5V 12W SMPS evaluation board with ICE3AR4780CJZ

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.
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THIS APPLICATION NOTE.
Information
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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
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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
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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
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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
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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.
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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)
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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.
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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
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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.
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Circuit diagram
6
Circuit diagram
Figure 2 – 12W 5V ICE3AR4780CJZ power supply schematic
Application Note AN-EVAL-3AR4780CJZ
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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