20W 5V SMPS Evaluation board using ICE3BR2280JZ

Application Note, V1.0, Jan 2011
AN-EVAL3BR2280JZ
20W 5V SMPS Evaluation Board with
CoolSET® F3R80 ICE3BR2280JZ
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Published by
Infineon Technologies AG
81726 Munich, Germany
© 2010 Infineon Technologies AG
All Rights Reserved.
Legal Disclaimer
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conditions or characteristics. With respect to any examples or hints given herein, any typical
values stated herein and/or any information regarding the application of the device,
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including without limitation, warranties of non-infringement of intellectual property rights
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contact the nearest Infineon Technologies Office (www.infineon.com).
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20W 5V Demo board using ICE3BR2280JZ on board
Revision History:
Previous Version:
Page
2011-1
none
Subjects (major changes since last revision)
20W 5V SMPS Evaluation Board with CoolSET®F3R80 ICE3BR2280JZ:
License to Infineon Technologies Asia Pacific Pte Ltd
Kyaw Zin Min
Kok Siu Kam Eric
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V1.0
AN-PS0051
20W 5V Demoboard using ICE3BR2280JZ
Table of Contents
Page
1
Abstract..........................................................................................................................................6
2
Evaluation board ...........................................................................................................................6
3
List of features ..............................................................................................................................7
4
Technical specifications...............................................................................................................7
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
Circuit description ........................................................................................................................8
Introduction......................................................................................................................................8
Line input.........................................................................................................................................8
Start up............................................................................................................................................8
Operation mode ..............................................................................................................................8
Soft start ..........................................................................................................................................8
RCD clamper circuit ........................................................................................................................8
Peak current control of primary current...........................................................................................8
Output stage....................................................................................................................................9
Feedback and burst entry/exit control.............................................................................................9
Blanking window for load jump........................................................................................................9
Brownout mode .............................................................................................................................10
Active burst mode .........................................................................................................................11
Jitter mode, soft gate drive and the 50Ω gate turn on resistor .....................................................11
Protection modes ..........................................................................................................................11
6
Circuit diagram............................................................................................................................13
7
7.1
7.2
PCB layout ...................................................................................................................................15
Top side.........................................................................................................................................15
Bottom side ...................................................................................................................................15
8
Component list ............................................................................................................................16
9
Transformer construction ..........................................................................................................17
10
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
Test results ..................................................................................................................................18
Efficiency .......................................................................................................................................18
Input standby power......................................................................................................................19
Line regulation...............................................................................................................................20
Load regulation .............................................................................................................................20
Max. input power...........................................................................................................................21
ESD test ........................................................................................................................................21
Lightning surge test.......................................................................................................................21
Conducted EMI .............................................................................................................................22
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
Waveforms and scope plots ......................................................................................................24
Start up at low and high AC line input voltage and max. load ......................................................24
Soft start at low and high AC line input voltage and max. load.....................................................24
Frequency jittering.........................................................................................................................25
Drain to source voltage and Current at max. load ........................................................................25
Load transient response (Dynamic load from 10% to 100%) .......................................................26
Output ripple voltage at max. load ................................................................................................26
Output ripple voltage during burst mode at 1 W load ...................................................................27
Entering active burst mode ...........................................................................................................27
Vcc over voltage protection (Odd skip auto restart mode)............................................................28
Over load protection (Odd skip auto restart mode).......................................................................28
Open loop protection (Odd skip auto restart mode)......................................................................29
VCC under voltage/Short optocoupler protection (Non switch auto restart mode).........................29
External protection enable (Non switch auto restart mode)..........................................................30
Brownout mode .............................................................................................................................30
12
12.1
Appendix ......................................................................................................................................31
Slope compensation for CCM operation .......................................................................................31
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
Table of Contents
13
Page
References ...................................................................................................................................31
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
1 Abstract
This document is an engineering report of a universal input 20W 5V off-line flyback converter power supply
utilizing IFX F3R80 CoolSET® ICE3BR2280JZ. The application demo board is operated in Discontinuous
Conduction Mode (DCM) and is running at 65kHz 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 ICE3BR2280JZ is the latest
version of the CoolSET®. Besides having the basic features of the F3R 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, adjustable brownout feature, built-in
soft start time, built-in and extendable blanking time, frequency jitter feature and external auto-restart enable,
etc. The particular features need to be stressed are the best-in-class low standby power and the good EMI
performance.
2 Evaluation board
Figure 1 – EVAL3BR2280JZ
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
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3
List of features
800V avalanche rugged CoolMOS® with Startup Cell
Active Burst Mode for lowest Standby Power
Selectable entry and exit burst mode level
65kHz internally fixed switching frequency with jittering feature
Auto Restart Protection for Over load, Open Loop, VCC Under voltage & Over voltage and Over
temperature
External auto-restart enable pin
Over temperature protection with 50°C hysteresis
Built-in 10ms Soft Start
Built-in 20ms and extendable blanking time for short duration peak power
Propagation delay compensation for both maximum load and burst mode
Adjustable brownout feature
Overall tolerance of Current Limiting < ±5%
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
75/85Vac
Input frequency
50/60Hz
Input Standby Power
< 100mW @ no load
Output voltage
5V +/- 1%
Output current
4A
Output power
20W
Active mode average efficiency
>80%
Output ripple voltage
< 50mVp-p
Application Note
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5
5.1
Circuit description
Introduction
The EVAL3BR2280JZ demo board is a low cost off-line flyback switch mode power supply (SMPS) using the
ICE3BR2280JZ integrated power IC from the CoolSET®-F3R80 family. The circuit, shown in Figure 3, details
a 5V, 20W power supply that operates from an AC line input voltage range of 85Vac to 282Vac and
brownout detect/reset voltage is 75/85Vac, 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, X1-capacitor
C11, and Y1-capacitor C15 act as EMI suppressors. Optional spark gap device SG1, SG2 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 startup cell in the ICE3BR2280JZ, there is no need for external start up resistors. The
startup cell is connecting the drain pin of the IC. Once the voltage is built up at the Drain pin of the
ICE3BR2280JZ, the startup 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, an external zener diode
ZD11 and resistor R14 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, C14 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 R15 and R16 which determine the
tolerance of the current limit control. Since ICE3BR2280JZ is a current mode controller, it would have a
cycle-by-cycle primary current and feedback voltage control and can make sure the maximum power of the
converter is controlled in every switching cycle. Besides, the patented propagation delay compensation is
implemented to ensure the maximum input power can be controlled in an even tighter manner throughout the
wide range input voltage. The demo board shows approximately. +/-3.86% (refer to Figure 14).
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
5.8
Output stage
On the secondary side the power is coupled out by a schottky diode D21. The capacitor C21 & C22 provide
energy buffering following with the LC filter L21 and C23 to reduce the output voltage ripple considerably.
Storage capacitors C21 & C22 are selected to have a very small internal resistance (ESR) to minimize the
output voltage ripple. The optional common mode choke L22 and ceramic capacitor C24 are added to
suppress the high voltage electrostatic static charge during ESD test.
5.9
Feedback and burst entry/exit control
FBB pin has 2 features; functions of output voltage feedback and burst entry 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 C26, C27, R23, 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 R21 and R22. Optocoupler
IC12 is used for floating transmission of the control signal to the “Feedback” input of the ICE3BR2280JZ. The
capacitor C19 at the FBB pin acts 2 functions; filter the noise from going to the pin and setting for the
selection of the burst entry control (explained below). The optocoupler used meets DIN VDE 884
requirements for a wider creepage distance.
C19 capacitor is also used to select the entry and exit burst level. The IC would generate the charge and
discharge current to the FBB pin and then detect the number of count for the charge and discharge cycle
during the 1st 1ms of IC start up (Vcc > 17V). Based on the detected number of count, the entry and exit
burst level are set. The below table is the recommended capacitance range for the entry and exit level with
the CFB (C19) capacitor.
CFB
Corresponding
no. of counts
≥ 6.8nF
1nF~2.2nF
220pF~470pF
≤100pF
≤7
8 ~ 39
40 ~ 91
≥ 92
Entry level
% of Pin_max
10%
6.67%
4.38%
0
Exit level
VFB_burst
1.6V
1.42V
1.27V
never
% of Pin_max
20%
13.30%
9.60%
0
Vcsth_burst
0.45V
0.37V
0.31V
always
5.10 Blanking window for load jump
In case of load jumps the controller provides a blanking window before activating the Over Load Protection
and entering the Auto Restart Mode. There are 2 modes for the blanking time setting; basic mode and the
extendable mode. If there is no capacitor added to the BBA pin, it would fall into the basic mode; i.e. the
blanking time is set at 20ms. If a longer blanking time is required, a capacitor, CBK (C18) can be added to
BBA pin to extend it. The extended blanking time can be achieved by the lead time of 256 times of charging
and discharging of CBK capacitor, which is generated by the controller. Thus the overall blanking time is the
addition of 20ms and the extended time. For example, CBK (C18) = 0.22uF, Ichg_EB (internal charging current)
= 720uA

  ( 4 .5 − 0 .9 ) × C
BK
tblanking = Basic + Extended = 20ms + 256 ×  


I chg _ EB



 
 +  C BK × 500 × ln( 4.5 )   = 346.9ms
 
0.9  


Since the BBA pin is multi-function pin, extended blanking time can be changed if the brownout resistor R110
( 28kΩ ) is added to the system, new Ichg_EB‘ and overall blanking time can be calculated as follows,
I chg _ EB ' = 720µA −
Application Note
(4.5 + 0.9)
= 623.6µA
2 * RBO 2
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20W 5V Demoboard using ICE3BR2280JZ

  ( 4 .5 − 0 .9 ) × C
BK
tblanking _ RBO 2 = 20ms + 256 ×  


I
'
chg _ EB



 
 +  C BK × 500 × ln( 4.5 )   = 390.4ms
 
0.9  


Note: A filter capacitor (e.g. 100pF (min. value)) may be needed to add to the BBA pin if the noise cannot be
avoided to enter that pin in the physical PCB layout. Otherwise, some protection features may be mistriggered and the system may not be working properly.
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 BBA pin through the resistors divider from the bulk capacitor. Once the voltage level at
BBA pin falls below 0.9V, the controller stops switching and enters into brownout mode. It is until the input
level goes back to input voltage range and the Vcc hits 17V, the brownout mode is released. Brownout
sensing resistor RBO1 and RBO2 can be calculated as below.
Figure 2 – Brownout detection circuit
RBO1 =
where
VBO _ hys
I chg _ BO
;
RBO 2 =
VBO _ ref × RBO1
VBO _ L − VBO _ ref
VBO_hys: input brownout hysteresis voltage
Ichg_BO = 10µA: charging current for brownout
VBO_ref = 0.9V: brownout reference voltage for IC
VBO_L: input brownout voltage (low point)
RBO1 and RBO2: resistors divider from input voltage to BBA pin
For example, if brownout release voltage is 85Vac and entry voltage is 75Vac and assuming there is a ripple
voltage of 14Vdc at the bulk capacitor before entering brownout at full load.
VBO _ H = 85 × 2 = 120Vdc
VBO _ L = 75 × 2 − 14 = 92Vdc
VBO _ hys = VBO _ H − VBO _ L = 28Vdc
RBO1 =
VBO _ hys
= 2.8MΩ
I chg _ BO
RBO 2 =
VBO _ ref × RBO1
= 28kΩ
VBO _ L − VBO _ ref
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
Note: The above calculation assumes the tapping point (bulk capacitor) has a 14Vdc ripple voltage at full
load when entering brownout mode. If there is no ripple voltage at light load, the enter brownout point will be
lower, 65Vac. Besides that the low side brownout voltage VBO_L added with the ripple voltage at the tapping
point should always be lower than the high side brownout voltage (VBO_H); VBO_H > VBO_L + ripple voltage.
Otherwise, the brownout feature cannot work properly. In short, when there is a high load running in system
before entering brownout, the input ripple voltage will increase and the brownout voltage will increase (VBO_L =
VBO_L+ ripple voltage) at the same time. If the VBO_hys is set too small and is close to the ripple voltage, then the
brownout feature cannot work properly (VBO_L = VBO_H).
If the brownout feature is not needed, it needs to tie the BBA pin to the Vcc pin through a current limiting
resistor (R17), 500kΩ~1ΜΩ. The BBA pin cannot be in floating condition. If the brownout feature is disabled
with a tie up resistor, there is a limitation of the capacitor CBK (C18) at the BBA pin. It is as below.
1
2
Vcc tie up resistor
500kΩ
1MΩ
CBK_max
0.47µF
0.22µF
5.12 Active burst mode
At light load condition, the SMPS enters into Active Burst Mode. For this 800V CoolSET, the enter/exit burst
mode level is selected by a FB capacitor (refer to section 5.9). The light load condition is actually reflected to
the FB voltage level for the 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 capacitor at FB capacitor. After
entering burst mode, the controller is always active and thus the VCC must always be kept above the 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 1V 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.
5.13 Jitter mode, soft gate drive and the 50Ω gate turn on resistor
In order to obtain better EMI performance, the ICE3BR2280JZ is implemented with frequency jittering, soft
gate drive and 50Ω gate turn on resistor.
The jitter frequency is internally set at 65kHz (± 2.6kHz) and the jitter period is set at 4ms.
5.14 Protection modes
Protection is one of the major factors to determine whether the system is safe and robust. Therefore
sufficient protection is necessary. ICE3BR2280JZ provides two kinds of protection 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 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.
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
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(1)
VCC overvoltage(2)
Over load
Open loop
VCC under voltage
short optocoupler
Over temperature
External protection enable
Application Note
Failure condition
VCC > 20.5V & VFBB > 4.5V & during soft start
period
VCC > 25.5V
VFBB > 4.5V, after blanking time
-> Overload
VCC < 10.5V
-> VCC Undervoltage
TJ > 130°C ( recovered with 50°C hysteresis)
VBBA < 0.4V
12
Protection Modes
Odd skip auto restart
Odd skip auto restart
Odd skip auto restart
Odd skip auto restart
Non switch auto restart
Non switch auto restart
Non switch Auto restart
Non switch auto restart
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6
Circuit diagram
Figure 3 – 20W 5V ICE3BR2280JZ power supply schematic
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
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 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 R15 and R16.
•
EMI return ground includes Y capacitor, C15.
Application Note
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7
7.1
PCB layout
Top side
Figure 4 – Top side component legend
7.2
Bottom side
Figure 5 – Bottom side copper & component legend
Application Note
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8
Component list
No
Designator
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
BR1
C11
C13
C14
C15
C16
C17
C18
C19
C21, C22
C23
C26
D11
D12
D21
F1
IC11
IC12
IC21
J1,J3,J4,J5,R25,L22
L11
L21
R11
R12
R13
R14
R15
R16
R18
R19
R21
R22
R23
R24, R26
R110
TR1
ZD11
Application Note
Component
description
DF08M(800V,1.5A)
0.22µF/305V
82µF/450V
2.2nF/400V
2.2nF/250V,Y1
22µF/35V
0.1µF
220nF
1nF
1000µF/25V
220µF/25V
1µF
UF4006
1N485B(200V,0.2A)
STPS30L45CT
1A
ICE3BR2280JZ
SFH617A-3
TL431
Jumper
2 x 27mH, 0.9A
1.5µH
330k(2W,5%)
0R(SMD 0805)
20R(SMD 0805)
47R(SMD 0805)
1R(0.5W,1%)
20R(SMD 1206)
1.8M
1M
150R(SMD 0805)
1.1K(SMD 0805)
510R(SMD 0805)
10k
28k(SMD 0805)
725µH(80:6:18)V1.0
22V
16
Part No.
Manufacturer
B32922C3224K000
B43504A5826M000
EPCOS
EPCOS
DE1E3KX222MA4BL01
MURATA
RPER71H104K2K1A03B
RPER71H224K2K1C03B
RPE5C1H102J2K1A03B
MURATA
MURATA
MURATA
UF4006
VISHAY
ICE3BR2280JZ
INFINEON
B82732F2901B001
EPCOS
B662061110T001
EPCOS
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20W 5V Demoboard using ICE3BR2280JZ
9
Transformer construction
Core: E20/10/6, N87(EPCOS)
Bobbin: Horizontal Version
Primary Inductance, Lp=725µH, measured between pin 4 and pin 5 (Gapped to inductance)
Transformer structure:
5
6
3
4
7
2
1
Figure 6 – Transformer structure and top view of transformer complete
Wire size requirement:
Application Note
Start
2
Stop
1
No. of turns
18
Wire size
1XAWG#30
3
7
7
4
6
6
40
6
6
1XAWG#30
2XAWG#26
2XAWG#26
/2 Primary
Secondary
Secondary
5
3
40
1XAWG#30
1
17
Layer
Auxiliary
1
/2 Primary
2011-01-03
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10
Test results
10.1 Efficiency
Active-Mode Efficiency versus AC Line Input Voltage
85.00
82.68
Efficiency [ % ]
82.33
82.56
82.09
81.20
82.19
81.68
80.00
81.95
82.02
81.19
80.75
78.63
75.00
85
115
150
180
230
282
AC Line Input Voltage [ Vac ]
Full load Efficiency
Average Efficiency(25%,50%,75% & 100%)
Figure 7 – Efficiency vs. AC line input voltage
Efficiency versus Output Power
95.00
Efficiency [ % ]
90.00
83.42
85.00
83.18
82.39
82.09
81.98
80.75
77.85
80.00
82.63
80.98
75.00
71.80
70.00
65.00
0
25
50
75
100
Output Power [ % ]
Vin=115Vac
Vin=230Vac
Figure 8 – Efficiency vs. output power @ low and high line
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
10.2 Input standby power
Stanby Power @ no-load versus AC Line Input Voltage
Input Power [ mW ]
100
80
64.40
60
87.80
45.80
37.60
40
24.60
29.50
20
19.56
20.12
22.31
32.50
27.60
25.50
0
85
115
150
180
230
282
AC Line Input Voltage [ Vac ]
Po = 0W(Enable Brownout)
Po=0W(Disable Brownout)
Figure 9 – Input standby power @ no load vs. AC line input voltage (measured by Yokogawa WT210
power meter - integration mode)
Standby Power versus AC Line Input Voltage(Enable Brownout)
Input Power [ W ]
5.0
4.0
3.0
3.65
2.41
2.0
1.22
3.70
3.53
2.45
2.41
1.23
1.26
3.73
2.47
1.27
3.78
3.86
2.52
2.58
1.31
1.35
1.0
0.0
0.63
0.64
0.66
0.67
0.70
0.73
85
115
150
180
230
282
AC Line Input Voltage [ Vac ]
Po=0.5W
Po=1W
Po=2W
Po=3W
Figure 10 – Input standby power vs. AC line input voltage
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
10.3 Line regulation
Output Voltage [ V ]
Line Regulation : Output Voltage @ Max. Load versus AC Line Input Voltage
5.2000
5.1000
5.0000
4.95
4.95
4.95
4.95
4.95
4.95
85
115
150
180
230
282
4.9000
4.8000
AC Line Input Voltage [ Vac ]
Vo @ max. load
Figure 11 – Line regulation Vo @ full load vs. AC line input voltage
10.4 Load regulation
Load Regulation: Vout versus Outoput Power
Ouput Voltage [ V ]
5.10
5.05
4.99
4.98
5.00
4.99
4.95
4.97
4.98
4.97
4.96
4.96
4.95
4.95
4.90
0
25
50
75
100
Output Pow er [ % ]
Output Voltage @ 230Vac
Output Voltage @ 115Vac
Figure 12 – Load regulation Vout vs. output power
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
10.5 Max. input power
Max. Overload Input Pow er ( Peak Pow er ) versus AC Line Input Voltage
Max. Overload Input Power [ W ]
Pin=30.18±2.02%
32
30.79
30.03
30
30.13
30.18
150
180
30.36
29.57
28
85
115
230
282
AC Line Input Voltage [ Vac ]
Peak Input Power
Figure 13 – Max. input power (before over-load protection) vs. AC line input voltage
10.6 ESD test
Pass* (EN61000-4-2): 20kV for contact discharge.
*Add L22 and C24
10.7 Lightning surge test
Pass* (EN61000-4-5) 6kV for line to earth
*Add SG1 & SG2 (DSP-301N-S00B)
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
10.8 Conducted EMI
The conducted EMI 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 (20W) with input voltage of 115Vac and
230Vac.
80
EN_V_QP
EN_V_AV
QP
AV
70
60
dBµV
50
40
30
20
10
0
-10
0.1
1
10
100
f / MHz
Figure 14 – Max. Load (20W) with 115 Vac (Line)
80
EN_V_QP
EN_V_AV
QP
AV
70
60
dBµV
50
40
30
20
10
0
-10
0.1
1
10
100
f / MHz
Figure 15 – Max. Load (20W) with 115 Vac (Neutral)
Application Note
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2011-01-03
20W 5V Demoboard using ICE3BR2280JZ
80
EN_V_QP
EN_V_AV
QP
AV
70
60
dBµV
50
40
30
20
10
0
-10
0.1
1
10
100
f / MHz
Figure 16 – Max. Load (20W) with 230 Vac (Line)
80
EN_V_QP
EN_V_AV
QP
AV
70
60
dBµV
50
40
30
20
10
0
-10
0.1
1
10
100
f / MHz
Figure 17 – Max. Load (20W) with 230 Vac (Neutral)
Pass conducted EMI EN55022 (CISPR 22) class B with > 8dB margin.
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
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 max. load
508ms
508ms
Entry/exit
burst
selection
Entry/exit
burst
selection
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Startup time = 508ms
Startup time = 508ms
Figure 18 – Startup @ 85Vac & max. load
Figure 19 – Startup @ 282Vac & max. load
11.2 Soft start at low and high AC line input voltage and max. load
9.7ms
9.7ms
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Soft Star time = 9.7ms(32 steps)
Soft Star time = 9.7ms(32 steps)
Figure 20 – Soft Start @ 85Vac & max. load
Figure 21– Soft Start @ 282Vac & max. load
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
11.3 Frequency jittering
66.5kHz
66.3kHz
(2msX2)
(2msX2)
61.6kHz
61.7kHz
Channel 1; C1 : Drain voltage (VDrain)
Channel 1; C1 : Drain voltage (VDrain)
Frequency jittering from 61.6 kHz ~ 66.3 kHz, Jitter
period is approximately 4ms(2msX2)
Frequency jittering from 61.7kHz ~ 66.5 kHz, Jitter
period is approximately 4ms(2msX2)
Figure 22 – Frequency jittering @ 85Vac and max.
load
Figure 23 – Frequency jittering @ 282Vac and
max. load
11.4 Drain to source voltage and Current at max. load
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Drain current (IDS)
Duty cycle = 41%, VDrain_peak = 321V
Figure 24 – Operation @ 85Vac and max. load
Application Note
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Drain current (IDS)
Duty cycle = 13%, VDrain_peak = 627V
Figure 25 – Operation @ 282Vac and max. load
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20W 5V Demoboard using ICE3BR2280JZ
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=524mV (Load change from10% to
100%,100Hz,0.4A/µS slew rate)
Vripple_pk_pk=527mV (Load change from10% to
100%,100Hz,0.4A/µS slew rate
Figure 26 – Load transient response @ 85Vac
Figure 27 – Load transient response @ 282Vac
11.6 Output ripple voltage at max. load
Channel 1; C1 : Output ripple voltage (Vo)
Channel 1; C1 : Output ripple voltage (Vo)
Vripple_pk_pk=17mV
Vripple_pk_pk = 17mV
Probe terminal end with decoupling capacitor
0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter
of
Figure 28 – AC output ripple @ 85Vac and max.
load
Application Note
Probe terminal end with decoupling capacitor of
0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter
Figure 29 – AC output ripple @ 282Vac and max.
load
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20W 5V Demoboard using ICE3BR2280JZ
11.7 Output ripple voltage during burst mode at 1 W load
Channel 1; C1 : Output ripple voltage (Vo)
Channel 1; C1 : Output ripple voltage (Vo)
Vripple_pk_pk=35mV
Vripple_pk_pk = 37mV
Probe terminal end with decoupling capacitor
0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter
of
Figure 30 – AC output ripple @ 85Vac and 1W load
Probe terminal end with decoupling capacitor of
0.1uF(ceramic) & 1uF(Electrolytic), 20MHz filter
Figure 31 – AC output ripple @ 282Vac and 1W
load
11.8 Entering active burst mode
19ms
19ms
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Blanking time to enter burst mode : 19ms (load step
down from 4A to 0.2A)
Figure 32 – Active burst mode @ 85Vac
Application Note
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Blanking time to enter burst mode : 19ms (load
step down from 4A to 0.2A)
Figure 33 – Active burst mode @ 282Vac
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20W 5V Demoboard using ICE3BR2280JZ
11.9 Vcc over voltage protection (Odd skip auto restart mode)
VCC OVP2
VCC OVP1
VCC OVP2
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
VCC OVP2 first & follows VCC OVP1 (R24
disconnected during system operating @ no load)
Figure 34 – Vcc overvoltage protection @ 85Vac
11.10
VCC OVP1
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
VCC OVP2 first & follows VCC OVP1 (R24
disconnected before system start up @ no load)
Figure 35 – Vcc overvoltage protection @ 282Vac
Over load protection (Odd skip auto restart mode)
built-in + extended blanking time
built-in + extended blanking time
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Over load protection with (built-in+extended)
blanking time = 470ms (output load change from 4A
to 5.5A)
Figure 36 – Over load protection with extended
blanking time @ 85Vac)
Application Note
28
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Over load protection with (built-in+extended)
blanking time = 409ms (output load change from
4A to 5.5A)
Figure 37 – Over load protection with extended
blanking time @ 282Vac)
2011-01-03
20W 5V Demoboard using ICE3BR2280JZ
11.11
Open loop protection (Odd skip auto restart mode)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Open loop protection (R24 disconnected during
system operation at max. load) – over load
protection
Open loop protection (R24 disconnected during
system operation at max. load) – over load
protection
Figure 38 – Open loop protection @ 85Vac
Figure 39 – Open loop protection @ 282Vac
11.12
VCC under voltage/Short optocoupler protection (Non switch auto restart
mode)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA
VCC under voltage/short optocoupler protection
(short the transistor of optocoupler during system
operating @ full load)
VCC under voltage/short optocoupler protection
(short the transistor of optocoupler during system
operating @ full load)
Figure 40 – Vcc under voltage/short optocoupler
protection @ 85Vac
Figure 41 – Vcc under voltage/short optocoupler
protection @ 282Vac
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
11.13
External protection enable (Non switch auto restart mode)
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFBB)
Channel 4; C4 : BBA voltage (VBBA
External protection enable (short BBA pin to Gnd by
10Ω resistor)
External protection enable (short BBA pin to Gnd
by 10Ω resistor)
Figure 42 – External protection enable @ 85Vac
Figure 43 – External protection enable @ 282Vac
11.14
Brownout mode
120Vdc
105Vdc
22.6Vdc
90.5Vdc
120Vdc
22.6Vdc
22.6Vdc
22.6Vdc
Channel 1; C1 : Bulk voltage(Vbulk)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Current sense voltage (VCS)
Channel 4; C4 : BBA voltage (VBBA)
Channel 1; C1 : Bulk voltage(Vbulk)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Current sense voltage (VCS)
Channel 4; C4 : BBA voltage (VBBA)
IC on & 1st detect brownout: Vbulk= 22.6Vdc (16Vac)
IC on & 1st detect brownout:Vbulk= 22.6Vdc (16Vac)
Brownout reset: Vbulk= 120Vdc (85Vac)
Brownout reset: Vbulk= 120Vdc (85Vac)
Brownout triggered: Vbulk= 105Vdc (74Vac)
Brownout triggered: Vbulk= 90.5Vdc (64Vac)
IC off: Vbulk= 22.6Vdc (16Vac)
IC off: Vbulk= 22.6Vdc (16Vac)
Figure 44 – Brownout mode with max. load
Figure 45 – Brownout mode with no load
Application Note
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20W 5V Demoboard using ICE3BR2280JZ
12
Appendix
12.1
Slope compensation for CCM operation
This demo board is designed in Discontinuous Conduction Mode ( DCM ) operation. If the application is
designed in Continuous Conduction Mode ( CCM ) operation where the maximum duty cycle exceeds the
50% threshold, it needs to add the slope compensation network. Otherwise, the circuitry will be unstable. In
this case, three more components ( 2 ceramic capacitors C17 / C18 and one resistor R19) is needed to add
as shown in the circuit diagram below.
Figure 46 – Circuit Diagram Switch Mode Power Supply with Slope Compensation
More information regarding how to calculate the additional components, see application note
AN_SMPS_ICE2xXXX – available on the internet: www.infineon.com (directory : Home > Power
Semiconductors > Integrated Power ICs > CoolSET® F2)
13
References
[1]
Infineon Technologies, Datasheet “CoolSET®-F3R80 ICE3BR2280JZ Off-Line SMPS Current Mode
Controller with integrated 800V CoolMOS® and Startup cell( brownout & Frequency Jitter) in DIP-7”
[2]
Kyaw Zin Min, Kok Siu Kam Eric, Infineon Technologies, Design Guide “ICE3XRxx80JZ CoolSET®
F3R80 (DIP-7) brownout & frequency jitter 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
31
2011-01-03
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