3 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Revision History Major changes since previous revision Date Version Changed By Change Description 23 Mar 2014 1.0 Kyaw Zin Min Release of final version We Listen to Your Comments Is there any information in this document that you feel is wrong, unclear or missing? Your feedback will help us to continuously improve the quality of our documentation. Please send your proposal (including a reference to this document title/number) to: [email protected] Application Note AN-EVAL-3AR4780CJZ 4 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Table of Contents Revision History .............................................................................................................................................. 4 Table of Contents ............................................................................................................................................ 5 1 Abstract ........................................................................................................................................ 7 2 Evaluation board .......................................................................................................................... 7 3 List of features (F3R80CCM CoolSET™ ICE3AR4780CJZ) ......................................................... 8 4 Technical specifications .............................................................................................................. 8 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 Circuit description ....................................................................................................................... 9 Introduction .................................................................................................................................... 9 Line input ....................................................................................................................................... 9 Start up .......................................................................................................................................... 9 Operation mode ............................................................................................................................. 9 Soft start ........................................................................................................................................ 9 RCD clamper circuit ....................................................................................................................... 9 Peak current control of primary current ........................................................................................... 9 Output stage .................................................................................................................................. 9 Feedback and burst entry/exit control ........................................................................................... 10 Blanking window for load jump ..................................................................................................... 10 Brownout mode ............................................................................................................................ 10 Fast AC reset ............................................................................................................................... 10 Active burst mode ........................................................................................................................ 10 Jitter mode, soft gate drive and the 50Ω gate turn on resistor ....................................................... 11 Protection modes ......................................................................................................................... 11 6 Circuit diagram........................................................................................................................... 12 7 7.1 7.2 PCB layout.................................................................................................................................. 13 Top side ....................................................................................................................................... 13 Bottom side .................................................................................................................................. 13 8 Component list ........................................................................................................................... 14 9 Transformer construction .......................................................................................................... 15 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 Test results................................................................................................................................. 16 Efficiency ..................................................................................................................................... 16 Input standby power ..................................................................................................................... 17 Line regulation ............................................................................................................................. 18 Load regulation ............................................................................................................................ 18 Maximum output power ................................................................................................................ 19 ESD immunity (EN61000-4-2) ...................................................................................................... 19 Surge immunity (EN61000-4-5) .................................................................................................... 19 Conducted emissions (EN55022, Class B) ................................................................................... 20 11 11.1 11.2 11.3 11.4 Waveforms and scope plots ...................................................................................................... 22 Start up at low and high AC line input voltage and maximum load................................................. 22 Soft start ...................................................................................................................................... 22 Frequency jittering........................................................................................................................ 23 Drain to source voltage and current at maximum load................................................................... 23 Application Note AN-EVAL-3AR4780CJZ 5 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 Load transient response (Dynamic load from 10% to 100%) ......................................................... 24 Output ripple voltage at maximum load......................................................................................... 24 Output ripple voltage during burst mode at 1 W load..................................................................... 25 Entering and leaving active burst mode ........................................................................................ 25 Vcc over voltage protection (Odd skip auto restart mode) ............................................................. 26 Over load protection (Odd skip auto restart mode) ........................................................................ 26 VCC under voltage/Short optocoupler protection (Normal auto restart mode) ................................. 27 External protection enable/Secondary OVP by internal short (Latch mode) ................................... 27 External protection enable/Secondary OVP by external short (Latch mode) .................................. 28 Brownout mode ............................................................................................................................ 28 Fast AC reset ............................................................................................................................... 29 12 References ................................................................................................................................. 29 Application Note AN-EVAL-3AR4780CJZ 6 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Abstract 1 Abstract This document is an engineering report of a universal input 12W 5V off-line flyback converter power supply utilizing IFX F3R80CCM CoolSET™ ICE3AR4780CJZ. The application demo board is operated in Continuous and Discontinuous Conduction Mode (CCM & DCM) and is running at 100 kHz switching frequency. It has a single output voltage with secondary side control regulation. It is especially suitable for small power supply such as DVD player, set-top box, game console, charger and auxiliary power of high power system, etc. The ICE3AR4780CJZ is the enhanced version of ICE3ARxx80JZ, the major new features includes slope compensation for continuous conduction mode (CCM), fast AC reset after latch enabled, fixed voltage brownout detect/reset. Besides having the basic features of the F3R80CCM CoolSET™ such as Active Burst Mode, propagation delay compensation, soft gate drive, auto restart protection for major faults (Vcc over voltage, Vcc under voltage, over temperature, over-load, open loop and short opto-coupler), it also has the BiCMOS technology design, selectable entry and exit burst mode level, built-in soft start time, built-in blanking time, frequency jitter feature and external latch enable, etc. The particular features need to be stressed are 800V Mosfet, CCM/DCM operation, fixed voltage Brownout detect/reset, fast AC reset, the best-in-class low standby power and the good EMI performance. 2 Evaluation board Figure 1 – EVAL-3AR4780CJZ This document contains the list of features, the power supply specification, schematic, bill of material and the transformer construction documentation. Typical operating characteristics such as performance curve and scope waveforms are showed at the rear of the report. Application Note AN-EVAL-3AR4780CJZ 7 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 List of features (F3R80CCM CoolSET™ ICE3AR4780CJZ) 3 List of features (F3R80CCM CoolSET™ ICE3AR4780CJZ) 800V avalanche rugged CoolMOS™ with Start-up Cell Active Burst Mode for lowest Standby Power Slope compensation for CCM operation Selectable entry and exit burst mode level 100kHz internally fixed switching frequency with jittering feature Auto Restart Protection for Over load, Open Loop, VCC Under voltage & Over voltage and Over temperature External latch enable pin and fast AC reset Over temperature protection with 50°C hysteresis Built-in 10ms Soft Start Built-in 40ms blanking time for short duration peak power Propagation delay compensation for both maximum load and burst mode Brownout feature BiCMOS technology for low power consumption and wide VCC voltage range Soft gate drive with 50Ω turn on resistor 4 Technical specifications Input voltage 85Vac~282Vac Brownout detect/reset voltage 65/85Vac Input frequency 50/60Hz Output voltage 5V Output current 2.4A Output power 12W Output ripple voltage < 50mVp-p No-load power consumption < 75mW (comply with EU CoC Version 5, Tier 2 and EPS of DOE USA) Active mode four point average efficiency (25%,50%,75% & 100%load) >80.3% (comply with EU CoC Version 5, Tier 2 and EPS of DOE USA) Active mode at 10% load efficiency >71% (comply with EU CoC Version 5, Tier 2) Application Note AN-EVAL-3AR4780CJZ 8 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Circuit description 5 Circuit description 5.1 Introduction The EVAL-3AR4780CJZ demo board is a low cost off-line flyback switch mode power supply (SMPS) using the ICE3AR4780CJZ integrated power IC from the CoolSET™-F3R80CCM family. The circuit, shown in Figure 3, details a 5V, 12W power supply that operates from an AC line input voltage range of 85Vac to 282Vac and brownout detect/reset voltage is 65/85Vac, suitable for applications in enclosed adapter or open frame auxiliary power supply for different system such as PC, server, DVD, LED TV, Set-top box, etc. 5.2 Line input The AC line input side comprises the input fuse F1 as over-current protection. The choke L11, X-capacitor C11 and Y-capacitor C12 act as EMI suppressors. Optional spark gap device SA1, SA2 and varistor VAR can absorb high voltage stress during lightning surge test. After the bridge rectifier BR1 and the input bulk capacitor C13, a voltage of 120 to 400 VDC is present which depends on input voltage. 5.3 Start up Since there is a built-in Start-up cell in the ICE3AR4780CJZ, there is no need for external start up resistors. The Start-up cell is connecting the drain pin of the IC. Once the voltage is built up at the Drain pin of the ICE3AR4780CJZ, the Start-up cell will charge up the Vcc capacitor C16 and C17. When the Vcc voltage exceeds the UVLO at 17V, the IC starts up. Then the Vcc voltage is bootstrapped by the auxiliary winding to sustain the operation. 5.4 Operation mode During operation, the Vcc pin is supplied via a separate transformer winding with associated rectification D12 and buffering C16, C17. In order not to exceed the maximum voltage at Vcc pin due to poor coupling of transformer design, an external zener diode ZD11 (optional) and a resistor R13 (optional) can be added. 5.5 Soft start The Soft-Start is a built-in function and is set at 10ms. 5.6 RCD clamper circuit While turns off the CoolMOS™ , the clamper circuit R11, C15 and D11 absorbs the current caused by transformer leakage inductance once the voltage exceeds clamp capacitor voltage. Finally drain-source voltage of CoolMOS™ is lower than maximum break down voltage (V(BR)DSS = 800V) of CoolMOS™ . 5.7 Peak current control of primary current The CoolMOS™drain source current is sensed via external shunt resistors R14 and R14A which determine the tolerance of the current limit control. Since ICE3AR4780CJZ is a current mode controller, it would have a cycleby-cycle primary current and feedback voltage control and can make sure the maximum power of the converter is controlled in every switching cycle. A revised propagation delay compensation with CCM and slope compensation factor is implemented. It can give a good maximum power control. 5.8 Output stage On the secondary side the power is coupled out by a schottky diode D21. The capacitor C22 provides energy buffering following with the LC filter L21 and C23 to reduce the output voltage ripple considerably. Storage capacitors C22 is selected to have a very small internal resistance (ESR) to minimize the output voltage ripple. Application Note AN-EVAL-3AR4780CJZ 9 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Circuit description 5.9 Feedback and burst entry/exit control FBB combines the feedback function and burst entry/exit control. The output voltage is controlled by using a TL431 (IC21) which incorporates the voltage reference as well as the error amplifier and a driver stage. Compensation network C25, C26, R24, R25, R26 and R27 constitutes the external circuitry of the error amplifier of IC21. This circuitry allows the feedback to be precisely matched to dynamically varying load conditions and provides stable control. The maximum current through the optocoupler diode and the voltage reference is set by using resistors R22 and R23. Optocoupler IC12 is used for floating transmission of the control signal to the “Feedback” input of the ICE3AR4780CJZ. The optocoupler used meets DIN VDE 884 requirements for a wider creepage distance. The capacitor C18 filters the noise from going to the FBB pin and the resistor R17 (Rsel resistor) at the FBB pin sets the selection of the burst entry/exit level. During IC first start up (Vcc=0~17V), R fb resistor is isolated from FBB pin and Isel (3.5µA) will start to charge the R17 (Rsel resistor). Based on the charged voltage level at R17 (Rsel resistor), the entry and exit burst level are set. The below table is the control logic for the entry and exit level with R17 (Rsel resistor) voltage and level 1 (Rsel =300kΩ) is selected for this demo board. Entry level Level Rsel VFBB 1 2 3 <405kΩ 685kΩ~900kΩ >1530kΩ VFBB < Vref1 (1.8V) Vref1 (1.8V) <VFBB < Vref2 (4V) VFBB > Vref2 (4V) 5.10 % of Pin_max 5% 10% 15% VFB_burst 1.29V 1.61V 1.84V Exit level % of Pin_max 11% 20% 27% Vcsth_burst 0.21V 0.29V 0.34V Blanking window for load jump In case of load jumps the controller provides the built in blanking window (40ms) before activating the Over Load Protection and entering the Odd skip Auto Restart Mode. 5.11 Brownout mode When the AC line input voltage is lower than the input voltage range, brownout mode is detected by sensing the voltage level at BRL pin through the voltage divider resistors from AC hold up circuit. Once the voltage level at BRL pin falls below 1V for 270µs, the controller stops switching and enters into brownout mode. It is until the input level goes back to input voltage range, VBRL > 1.25V and the Vcc hits 17V, the brownout mode is released. If the brownout feature is not needed, it needs to tie the BRL pin to the Vcc pin through a current limiting resistor (R12B), 5MΩ~10ΜΩ. The BRL pin cannot be in floating condition. The exit brownout at >85Vac and entry brownout at <65 VAC is set in this demo board. Note: A filter capacitor (e.g. 100pF (min. value)) may be needed to add to the BRL pin if the noise cannot be avoided to enter that pin in the physical PCB layout. Otherwise, some protection features may be mis-triggered and the system may not be working properly. 5.12 Fast AC reset During normal operation, the ICE3AR4780CJZ can be latched by pulling down the BRL voltage below 0.4V for 210µs and this can be reset by 2 conditions. The first one is to pull down the Vcc voltage to below 8V. However, the Vcc drop would take quite a long time if it is by normal AC power down. The second one is to have a slow rise time of the BRL voltage from 0.4V to 1V for at least 450µs after the BRL pin is pulled down, then IC can reset latch mode and it is also called the fast AC reset. 5.13 Active burst mode At light load condition, the SMPS enters into Active Burst Mode. For this F3R80CCM CoolSET™, the entry/exit burst mode level is selected by a Rsel resistor at FBB pin (refer to section 5.9). The light load condition is actually reflected to the FB voltage level for the CCM/DCM operation; i.e. FB voltage drops according to how light the load is. With the selectable feature, the enter burst mode level, VFB_burst is determined by the Rsel resistor at FBB pin. After entering burst mode, the controller is always active and thus the VCC must always be kept above the Application Note AN-EVAL-3AR4780CJZ 10 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 switch off threshold VCCoff ≥ 10.5V. During the active burst mode, the efficiency maintains in a very high level and at the same time it supports low ripple on VOUT and fast response on load jump. To avoid mis-triggering of the burst mode, there is a 20ms internal blanking time. Once the FB voltage drops below VFB_burst, the internal blanking timer starts to count. When it reaches the built-in 20ms blanking time, it then enters Active Burst Mode. During Active Burst Mode the current sense voltage limit is reduced from 0.76V to Vcsth_burst so as to reduce the conduction losses and audible noise. All the internal circuits are switched off except the reference and bias voltages to reduce the total VCC current consumption to below 0.62mA. At burst mode, the FB voltage is changing like a sawtooth between 3.2 and 3.5V. To leave Burst Mode, FB voltage must exceed 4V. It will reset the Active Burst Mode and turn the SMPS into Normal Operating Mode. Maximum current can then be provided to stabilize VOUT. 5.14 Jitter mode, soft gate drive and the 50Ω gate turn on resistor In order to obtain better EMI performance, the ICE3AR4780CJZ is implemented with frequency jittering, soft gate drive and 50Ω gate turn on resistor. The jitter frequency is internally set at 100 kHz (+/-4 kHz) and the jitter period is set at 4ms. 5.15 Protection modes Protection is one of the major factors to determine whether the system is safe and robust. Therefore sufficient protection is necessary. ICE3AR4780CJZ provides three kinds of protection mode; normal auto restart mode, odd skip auto restart mode and non switch auto restart mode. In odd skip auto restart mode, there is no detect of fault and no switching pulse for the odd number restart cycle. At the even number of restart cycle, the fault detects and soft start switching pulses are maintained. If the fault persists, it would continue the auto-restart mode. However, if the fault is removed, it can release to normal operation only at the even number auto restart cycle. Non switch auto restart mode is similar to odd skip auto restart mode except the start up switching pulses are also suppressed at the even number of the restart cycle. The detection of fault still remains at the even number of the restart cycle. When the fault is removed, the IC will resume to normal operation at the even number of the restart cycle. The main purpose of the odd skip auto restart is to extend the restart time such that the power loss during auto restart protection can be reduced when a small Vcc capacitor is used. A list of protections and the failure conditions are shown in the following table. Protection functions VCC overvoltage Over load Open loop VCC under voltage short optocoupler Over temperature External protection enable Failure condition VCC > 25.5V & last for 150µs VFBB > 4.5V & last for 40ms -> Overload VCC < 10.5V -> VCC under voltage TJ > 130°C ( recovered with 50°C hysteresis) VBBA < 0.4V & last for 210µs Protection Modes Odd skip auto restart Odd skip auto restart Odd skip auto restart Normal auto restart Normal auto restart Non switch auto restart Latch N.B.: For External protection enable/Secondary OVP by external voltage source short (Latch mode) as shown in 11.14 (Fig 44 & 45), optional (OVP ckt power) & (FB disable ckt) are necessary to add. The purpose of (OVP ckt power) is feeding the power to IC13 (optocoupler) during normal time and disable the power during fault time, so that IC can enter latch mode in any fault conditions. The purpose of (FB disable ckt) is to exit the IC from burst mode to normal mode during fault time, since external protection enable feature is only work in normal operation mode. Application Note AN-EVAL-3AR4780CJZ 11 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Circuit diagram 6 Circuit diagram Figure 2 – 12W 5V ICE3AR4780CJZ power supply schematic Application Note AN-EVAL-3AR4780CJZ 12 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 PCB layout N.B.: In order to get the optimized performance of the CoolSET™, the grounding of the PCB layout must be connected very carefully. From the circuit diagram above, it indicates that the grounding for the CoolSET™ can be split into several groups; signal ground, Vcc ground, Current sense resistor ground and EMI return ground. All the split grounds should be connected to the bulk capacitor ground separately. Signal ground includes all small signal grounds connecting to the CoolSET™ GND pin such as filter capacitor ground, C17, C18, C19, C111, C115 and opto-coupler ground. Vcc ground includes the Vcc capacitor ground, C16 and the auxiliary winding ground, pin 2 of the power transformer. Current Sense resistor ground includes current sense resistor R14 and R15. EMI return ground includes Y capacitor, C12. 7 PCB layout 7.1 Top side Figure 3– Component side (Top view) 7.2 Bottom side Figure 4 – Solder side (Bottom view) Application Note AN-EVAL-3AR4780CJZ 13 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Component list 8 Component list No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Designator 5V Com BR1 C11 C110A C111 C112 C12 C13 C15 C16 C17,C26,C27 C18,C19 C22 C22A C24 C25 D11,D13,D14 D12 D21 D22 F1 HS1 IC11 IC12,IC12A IC21,IC21A J11,J12,J13,J14,J15,J21,R12A,R115,L22 LN L11 L21 Q11,Q12,Q13 R11 R12 R12C,R12E R12D R12F R14 R15,R15A,R15B R15C R16 R16A R17 R22,R22A R23,R23A R24 R26,R25,R25A R26A 47 TR1 Component description Connector 600V,1.1A 0.1µF,305V 100nF,50V 0.1µF,450V 47nF,50V 2.2nF,250V 39µF,450V 1nF,630V 22µF,35V 0.1µF,50V 1nF,50V 1500µF,10V 10µF,50V 1000µF,10V 1µF,50V 600V,0.8A 200V,0.2A 45V,30A 100V,0.1A 0.5A,250V Heat sink ICE3AR4780CJZ SFH617A-3 TL431 Jumper Connector 2 x 47mH, 0.5A 1.5uH,6.3A 60V,0.3A 100k,1W 20R 100k 40k 40k 1.33R,0.6W,1% 3M 24k 105k 0R 300k 150R 1.1k 1k 10k,1% 6.2k,1% Lp=1.25mH(80:6:20), EE20/10/6(TP4A) Application Note AN-EVAL-3AR4780CJZ 14 Part No. 691103110002 LN1WBA60 B32922C3104K Manufacturer WURTH ELECTRONICS SHINDENGEN EPCOS GR332DD72W104KW01 MURATA DE1E3KX222MA4BL01 450KXF39MEFCSN20X20 B32529C8102J289 B41828A7226M RPER71H104K2K1A03B RPE5C1H102J2K1A03B 10ZLH1500MEFC10X16 B41851A6106M 10ZLH1000MEFC10X12.5 MURATA RUBYCON EPCOS EPCOS MURATA MURATA RUBYCON EPCOS RUBYCON D1NK60 1N485B STPS3045CFP 1N4148 40005000000 574502B03300G ICE3AR4780CJZ SFH617A-3 TL431 SHINDENGEN 691102710002 B82731M2501A030 WURTH ELECTRONICS EPCOS 2N7002 MFP1-100K JI INFINEON INFINEON MRS25000C1338FCT00 750342032 WURTH ELECTRONICS MIDCOM Quantity 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1 3 1 1 1 1 1 1 2 2 10 1 1 1 3 1 1 2 1 1 1 3 1 1 1 1 2 2 1 1 1 1 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Transformer construction 9 Transformer construction Core and material Bobbin part number Primary Inductance Manufacturer and part number : EE20/10/6(EF20), TP4A (TDG) : 070-4989 (Horizontal Version) : Lp=1.25mH (±10%), measured between pin 4 and pin 5 : Wurth Electronics Midcom (750342032) Start Stop No. of turns 5 3 40 1 x AWG#32 Wire size Layer 8,9 6,7 6 4 x TIW(0.45mm) Secondary 3 4 40 1 x AWG#32 1 2 1 20 1 x AWG#32 Auxiliary 1 /2 Primary /2 Primary Figure 5 – Transformer structure Application Note AN-EVAL-3AR4780CJZ 15 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Test results 10 Test results 10.1 Efficiency VOut_ripple Vin(Vac) Pin(W) Vo(Vdc) 0.0285 1.5100 3.6900 7.2800 10.9600 14.8000 0.0308 1.4900 3.6600 7.2300 10.8300 14.4800 0.0439 1.5400 3.9300 7.3000 10.8000 14.4800 0.0534 1.5900 4.1000 7.5400 11.0300 14.5800 85 115 230 282 5.02 5.02 5.02 5.01 5.01 5.01 5.02 5.02 5.02 5.01 5.01 5.01 5.02 5.02 5.02 5.01 5.01 5.01 5.02 5.02 5.02 5.01 5.01 5.01 Io(A) Po(W) _pk_pk (mV) 21.80 31.50 10.80 13.20 17.60 20.50 22.10 31.90 13.10 14.10 16.20 19.20 23.50 37.80 11.20 13.20 16.80 20.20 24.70 39.30 12.90 14.80 17.60 19.80 0.00 0.24 0.60 1.20 1.80 2.40 0.00 0.24 0.60 1.20 1.80 2.40 0.00 0.24 0.60 1.20 1.80 2.40 0.00 0.24 0.60 1.20 1.80 2.40 0.00 1.20 3.01 6.01 9.02 12.02 0.00 1.20 3.01 6.01 9.02 12.02 0.00 1.20 3.01 6.01 9.02 12.02 0.00 1.20 3.01 6.01 9.02 12.02 η (%) 79.79 81.63 82.58 82.28 81.24 0.00 80.86 82.30 83.15 83.27 83.04 0.00 78.23 76.64 82.36 83.50 83.04 0.00 75.77 73.46 79.73 81.76 82.47 Average η (%) OLP Pin (W) OLP Iout (A) 18.16 2.93 19.66 3.23 21.76 3.59 23.00 3.85 81.93 82.94 81.38 79.36 The domo board energy spec. complies with Europe’s Code of Conduct (Version 5) tier 2 and External Power Supplies (EPS) of DOE USA. Active-Mode Efficiency versus AC Line Input Voltage 84.00 83.04 83.04 Efficiency [ % ] 82.47 81.93 82.94 82.00 81.24 81.38 80.00 79.36 78.00 85 115 230 282 AC Line Input Voltage [ Vac ] Full load Efficiency Average Efficiency(25%,50%,75% & 100%) Figure 6 – Efficiency vs. AC line input voltage Application Note AN-EVAL-3AR4780CJZ 16 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Test results Efficiency versus Output Power 85.00 82.58 81.63 82.28 82.47 Efficiency [ % ] 79.79 80.00 81.76 81.24 75 100 79.73 75.00 75.77 73.46 70.00 10 25 50 Output Power [%] Vin=85Vac Vin=282Vac Figure 7 – Efficiency vs. output power @ low and high line 10.2 Input standby power Figure 8 – Input standby power @ no load vs. AC line input voltage (measured by Yokogawa WT210 power meter - integration mode) Application Note AN-EVAL-3AR4780CJZ 17 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Test results 10.3 Line regulation Line Regulation: Output voltage @ max. load versus AC line input voltage Output Voltage [ V ] 5.5 5.3 5.01 5.01 5.01 5.01 85 115 230 282 5.1 4.9 4.7 4.5 AC Line Input Voltage [ Vac ] Vo @ maximum load Figure 9 – Line regulation Vo @ full load vs. AC line input voltage 10.4 Load regulation Load Regulation: Vout versus output power Output Voltage [ V ] 5.50 5.30 5.10 4.90 5.02 5.02 5.02 5.01 5.01 5.02 5.01 5.01 5.01 5.01 4.70 4.50 10 25 50 75 100 Output Power [%] Output voltage @ 115Vac Output voltage @ 230Vac Figure 10 – Load regulation Vout vs. output power Application Note AN-EVAL-3AR4780CJZ 18 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Test results 10.5 Maximum output power 25 Pin=20.58 11.76% W IO=3.39 13.57% A 23.00 6 21.76 20 19.66 18.16 4 3.85 3.59 3.23 2.93 15 2 85 115 230 Peak Output Current (A) Peak Input Power(OLP) [ W ] Peak input power(OLP)/Peak output current versus AC Line Input Voltage 282 AC Line Input Voltage [ Vac ] Peak Input Power Peak Output Current Figure 11 – Maximum input power (before over-load protection) vs. AC line input voltage 10.6 ESD immunity (EN61000-4-2) Pass (Special level (±16kV) for contact discharge) 10.7 Surge immunity (EN61000-4-5) Pass (Installation class 4, 4kV for line to earth) Application Note AN-EVAL-3AR4780CJZ 19 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Test results 10.8 Conducted emissions (EN55022, Class B) The conducted emissions was measured by Schaffner (SMR4503) and followed the test standard of EN55022 (CISPR 22) class B. The demo board was set up at maximum load (12W) with input voltage of 115Vac and 230Vac. 80 EN_V_QP EN_V_AV 70 QP AV 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 -20 f / MHz Figure 12 – Maximum Load (12W) with 115 Vac (Line) 80 EN_V_QP EN_V_AV 70 QP AV 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 -20 f / MHz Figure 13 – Maximum Load (12W) with 115 Vac (Neutral) Application Note AN-EVAL-3AR4780CJZ 20 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Test results 80 EN_V_QP EN_V_AV 70 QP AV 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 10 100 -20 f / MHz Figure 14 – Maximum Load (12W) with 230 Vac (Line) 80 EN_V_QP EN_V_AV 70 QP AV 60 50 dBµV 40 30 20 10 0 -10 0.1 1 -20 f / MHz Figure 15 – Maximum Load (12W) with 230 Vac (Neutral) Pass conducted emissions EN55022 (CISPR 22) class B with > 10dB margin. Application Note AN-EVAL-3AR4780CJZ 21 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11 Waveforms and scope plots All waveforms and scope plots were recorded with a LeCroy 6050 oscilloscope 11.1 Start up at low and high AC line input voltage and maximum load 500ms 500ms Entry/exit burst selection Level 1, (Rsel<405kΩ >> VFBB<1.8V) Entry/exit burst selection Level 1, (Rsel<405kΩ >> VFBB<1.8V) Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Start-up time = 500ms Start-up time = 500ms Figure 16 – Start-up @ 85Vac & maximum load Figure 17 – Start-up @ 282Vac & maximum load 11.2 Soft start 8.4ms Channel Channel Channel Channel 1; C1 : Current sense voltage (VCS) 2; C2 : Supply voltage (VCC) 3; C3 : Feedback voltage (VFBB) 4; C4 : BRL voltage (VBRL) Soft Start time = 8.4ms Figure 18 – Soft Start @ 85Vac & maximum load Application Note AN-EVAL-3AR4780CJZ 22 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11.3 Frequency jittering 3.79ms Channel 1; C1 : Drain voltage (VD) Channel F1: Frequency track of Drain voltage (VD) Frequency jittering from 97 kHz ~ 105 kHz, Jitter period is 3.79ms Figure 19 – Frequency jittering @ 85Vac and maximum load 11.4 Drain to source voltage and current at maximum load Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Drain current (IDrain) VDrain_peak = 349V Figure 20 – CCM Operation @ 85Vac and maximum load Application Note AN-EVAL-3AR4780CJZ Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Drain current (IDrain) VDrain_peak = 628V Figure 21 – DCM Operation @ 282Vac and maximum load 23 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11.5 Load transient response (Dynamic load from 10% to 100%) Channel 1; C1 : Output ripple voltage (Vo) Channel 2; C2 : Output current (Io) Channel 1; C1 : Output ripple voltage (Vo) Channel 2; C2 : Output current (Io) Vripple_pk_pk=146mV (Load change from10% to 100%,100Hz,0.4A/μs slew rate) Probe terminal end with decoupling capacitor of 0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter Vripple_pk_pk=154mV (Load change from10% to 100%,100Hz,0.4A/μs slew rate Probe terminal end with decoupling capacitor of 0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter Figure 22 – Load transient response @ 85Vac Figure 23 – Load transient response @ 282Vac 11.6 Output ripple voltage at maximum load Channel 1; C1 : Output ripple voltage (Vo) Channel 2; C2 : Output current (Io) Channel 1; C1 : Output ripple voltage (Vo) Channel 2; C2 : Output current (Io) Vripple_pk_pk=19mV Probe terminal end with decoupling capacitor of 0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter Vripple_pk_pk = 20mV Probe terminal end with decoupling capacitor of 0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter Figure 24 – AC output ripple @ 85Vac and maximum load Figure 25 – AC output ripple @ 282Vac and maximum load Application Note AN-EVAL-3AR4780CJZ 24 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11.7 Output ripple voltage during burst mode at 1 W load Channel 1; C1 : Output ripple voltage (Vo) Channel 2; C2 : Output current (Io) Channel 1; C1 : Output ripple voltage (Vo) Channel 2; C2 : Output current (Io) Vripple_pk_pk=28.8mV Probe terminal end with decoupling capacitor of 0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter Vripple_pk_pk = 38.7mV Probe terminal end with decoupling capacitor of 0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter Figure 26 – AC output ripple @ 85Vac and 1W load Figure 27 – AC output ripple @ 282Vac and 1W load 11.8 Entering and leaving active burst mode 19 ms Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Condition: VFB< VFB_burst3 (1.29V) and tBK_burst =20ms (load change form full load to 1W load) Figure 28 – Entering active burst mode @ 85Vac Application Note AN-EVAL-3AR4780CJZ Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Condition: VFB>4V (load change form 1W load to full load) Figure 29 – Leaving active burst mode @ 85Vac 25 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11.9 Vcc over voltage protection (Odd skip auto restart mode) VCC OVP Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Condition: VCC > 25.5V & last for 150µs (Remove J13(disable latch mode) and disconnect J21 during system operating at no load) Figure 30 – Vcc overvoltage protection @ 85Vac 11.10 Over load protection (Odd skip auto restart mode) Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Condition: VFBB > 4.5V & last for 40ms (output load change from full load(2.4A) to 3A Load) Figure 31 – Over load protection with built-in blanking time @ 85Vac) Application Note AN-EVAL-3AR4780CJZ 26 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11.11 VCC under voltage/Short optocoupler protection (Normal auto restart mode) Enter auto restart Exit auto restart Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Condition: VCC < 10.5V (short the transistor(Pin 3 & 4) of optocoupler (IC12) during system operating @ full load & release) Figure 32 – Vcc under voltage/short optocoupler protection @ 85Vac 11.12 External protection enable/Secondary OVP by internal short (Latch mode) Enter latch mode Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFBB) Channel 4; C4 : BRL voltage (VBRL) Condition: VBBA < 0.4V & last for 210µs (VO > 6.5V) (short R26 during system operating at no load) Figure 33 – External protection enable @ 85Vac Application Note AN-EVAL-3AR4780CJZ 27 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 Waveforms and scope plots 11.13 External protection enable/Secondary OVP by external short (Latch mode) Enter latch mode Channel 1; C1 : Drain voltage (VD) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Output voltage (VO) Channel 4; C4 : BRL voltage (VBRL) Condition: VBBA < 0.4V & last for 210µs (VO > 6.5V) (feed 8V/0.5A external power source to output voltage,5V rail during system operating at no load) Figure 34 – External protection enable @ 85Vac 11.14 Brownout mode Leave Brownout @ 111Vdc Leave Brownout @ 111Vdc Enter brownout @ 88Vdc Enter brownout @ 92Vdc Channel 1; C1 : DC input voltage (VC111) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Output voltage (VO) Channel 4; C4 : BRL voltage (VBRL) Condition: VBO_L > 1.25V (VC111 ≈ 111Vdc/83Vac) VBO_E < 1V & last for 270μs (VC111 ≈ 92Vdc/65Vac) (feed AC line voltage start from 0 to 85V then reduced gradually until 0V) Channel 1; C1 : DC input voltage (VC111) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Output voltage (VO) Channel 4; C4 : BRL voltage (VBRL) Condition: VBO_L > 1.25V (VC111 ≈ 111Vdc/83Vac) VBO_E < 1V & last for 270μs (VC111 ≈ 88Vdc/63Vac) (feed AC line voltage start from 0 to 85V then reduced gradually until 0V) Figure 35 – Brownout mode with maximum load Figure 36 – Brownout mode with no load Application Note AN-EVAL-3AR4780CJZ 28 V1.0, 2014-03-23 5V 12W SMPS evaluation board with ICE3AR4780CJZ ANPS0083 References 11.15 Fast AC reset Enter Latch AC off Channel Channel Channel Channel AC on 1; C1 : Current sense voltage (VCS) 2; C2 : Supply voltage (VCC) 3; C3 : Feedback voltage (VFBB) 4; C4 : BRL voltage (VBRL) Condition: After latch mode, then VBRL rise time from 0.4V to 1V > 450μs AC reset time=0.28s short the R26 while system running at no load(to simulate latch), then switch off main AC & on again Figure 37 – Fast AC reset timing @ 85Vac 12 References [1] Infineon Technologies, Datasheet “CoolSET™-F3R80CCM ICE3AR4780CJZ Off-Line SMPS Current Mode Controller with integrated 800V CoolMOS™and Start-up cell( brownout & CCM) in DIP-7” [2] Kyaw Zin Min, Kok Siu Kam Eric, Infineon Technologies, Design Guide “ICE3ARxx80CJZ CoolSET™ F3R80CCM (DIP-7) brownout & CCM version Design Guide” [3] Harald Zoellinger, Rainer Kling, Infineon Technologies, Application Note “AN-SMPS-ICE2xXXX-1, CoolSET™ ICE2xXXXX for Off-Line Switching Mode Power supply (SMPS )” Application Note AN-EVAL-3AR4780CJZ 29 V1.0, 2014-03-23 w w w . i nf i n eo n. com Published by Infineon Technologies AG