ICE3B0365J ref design

Application Note, V1.0, May 2010
AN-EVALSF3-ICE3B0365J
5W 2 outputs (5V & 18V) DC/DC SMPS
Demo Board with CoolSET® F3 ICE3B0365J
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2010-05-19
Published by Infineon Technologies Asia Pacific,
8 Kallang Sector,
349282 Singapore
© Infineon Technologies AP 2010.
All Rights Reserved.
Attention please!
The information herein is given to describe certain components and shall not be considered as a guarantee
of characteristics.
Terms of delivery and rights to technical change reserved.
We hereby disclaim any and all warranties, including but not limited to warranties of non-infringement,
regarding circuits, descriptions and charts stated herein.
Information
For further information on technology, delivery terms and conditions and prices please contact your 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 your nearest Infineon Technologies Office.
Infineon Technologies Components may only be used in life-support devices or systems 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
®
5W 2 outpus (5V & 18V) DC/DC Demo board with CoolSET F3 ICE3B0365J
Revision History:
2010-05
Previous Version:
none
Page
V1.0
Subjects (major changes since last revision)
®
5W 2 outputs (5V & 18V) DC/DC Demo Board with CoolSET F3 ICE3B0365J:
License to Infineon Technologies Asia Pacific Pte Ltd
Kyaw Zin Min
Kok Siu Kam Eric
He Yi
Jeoh Meng Kiat
We Listen to Your Comments
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Your feedback will help us to continuously improve the quality of this document.
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AN-PS0046
5W 2 outputs DC/DC Demo board using ICE3B0365J
Table of Contents
Page
1
Abstract..........................................................................................................................................5
2
Evaluation board ...........................................................................................................................5
3
List of features...............................................................................................................................6
4
Technical specifications...............................................................................................................6
5
Description of function and components...................................................................................7
6
6.1
6.2
PCB layout .....................................................................................................................................9
Top side...........................................................................................................................................9
Bottom side .....................................................................................................................................9
7
Component list ............................................................................................................................10
8
Transformer construction ..........................................................................................................11
9
9.1
9.2
9.3
9.4
Test results ..................................................................................................................................12
Efficiency .......................................................................................................................................12
Input standby power ......................................................................................................................12
Line regulation...............................................................................................................................14
Load regulation .............................................................................................................................14
10
10.1
10.2
10.3
10.4
Waveforms and scope plots ......................................................................................................15
Start up at low and high DC input voltage and max. load.............................................................15
Soft start at low and high DC input voltage and max. load ...........................................................15
Frequency jittering.........................................................................................................................16
Entering active burst mode ...........................................................................................................16
11
References ...................................................................................................................................17
Application Note
4
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5W 2 outputs DC/DC Demo board using ICE3B0365J
1 Abstract
®
This application note describes a non-isolated flyback converter power supply utilizing IFX F3 CoolSET
ICE3B0365J. The application demo board works with an input voltage from 275VDC to 375VDC and it has
two output voltages, 5V and 18V with simple single transistor control regulation. The sum of the output power
is up to 5W shared to both outputs. It is operated in Discontinuous Conduction Mode (DCM) and is running at
67 kHz switching frequency with jittering mode. It is especially suitable for auxiliary power supply of
consumer home appliance such as white goods, air conditioner, refrigerator, cookers, etc. The particular
features needs to be stressed are the best in class low standby power and the good EMI performance.
2 Evaluation board
Figure 1 – EVALSF3-ICE3B0365J
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
5
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5W 2 outputs DC/DC Demo board using ICE3B0365J
3
List of features
®
650V avalanche rugged CoolMOS with built in switchable Startup Cell
Active Burst Mode for lowest Standby Power @ light load controlled by Feedback signal
BiCMOS technology provide wide Vcc voltage range
Fast load jump response in Active Burst Mode
67kHz fixed switching frequency
Auto Restart Mode for Over temperature protection, Overvoltage protection, Overload protection, Open
Loop protection and VCC Undervoltage protection
Blanking Window for short duration max current
User defined Soft Start
Max Duty Cycle 72%
Propagation delay compensation provide accurate primary current limit
Frequency jittering for low EMI
4 Technical specifications
Input voltage
275Vdc~375Vdc
Output 1 voltage and current
5V +/- 5%, (0.2A)
Output 2 voltage and current
18V +/- 10%, (0.22A)
Output power
5W
Acitve mode average efficiency (25%, 50%, 75%, 100%)
>80%
Switching frequency
67kHz
Application Note
6
2010-05-19
Application Note
7
R2
5R1
Vcc
1uF
C5
SoftS
CS
0.1uF
C3
FB
C6
1nF
IC1
ICE3B0365J
GND
DRAIN
33uF/35V
C4
D1
UF4006
22R
R3
C2
2.2nF/400V
4 Nov 2009
5W 18V, 5V Non-isolated flyback SMPS converter using ICE3B0365J
GND
C1
10uF/400V
10uF
R1
330k
8
5
7
Q1
BC547B
2.2nF
C7
1N4148
D2
5.67mH(195:12:40)
1
3
T1
2K
R4
ZD1
5V1
C8
47uF/25V
Res2
22R
R5
D4
C9
47uF/25V
UF4003
D3
UF4005
Gnd
5V/0.2A
18V/0.22A
5
Gnd
DC(275~375)V
4
5W 2 outputs DC/DC Demo board using ICE3B0365J
Description of function and components
Figure 2 – 5W 2 outpus (18V & 5V) ICE3B0365J power supply schematic
2010-05-19
5W 2 outputs DC/DC Demo board using ICE3B0365J
The circuit, shown in Figure 2, details a 5V & 18V, 5W non-isolated flyback converter module that operates
from an DC input voltage range of 275Vdc to 375Vdc.
Since there is a built-in startup cell in the ICE3B0365J, there is no need for external start up resistor. The
startup cell is connecting the drain pin of the IC. Once the voltage is built up at the Drain pin of the
ICE3B0365J, the startup cell will charge up the Vcc capacitor C3 and C4. When the Vcc voltage exceeds the
UVLO at 18V, the IC starts up. Then the Vcc voltage is bootstrapped by the 18V winding of T1 to sustain the
operation. The ICE3B0365J (IC1) begins a soft start cycle (programmed by C5). In parallel, the both output
voltages across C8 and C9 rise until the zener voltage of ZD1 is reached.
ZD1 and R4 forms the voltage sense circuit and the Q1 acts as an error amplifier with VBE as the reference
voltage and C7 is the loop gain compensator.
R1, C2 and D1 form a clamper snubber circuit on the primary transformer side. This circuit limits the excess
transient voltage rising on the switching transistors drain caused by the transformers leakage inductance
after switching off. R2 is the current sense resistor used in two ways: The voltage drop across this resistor
provides the current ramp to be compare with FB signal by the PWM comparator of the current mode
regulation circuit of the IC. Additionally, this value is compared with a fix VCS_max threshold to prevent any
overcurrent condition in each switching cycle.
The SoftS capacitor (CSoftS), C5 can be used to program 3 functions;
1. Soft Start time : t Softs = 0.793 ⋅ C SoftS * RSoftS = 35ms , where CSoftS=1uF, RSoftS=45KΩ
2. Over load blanking time / enter burst mode blanking time :
where CSoftS=1uF, RSoftS=45KΩ
3. Frequency jittering period :
t blanking = 0.47 ⋅ C SoftS * RSoftS = 21ms ,
t jittering = 3200 ⋅ C SoftS = 3.2ms , where CSoftS=1uF
In order to obtain the lowest standby power performance, the IC provides the active burst mode. When the
output loading decreases, the feeback voltage decreases at the same time. When the feedback, FB voltage
drops below 1.35V, the system will enter the “Active burst mode”; standby mode. In the standby mode, the
only active part in the IC is the FB and thus the IC has very limited power consumption. Together with the
active burst mode, the standby power can be reduced tremendously. Operation of the active burst mode is
as below.
1. Enter burst mode condition : VFB < 1.35V and after blanking time (programmed by CSoftS)
2. Working in burst mode : Burst “On” (with switching pulses) when VFB reaches 3.6V and Burst “Off” (
no switching pulse) when VFB drops to 3.0V, at the same time Vcs reduces to 0.32V ( Note the Vcc
voltage must be kept above 10.3V to maintain IC on )
3. Leave burst mode : VFB reaches 4.5V
The IC also implements with frequency jittering to achieve good EMI performance. The jittering frequency is
±4% of the switching frequency and the frequency jittering period can be programmed by the CSoftS.
Besides, there are various built-in protections (auto restart mode) to protect the system from damages. The
protection conditions are as below.
Protection function
Failure condition
Vcc Over-voltage
Vcc > 20.5V & VFB > 4.5V & VSoftS > 4.0V
Auto Restart
Over-temperature
(controller junction)
TJ > 140°C
Auto Restart
Over-load / Open loop / output
short circuit
VFB > 4.5V and VSoftS > 4.0V
Auto Restart
Vcc Under-voltage / short
Opto-coupler
Vcc < 10.3V
Auto Restart
Application Note
Protection Mode
8
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5W 2 outputs DC/DC Demo board using ICE3B0365J
6
6.1
PCB layout
Top side
Figure 4 – Top side component legend
6.2
Bottom side
Figure 5 – Bottom side copper
Application Note
9
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5W 2 outputs DC/DC Demo board using ICE3B0365J
7
Component list
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Designator
C1
C2
C3
C4
C5
C6
C7
C8,C9
D1
D2
D3
D4
IC1
Q1
R1
R2
R3,R5
R4
T1
ZD1
Application Note
Component description
10uF/400V
2.2nF/400V
0.1uF
33uF/35V
1uF
1nF
2.2nF
47uF/25V
UF4006
1N4148
UF4005
UF4003
ICE3B0365J
BC547B
330k(1W,5%)
5R1(0.5W,1%)
22R
2k
5670uH(195:12:40)
5V1
10
Part No.
Manufacturer
RPER71H104K2K1A03B
B41851A7336M000
MURATA
EPCOS
RPER71H102K2K1A03B
MURATA
B41821A5476M000
EPCOS
ICE3B0365J
INFINEON
E16/8/5,N87
EPCOS
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5W 2 outputs DC/DC Demo board using ICE3B0365J
8
Transformer construction
Core: E16/8/5, N87(EPCOS)
Bobbin: vertical Version
Primary Inductance, Lp=5.67mH, measured between pin 4 and pin 1 (Gapped to inductance)
Transformer structure:
4
7
3
5
8
1
Pin 1
Pin 2
Pin 3
Pin 4
TOP VIEW
Vertical bobbin
Pin 8
Pin 7
Pin 6
Pin 5
Figure 6 – Transformer structure and top view of transformer complete
Wire size requirement:
Start
3
5
8
4
Application Note
Stop
1
7
5
3
No. of
turns
65
28
12
130
Wire size
1XAWG#38
1XAWG#27
1XAWG#27
1XAWG#38
11
Layer
/2 Primary
Secondary2
Secondary1
1
/2 Primary
1
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5W 2 outputs DC/DC Demo board using ICE3B0365J
9
Test results
9.1
Efficiency
Active-Mode Efficiency versus DC Input Voltage
Efficiency [ % ]
88.00
85.1
86.00
85.5
85.3
85.4
84.00
83.1
82.4
81.1
82.00
80.6
80.00
275
300
350
375
DC Input Voltage [ Vdc ]
Full load Ef ficiency
Average Eff iciency(25%,50%,75%,100%)
Figure 7 – Efficiency vs. DC input voltage
Active-Mode Efficiency versus Output Power
90.00
Efficiency [ % ]
85.4
85.00
79.5
80.00
84.3
83.5
83.1
80.0
78.1
85.1
83.3
75.8
75.00
73.6
73.0
70.00
1.0
1.3
1.5
2.6
3.9
5.1
Onput Power [ W ]
275Vdc
375Vdc
Figure 8 – Efficiency vs. output power @ low and high DC input voltage
9.2
Input standby power
Stanby Power @ no-load versus DC Input Voltage
Input Power [ mW]
50
40
30
17.450
17.590
17.590
21.34
20
10
0
275
300
350
375
DC Input Voltage [ Vdc ]
Po = 0W
Figure 9 – Input standby power @ no load vs. DC input voltage (measured by Yokogawa WT210 power
meter - integration mode)
Application Note
12
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5W 2 outputs DC/DC Demo board using ICE3B0365J
Standby Efficiency & Input Power Vs DC Input Voltage
0.776
0.78
69.88
69.80
0.772
Input Power (W)
70.20
69.40
69.36
0.768
0.767
0.764
69.00
68.60
0.760
0.756
68.20
68.07
0.753
0.752
Efficiency (%)
0.780
67.80
0.748
0.747
0.744
67.40
67.25
67.00
0.740
275
300
350
375
DC Input Voltage(Vdc)
Input Power at 0.5W load
Efficiency at 0.5W Load
Figure 10 – Input standby power & efficiency @ 0.5W ( 0.25W(5V)+0.25W(18V) ) vs. DC input voltage
(measured by Yokogawa WT210 power meter - integration mode)
Input versus DC Input Voltage
Input Power [ W ]
2.500
1.86
2.000
1.500
1.000
1.36
1.94
1.89
1.40
1.37
1.98
1.41
0.75
0.75
0.77
0.78
275
300
350
375
0.500
0.000
DC Line Input Voltage [ Vdc ]
I/P pow er @ 0.5W Load
I/P Pow er @ 1W Load
I/P Power @ 1.5W Load
Figure 11 – Light load input power vs. DC input voltage ( 0.5W : 0.25W(5V)+0.25W(18V), 1W :
0.25(5V)+0.75W(18V), 1.5W : 0.25W(5V)+1.25W(18V) )
Efficiency versus DC Input Voltage
83.11
85.00
81.79
Efficiency [ % ]
79.68
80.00
75.00
75.8
69.9
70.00
75.2
73.6
69.4
68.1
78.07
73.0
67.3
65.00
60.00
275
300
350
375
DC Line Input Voltage [ Vdc ]
Ef ficiency @ 0.5W Load
Eff iciency @ 1W Load
Efficiency @ 1.5W Load
Figure 12 – Light load Efficiency vs. DC input voltage ( 0.5W : 0.25W(5V)+0.25W(18V), 1W :
0.25(5V)+0.75W(18V), 1.5W : 0.25W(5V)+1.25W(18V) )
Application Note
13
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5W 2 outputs DC/DC Demo board using ICE3B0365J
9.3
Line regulation
Line Regulation @ max. Load vs DC input Voltage
5V output
5.15
5.05
4.95
18.70
18.70
18.71
5.06
5.06
5.07
18.72
18.50
5.07
18.00
4.85
17.50
4.75
17.00
275
300
350
18V output
19.00
5.25
375
DC input voltage(Vdc)
5V @ max. load
18V @ max. load
Figure 13 – Line regulation @ full load vs. DC input voltage
9.4
Load regulation
Load Regulation Vout vs Output Power
5.25
5V output
19.45
5.05
5V @ 0.05A &
18V @ 0.055A
5V @ 0.1A &
18V @ 0.11A
5.11
5.10
5.08
5V @ 0.15A &
18V @ 0.165A
5V @ 0.2A &
18V @ 0.22A
19.50
5.06
5.08
19.00
4.95
18.76
18.79
18.75
4.85
18.72
4.75
18V output
5.15
20.00
5V @ 0.05A &
18V @ 0.014A
18.50
18.00
0.5
1.3
2.6
3.9
5.1
DC input voltage(Vdc)
5V o/p @ 275Vdc
18V o/p @ 275Vdc
Figure 14 – Load regulation Vout vs. output power
Application Note
14
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5W 2 outputs DC/DC Demo board using ICE3B0365J
10
Waveforms and scope plots
All waveforms and scope plots were recorded with a LeCroy 6050 oscilloscope
10.1 Start up at low and high DC input voltage and max. load
873ms
873ms
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : SoftS voltage (VsoftS)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : SoftS voltage (VsoftS)
Startup time = 873ms
Startup time = 873ms
Figure 15 – Startup @ 275Vdc & max. load
Figure 16 – Startup @ 375Vdc & max. load
10.2 Soft start at low and high DC input voltage and max. load
43ms
43ms
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : SoftS voltage (VsoftS)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : SoftS voltage (VsoftS)
Soft Star time = 43ms
Soft Star time = 43ms
Figure 17 – Soft Start @ 275Vdc & max. load
Figure 18– Soft Start @ 375Vdc & max. load
Application Note
15
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5W 2 outputs DC/DC Demo board using ICE3B0365J
10.3 Frequency jittering
63 kHz
68 kHz
63 kHz
68 kHz
Channel 1; C1 : Drain voltage (VDrain)
Channel 1; C1 : Drain voltage (VDrain)
Frequency jittering from 63 kHz ~ 68 kHz, Jitter
period is set at 4ms internally , VDrain_PP=475V
Frequency jittering from 63kHz ~ 68 kHz, Jitter
period is set at 4ms internally, VDrain_PP=575V
Figure 19 – Frequency jittering @ 275Vdc and
max. load
Figure 20 – Frequency jittering @ 375Vdc and
max. load
10.4 Entering active burst mode
19ms
19ms
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : SoftS voltage (VsoftS)
Blanking time to enter burst mode : 19ms (load step
down from 4A to 0.2A)
Figure 21 – Entering Active burst mode @ 275Vdc
Application Note
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : SoftS voltage (VsoftS)
Blanking time to enter burst mode : 19ms (load
step down from 4A to 0.2A)
Figure 22 – Entering Active burst mode @ 375Vdc
16
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5W 2 outputs DC/DC Demo board using ICE3B0365J
11
References
®
[1]
Infineon Technologies, Datasheet “CoolSET -F3 ICE3BXX65J Off-Line SMPS Current Mode Controller
®
with integrated 650V CoolMOS and Startup cell”
[2]
Luo Junyang, Jeoh Meng Kiat, Lim Chee Siong Simon, Kok Eric, Infineon Technologies, Design Guide
®
“ICE3AXXX/ICE3BXXX CoolSET - F3 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
17
2010-05-19