110 W / 54 V P o wer S u p p ly D em o B oar d usin g I CL 5 101 in PF C & L L C Top ol og y Application Note About this document Scope and purpose This document presents the details about the ICL5101 evaluation board and ICL5101 product feature set. It illustrates all necessary steps to get the board and related environment up and running, and provides all information to become familiar with this comprehensive solution. The evaluation board passes EMI conductive, radiated and is CE certificated. The ICL5101 is a mixed signal PFC + resonant controller for non-dimmable and dimmable LED light applications using LLC topology for highest efficiency levels exceeding 94 %, including a PFC stage for lowest THD < 5 % and high power factor correction figures > 95 % @ > 50 % load in a wide line input voltage range. The ICL5101 evaluation board is designed to evaluate the performance and flexibility of the ICL5101. It supports an output power of 110 W, easily configurable by using only resistor settings without any user interface tool. Intended audience This document is intended for anyone who needs to use the ICL5101 evaluation board, either for their own application tests or to use it as a reference for a new ICL5101-based development. 1 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Table of Contents Table of Contents 1 Introduction ............................................................................................................... 3 2 Technical Specification ................................................................................................ 4 3 Schematic .................................................................................................................. 5 4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.2 4.3 4.4 4.4.1 4.4.2 4.5 Key Measurements and Waveforms ............................................................................... 6 Line Regulation, Startup Time, Load Regulation, PF and THD .......................................................... 6 Line Regulation ............................................................................................................................. 6 Startup Time.................................................................................................................................. 7 Load Regulation ............................................................................................................................ 9 PF and THD vs. POUT ....................................................................................................................... 9 Surge Protection ............................................................................................................................... 12 Harmonics ......................................................................................................................................... 13 System Efficiency and Standby Power ............................................................................................. 14 System Efficiency ........................................................................................................................ 14 Power Consumption at Output Open Loop (Standby Power) ................................................... 15 EMI Test.............................................................................................................................................. 16 5 5.1 5.2 5.3 Surge, Flicker & Burst Test Results .............................................................................. 20 Surge .................................................................................................................................................. 20 Flicker ................................................................................................................................................ 21 Burst................................................................................................................................................... 23 6 6.1 6.2 6.3 6.4 Power Transformer Specification ............................................................................... 24 Common Mode Choke Spec L1 ......................................................................................................... 24 PFC Choke Spec T1 ............................................................................................................................ 25 LLC Resonant Choke Spec L2 ............................................................................................................ 26 LLC Transformer Spec T2 .................................................................................................................. 27 7 Board Layout ............................................................................................................ 28 8 Bill of Material (BOM)................................................................................................. 29 9 References ............................................................................................................... 33 Application Note 2 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Introduction 1 Introduction This application note describes the characteristics and features of a 110 W SMPS demonstration board with constant 54 V voltage output. High efficiency, high PF, low THD and very stable output voltage with low ripple at whole power range are the key features of this demonstration board, which makes it very suitable to be used as a primary power supply for low power systems, such as LED lighting. Its compact design and low BOM cost is due to Infineon IC ICL5101 (CrCM PFC and resonant block are integrated together), which is used as main controller here. With this highly integrated smart IC, the circuit design is dramatically simplified, which results space and BOM cost saving. Furthermore, numerous monitor and protection features ensure highest reliability. Key specification measurements and waveforms are also shown in this application note. Figure 1 Demonstration Board of 110 W / 54 V LED Driver Application Note 3 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Technical Specification 2 Technical Specification This demo board consists of a CrCM PFC and a half-bridge LLC, which outputs a stable 54 VDC voltage. The PFC stage of this demo board is controlled by the PFC block of the ICL5101, which has an integrated digital PFC control loop and improved compensation for low THD of AC input current. It operates in critical conduction mode (CrCM) in a load range from 10 % to 100 % to achieve a very good power factor and very low THD. When the load is smaller than 10 %, in order to limit the PFC switching frequency, the IC controls the PFC to operate in discontinuous conduction mode (DCM). The half-bridge LLC stage has a fixed duty cycle of D=0.5 and an adjustable self-adapting dead time from 0.5 µs to 1 µs. The operation frequency starts from typical 135 kHz at start-up and decreases to a range of between 45 kHz (full load) and 75 kHz (output open loop). The 54 V output voltage has a very stable value throughout the whole output power range. The value variation is tested to be smaller than 0.2 % from full load to open loop. Over voltage protection (OVP) is implemented at the main output. When the output voltage reaches 60 V, the main converter is stopped by the OVP circuit. It starts to operate again when the main output decreases to 54 V. In addition, many other protection functions are also implemented, such as Output Short Circuit Protection of the main output (OSCP), LLC primary winding short circuit protection (WSCP), Capacitive Mode Protection of the main output (CMP), LLC Over Current Protection (LOCP), over temperature protection (OTP) at certain hot spot on board and more. These protection functions are realized by the built-in protection functions of the IC ICL5101. Features Input voltage range: 85–305 VAC Input voltage frequency: 47–63 Hz Regulated main output voltage: 54 VDC / 2.06 A Efficiency at nominal load: ≥ 93.5 % at 230 VAC Input current THD: < 10 % @ > 35% Load at 230 VAC Harmonics: According to EN61000-3-2 Class-D EMI: According to EN55015 Safety : According to EN61347-2-13 Board dimensions: 247.3 mm (L) x 48.25 mm (W) x 34.2 mm (H) Application Note 4 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Schematic 3 Schematic Figure 2 shows the schematic of the ICL5101 demonstration board. Figure 2 Schematic of 110 W / 54 V Power Supply Demo Board Application Note 5 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4 Key Measurements and Waveforms 4.1 Line Regulation, Startup Time, Load Regulation, PF and THD 4.1.1 Line Regulation The output voltage of the demo board is tested under nominal load (110 W) with input voltages from 85 VAC up to 300 VAC. The detailed test results are shown in Figure 3. VOUT versus VIN at Nominal Load 54,2 54,1 54 Output Voltage [V] 53,9 53,8 53,7 53,6 53,5 53,4 53,3 53,2 80 95 110 125 140 155 170 185 200 215 230 245 260 275 290 305 Input Voltage [V] OUTPUT VOLTAGE Figure 3 DC Output Voltage at Different VIN Values Application Note 6 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4.1.2 Startup Time Start-up time is shorter than 200ms at whole input voltage and power range. Oscilloscope pictures are shown in pictures from Figure 4 to Figure 9 Figure 4: AC Input Voltage 85VACIN, NO Load CH1: Chip Supply Voltage VCC (Yellow) to IC GND; 5V/div CH2: Low Side Gate Drive VLSGD (Blue) to IC GND; 10V/div CH3: PFC BUS Voltage VBUS to Power GND (Magenta); 100V/div CH4: Output Voltage VOUT (Green) to Sec GND; 10V/div Time: 100ms/div; Start-up time:180.1ms Figure 5: AC Input Voltage 85VACIN, Full Load CH1: Chip Supply Voltage VCC (Yellow) to IC GND; 5V/div CH2: Low Side Gate Drive VLSGD (Blue) to IC GND; 10V/div CH3: PFC BUS Voltage VBUS to Power GND (Magenta); 100V/div CH4: Output Voltage VOUT (Green) to Sec GND; 10V/div Time: 100ms/div; Start-up time:195.1ms Figure 6: AC Input Voltage 230VACIN, NO Load CH1: Chip Supply Voltage VCC (Yellow) to IC GND; 5V/div CH2: Low Side Gate Drive VLSGD (Blue) to IC GND; 10V/div CH3: PFC BUS Voltage VBUS to Power GND (Magenta); 100V/div CH4: Output Voltage VOUT (Green) to Sec GND; 10V/div Time: 50ms/div; Start-up time: 88ms Figure 7: AC Input Voltage 230VACIN, Full Load CH1: Chip Supply Voltage VCC (Yellow) to IC GND; 5V/div CH2: Low Side Gate Drive VLSGD (Blue) to IC GND; 10V/div CH3: PFC BUS Voltage VBUS to Power GND (Magenta); 100V/div CH4: Output Voltage VOUT (Green) to Sec GND; 10V/div Time: 50ms/div; Start-up time: 100ms Application Note 7 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Figure 8: AC Input Voltage 300VACIN, NO Load CH1: Chip Supply Voltage VCC (Yellow) to IC GND; 5V/div CH2: Low Side Gate Drive VLSGD (Blue) to IC GND; 10V/div CH3: PFC BUS Voltage VBUS to Power GND (Magenta); 100V/div CH4: Output Voltage VOUT (Green) to Sec GND; 10V/div Time: 50ms/div; Start-up time: 88ms Application Note Figure 9: AC Input Voltage 300VACIN, Full Load CH1: Chip Supply Voltage VCC (Yellow) to IC GND; 5V/div CH2: Low Side Gate Drive VLSGD (Blue) to IC GND; 10V/div CH3: PFC BUS Voltage VBUS to Power GND (Magenta); 100V/div CH4: Output Voltage VOUT (Green) to Sec GND; 10V/div Time: 50ms/div; Start-up time: 93.5ms 8 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4.1.3 Load Regulation The output voltage of the demo board is tested at 230 VAC input voltage and with loads from 0 % up to 100 % (110 W). The detailed test results are shown in Figure 10. VOUT versus POUT @ VACIN = 230V 54,4 54,3 54,2 Output Voltage [V] 54,1 54 53,9 53,8 53,7 53,6 53,5 53,4 0 10 20 30 40 50 60 70 80 90 100 110 Output Power [W] VOUT Figure 10 Output Voltage VOUT versus POUT 4.1.4 PF and THD vs. POUT Due to the smart internal digital PFC controller and improved THD correction of the ICL5101, PF values of greater than 94 % and THD values of lower than 10 % from loads upwards of 45 % are achieved at VIN = 230 VAC. The detailed test results are shown in Figure 11. PF / THD vs. Load @ VACIN = 230 using diff. RZCD 110W 45 100 40 90 80 35 THD [%] 60 RZCD = 51kΩ ideal for stable Load Conditions 25 Mode change from CritCM into WCM 50 20 Limit starting THD is higher 15 40 Power Factor PF [%] 70 30 30 10 20 5 10 RZCD = 39kΩ ideal for vary Load Conditions Smooth mode change 0 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 Load[%] THD [%] 39kΩ THD [%] 51kΩ Power Factor [%] #48 Ref Figure 11 PF and THD versus Load Application Note 9 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Introduction THD Adjustment: In order to provide an excellent THD result, the THD of the ICL5101 is adjustable. Especially at high line input voltage and low load condition, the THD is a critical value. It doesn´t matter in which condition: - Line input voltage - Stable load - Load variation the ICL5101 is providing best results for all cases – only in trimming the ZCD resistor at PIN 7 see Figure 12. VBUS HS MOSFET LS MOSFET 1 0.8VRefCS LVcc LPFC HSVCC 15 3 VCC HSGND 14 4 GND PFC MOSFET 5 PFCGD 1.0VRefPFCS HSGD 16 2 LSCS 6 PFCCS ICL5101 VBUS LSGD Vcc ϑR OTP 13 OVP 12 Vcc n.a. 11 VBUS LPFCsec 7 PFCZCD n.a. 10 2.5VRefPFCVS 8 PFCVS RFM 9 RfRUN Rfmin PG-DSO-16 (150mil) Figure 12 PIN SetUP ICL5101 How to do: To improve the THD the resistor – see red signed resistor in Figure 12 – at ZCD PIN 7 can be trimmed to an optimal value (several k-ohm ~ 20 up to 100k) in order to reach best THD results. Step one is to define the inductivity of the PFC choke and the MOSFET. After fixing PFC choke and transistor, two scenarios are happen: 1/ operation in stable load condition e.g. lamp ON / OFF SET nominal load condition and vary the value of the resistor until you get the best THD results. Outcome sees in Figure 11 black curve 2/ operation with load variation e.g. dimming of an LED Choose a resistor and vary the load. Change value up or down in order to get your best result over the whole load range – outcome sees Figure 11 red curve. Application Note 10 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Mechanism: The controller operates in two modes: - Critical Conduction Mode (CrCM) in a wide load range - Wait Cycle Mode (WCM – a kind of DCM) for low load Switch from CrCM into WCM): The ICL5101 has an integrated logic which can be regulated via the resistor at the ZCD PIN 7 in varying the value of the resistor. Limit: The digital logic of the controller is limited. At high line input voltages, the controller reduces the ON time of the PFC gate driver. If the minimum ON time is reached – physically given by the internal digital stage – the controller switches over from the critical conduction mode CrCM into the wait cycle mode WCM. This switch over can be seen in the THD measurement shown in Figure xx. Depending on the load (stable or variable) the optimum configuration can be found, shown in . This effect can be prevented by trimming the resistor at the ZCD PIN 7 – lower the resistance leads to a smother cross over from CrCM into WCM (red curve) but increases slightly the THD. Application Note 11 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4.2 Surge Protection Description SURGE Protection In case of a surge event, the voltage at the BUS capacitors C5 & C8 rises up, the driver stages of the ICL5101 are shut off when VLSCS > 0.8V and VBUS > 109% for longer than 500ns. After the surge the controller restarts automatically when VBUS drops below 109% of the rated voltage. This feature allows driving 500V MOSFETs at the half bridge stage when adequate EMI and DC LINK networking is present. SURGE Detection If the bus voltage exceeds: VBUS > 109% and the voltage at the low side current sense pin 2 exceeds: VLSCS > 0.8V for longer than t = 500ns SURGE Protection All Gate Drives OFF Auto Restart: VBUS < 109% Measurement Surge Event of 1.7kV WITHOUT Varistor VR1 Figure 13: SURGE 1.7kV / FULL Load / Detail L N / Phase: 90° Figure 14: SURGE 1.7kV / FULL Load / Auto Restart L N / Phase: 90° Ch 1 dark blue: VLSCS LS Current Sense to IC GND Ch 1 dark blue: VLSCS LS Current Sense to IC GND Ch 2 blue: VBUS to Power GND Ch 2 blue: VBUS to Power GND Ch 3 magenta: VLSDS LS Drain to Power GND Ch 3 magenta: VLSDS LS Drain to Power GND Ch 4 green: VPFCDS PFC Drain to Power GND Ch 4 green: VPFCDS PFC Drain to Power GND Surge Event: VBUS > 109% & VLSCS > 800mV Auto Restart:VBUS < 109% Application Note 12 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4.3 Harmonics Harmonics are tested according to the standard EN61000-3-2 Class-D, as shown in the following figures. Figure 15 Input Current Harmonic Spectrum at Full Load and VIN = 85 VAC Figure 16 Input Current Harmonic Spectrum at Full Load and VIN = 230 VAC Application Note 13 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Figure 17 Input Current Harmonic Spectrum at Full Load and VIN = 300 VAC 4.4 System Efficiency and Standby Power 4.4.1 System Efficiency The efficiency of the demo board is tested at 230 VAC input voltage and under different output power from 0 W to 110 W. System Effieciency [%] System - ƞ versus Load @ VACIN = 230V 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 Load [%] Efficiency Figure 18 System Efficiency versus Load Application Note 14 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4.4.2 Power Consumption at Output Open Loop (Standby Power) At output open loop (NO Load), the power converter keeps the output voltage at a stable value of 54 V and will not go into burst mode. STB versus VIN at NO Load 1,8 1,6 1,4 Standby Power [W] 1,2 1 0,8 0,6 0,4 0,2 0 50 100 150 200 250 300 350 Input Voltage [V] STB [W] Figure 19 Standby Power versus VAC Application Note 15 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms 4.5 EMI Test Conducted EMI and radiated EMI are tested according to the standard EN55015. Figure 20 Conducted EMI -- 230VAC/50Hz N Figure 21 Conducted EMI -- 230VAC/50Hz L Application Note 16 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Figure 22 Conducted EMI -- 120VAC/60Hz N Figure 23 Conducted EMI -- 120VAC/60Hz L Application Note 17 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Figure 24 Radiated EMI -- 230VAC/50Hz Horizontal Figure 25 Radiated EMI -- 230VAC/50Hz Vertical Application Note 18 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Key Measurements and Waveforms Figure 26 Radiated EMI -- 120VAC/60Hz Horizontal Figure 27 Radiated EMI -- 120VAC/60Hz Vertical Application Note 19 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Surge, Flicker & Burst Test Results 5 Surge, Flicker & Burst Test Results 5.1 Surge Application Note 20 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Surge, Flicker & Burst Test Results 5.2 Flicker Application Note 21 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Surge, Flicker & Burst Test Results Application Note 22 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Surge, Flicker & Burst Test Results 5.3 Burst Application Note 23 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Power Transformer Specification 6 Power Transformer Specification 6.1 Common Mode Choke Spec L1 Figure 28 Common Mode Choke Application Note 24 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Power Transformer Specification 6.2 PFC Choke Spec T1 110W/ PFC Inductance Core form and material:EV30,TPA44 Bobbin former: Horizontal version Primary inductance and saturation current: LP = 580µH / ISAT = 6A 6 turns 6 x 0.15mm 79 turns 50 x 0.1mm Pin 6 Pin 5 Pin 1 Pin 12 Sec.1 4layer Prim Center leg means one layer Makrofol Start End No of Turns Wire size Layer Method 12 1 79 50 x 0.1 mm Primary Tight 5 6 6 6 x 0.15 mm Sec.1 Tight Top View: Pin 1 • ∙ Pin 12 Pin 5 ∙ Pin 6 Figure 29 PFC Choke Application Note 25 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Power Transformer Specification 6.3 LLC Resonant Choke Spec L2 110W/ LLC Resonence Inductance Core form and material:EP20,TPW33 Bobbin former: Vertical version Primary inductance and saturation current: LP = 225µH Pin3 41 turns 40 x 0.1mm 4layer Pin1 Center leg means one layer Makrofol Start End No. of Turns Wire size 1 3 41 40 x 0.1mm Top View : Pin 1 • Pin 2 ∙ Pin 3 ∙ Layer Method Tight ∙ Pin 5 Figure 30 LLC Resonant Choke Application Note 26 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Power Transformer Specification 6.4 LLC Transformer Spec T2 110W/LLC transformer Core form and material:ED26/7/30,TPW33 Bobbin former: Horizontal version Primary inductance : LP = 2700µH 1 = 15Turns 5 turns 1Sec x 0.15mm 27 turns 1 x 0.4mm Prim VCC 2layer ½ Prim 13 turns 1 x 0.65mm Sec.2 13 turns 1 x 0.65mm Sec.1 27 turns 1 x 0.4mm Pin 6 Pin 5 Pin 1 Pin 3/float Pin 7 Pin 8 2layer Pin 9 Pin 10 Pin 3/float Pin 2 ½ Prim Center leg means one layer Makrofol Start End No of Turns Wire size Layer Method 2 3 / flox 27 0.4mm 1/2 Primary Tight 10 9 13 0.65mm, tripple isolation Sec.1 Tight 8 7 13 0.65mm, tripple isolation Sec.2 Tight 3 / float 1 27 0.4mm 1/2 Primary Tight 5 6 5 0.15mm VCC spread Top View: Pin Pin Pin Pin Pin Pin 1 2 3 4 5 6 • ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ Pin Pin Pin Pin Pin Pin 12 11 10 9 8 7 Figure 31 LLC Transformer Application Note 27 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Board Layout 7 Board Layout Figure 32 Layout of 110 W / 54 V Power Supply Demo Board (Bottom View) Figure 33 Assembly Print (Top View) Figure 34 Assembly Print (Bottom View) Application Note 28 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Bill of Material (BOM) 8 Bill of Material (BOM) Designator Part Value Description Packag/Footprint Supplier Order Number BR1 C1 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C2 C20 C21 C22 C23 C24 C25 C26 C27 C28 LL15XB60 330nF/305V/X2 100nF/50V 22nF/50V 100nF/50V 100pF/50V 100nF/50V 4n7/50V 220nF/50V 33nF/630V 100uF/35V 2n2/400V/Y2 100nF/305V/X2 150nF/520V 220nF/50V 330uF/100V 100pF/50V 100pF/630V 100uF/100V 100pF/630V 1nF/50V 100nF/305V/X2 bridge, 15A/600V 305V/X2 capacitor ceramic capacitor ceramic capacitor ceramic capacitor ceramic capacitor ceramic capacitor ceramic capacitor ceramic capacitor film capacitor Aluminium Electrolyte 400V/Y2 capacitor 305V/X2 capacitor film capacitor ceramic capacitor Aluminium Electrolyte HV ceramic capacitor HV ceramic capacitor Aluminium Electrolyte ceramic capacitor ceramic capacitor 305V/X2 capacitor GSIB-5S FCAP-18-9-15/10 C0805 C0805 C0805 C0805 C1206 C1206 C1206 FCAP-18-6-12-15-H EUE2.5-7 FCAP-18-6-15/10 FCAP-13-6-10 FCAP-18-6-12-15-H C1206 EUE5-B12,5-L35 C1206 C1206 ECAP-10-5 C1206 C0805 FCAP-18-9-15/10 SHINDENGEN EPCOS LL15XB60 BS2922C3334M EPCOS RUBYCON B32672L6333K RUBYCON EPCOS EPCOS B32921C3104M B32672Z5154K RUBYCON 100ZLJ330M12.5X35 RUBYCON 100ZLJ100M10X20 EPCOS, B32921C3104M C29 C3 C30 C31 C32 C33 C34 C4 C5 C6 C7 C8 C9 CY1 CY2 D1 D10 D11 D12 D13 D14 D15 D16 D2 D3 100nF/50V 2u2/50V 470nF/630V 10nF/630V 10nF/630V 100nF/630V 47pF/1kV 470nF/630V 150uF/250V 100nF/50V 2u2/50V 150uF/250V 2n2/50V 2n2/400V/Y2 2n2/400V/Y2 8ETL06PBF 1N4148 MURS160 SS210 1N4148 V10150C V10150C BZT52C9V1 S2JA BZT52C16 ceramic capacitor ceramic capacitor film capacitor HV ceramic capacitor HV ceramic capacitor HV ceramic capacitor HV ceramic capacitor film capacitor Aluminium Electrolyte ceramic capacitor ceramic capacitor Aluminium Electrolyte ceramic capacitor 400V/Y2 capacitor 400V/Y2 capacitor rectification diode small single switch diode rectification diode rectification diode small single switch diode rectification diode rectification diode Zener diode rectification diode Zener diode C1206 C1206 FCAP-18-6-15/10 C1206 C1206 C1812 C050-024x044 FCAP-18-6-15/10 ECAP-12.5-5-H C0805 C1206 ECAP-12.5-5-H C0805 FCAP-18-6-15/10 FCAP-18-6-15/10 TO220-2 SOD-123_MINI-SM SMA SMA SOD-123_MINI-SM TO220 TO220 SOD-123_MINI-SM SMA SOD-123_MINI-SM EPCOS B32922 EPCOS NICHICON B32652A6224K UCY2E151MHD6 NICHICON UCY2E151MHD6 VISHAY 8ETL06PBF ON VISHAY ON VISHAY VISHAY VISHAY V10150C V10150C diodes diodes Application Note 29 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Bill of Material (BOM) D4 D5 D8 D9 F1 IC1 L1 BZT52C16 BZT52C13 BZT52C15 BZT52C8V2 3.15A/300V ICL5101 2x10mH CM choke Zener diode Zener diode Zener diode Zener diode fuse control IC CM inductance SOD-123_MINI-SM SOD-123_MINI-SM SOD-123_MINI-SM SOD-123_MINI-SM FUSE8.5-4 SOP16 EMI_CHOKE_14,5X24, 5EF16LONG L11 B core bead L12 L14 L2 L3 L4 L5 L6 L7 L8 OT1 OT2 Q1 Q10 Q11 Q12 Q13 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 R1 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R2 R20 R21 R22 R23 R24 R25 R26 2X1mH/2A CM choke 470uH/1A inductance IND,EF20 B core B core B core B core 4.7uH/3.7A inductance 860uH/3A inductance VOL617A-3 VOL617A-3 PMMT491 KST2222 KST2222 KST2907 KST2222 KST5551MTF IPP60R125C6 2N7002 KST2907 2N7002 IPD60R450E6 IPD60R450E6 BSP135 10k 4R99 2K 562K 2M 2M 25K5 0R 10k 2K21 12k1 51k1 n.c. 0R 133k 9k1 0R0 47k5 0R CM choke inductance inductance bead bead bead bead inductance inductance optocoupler optocoupler NPN transister NPN transister NPN transister NPN transister NPN transister NPN transister N MOSFET N MOSFET PNP transistor N MOSFET N MOSFET N MOSFET depletion MOSFET film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor Application Note 30 INFINEON ICT ICL5101 NP2014-9132 WE-CBF_1812 WÜRTH 742792515 WE-CMB_XS FERRITE_R16 EF20 WE_PBF_7427932 WE_PBF_7427932 WE_PBF_7427932 1812 5070 WE_7447075 DIL4-SMD DIL4-SMD SOT23 SOT23 SOT23 SOT23 SOT23 SOT23 TO220 SOT23 SOT23 SOT23 TO252 TO252 SOT223 R0805 R0805 R1206 R1206 R1206 R1206 R0805 R1206 R0805 R1206 R0805 R1206 R0805 R1206 R0805 R0805 R0805 R0805 R0805 WÜRTH WÜRTH ICT WÜRTH WÜRTH WÜRTH WÜRTH WÜRTH WÜRTH VISHAY VISHAY 744821201 7447010 NP2014-9133 7427932 7427932 7427932 742792515 7447462047 7447075 VOL617A-3 VOL617A-3 INFINEON IPP60R125C6 INFINEON INFINEON INFINEON IPD60R450E6 IPD60R450E6 BSP135 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Bill of Material (BOM) R27 R28 R29 R3 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R4 R40 R41 R42 R43 R44 R45 R46 R47 R48 R49 R5 R50 R51 R52 R53 R54 R55 R56 R57 R58 R59 R6 R60 R61 R62 R63 R64 R65 R66 R67 R68 R69 R7 R70 R71 R72 R73 4M02 10R 0R 0R68 33K 22R 22R n.c. 0R0 10k 10k n.c. 1K 1R5 0R68 35R 1R5 2R 2R0 10K 30K 680R 10K 10K 100R 0R0 7K5 20K 127K 34K 221K 51K 464K 200K 182K 830K 10k 150K 1M 680R 1M n.c. 15R n.c. 1M 1M 0R 2k21 0R 0R 0R 0R Application Note film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor PTC film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor R0805 R1206 R0805 R1206 R0805 R1206 R1206 R1206 R1206 R1206 R1206 R1206 R1206 R1206 R1206 R0805 R1206 R1206 R1206 R0805 R1206 R1206 R0805 R0805 R0805 R0805 R1206 R1206 R1206 R1206 R0805 R0805 R0805 R0805 R0805 R0805 R0805 R0805 R1206 R0805 R1206 R1206 R0805 R1206 R1206 R1206 R1206 R1206 R1206 R1206 R1206 R0805 31 EPCOS B59701A0100A062 Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 Bill of Material (BOM) R74 R75 R76 R77 0R 0R 0R 680R film resistor film resistor film resistor PTC R1206 R1206 R0805 R0805 R78 R79 R8 R80 R81 R82 R83 R84 R85 R9 T1 T2 U1 U6 VR1 X1 X2 255K 0R 2k21 0R 0R 22R 0R68 0R5 20K 100K EVD30 transformer AZ431 AZ431 S10K350E2K1 3pin connector 2pin connector heatsink-second heatsink-prim. film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor film resistor PFC inductance llc transformer V-regulator V-regulator varistor connector connector heatsink heatsink R0805 R1206 R1206 R1206 R1206 R0805 R1206 R1206 R0805 R0805 EVD30 ED26/7/30-12PIN SOT-23 SOT-23 VR-8*4*5P WAGO3P WAGO2P Application Note 32 EPCOS B59701A0100A062 ICT ICT NP2014-9135 NP2014-9134 EPCOS WÜRTH WÜRTH S10K350E2K1 691412120003B 691412120002B Revision 2.2, 2015-09-22 110 W / 54 V Power Supply Demo Board using ICL5101 References 9 References [1] ICL5101 Data Sheet Application Note 33 Revision 2.2, 2015-09-22 ICL5101 Evaluation Board Revision History Revision History Major changes since the last revision Date Version Changed by Change Description 2015-02-03 1.1 KLING Published & initial 2015-02-11 2.0 KLING EMI Performance Conductive and Radiated / CE Certificated 2015-02-11 2.0 KLING Section 1: Board Photo 2015-02-13 2.0 KLING Section 2: Board Dimension Adjustment 2015-02-13 2.0 KLING Section 3: Schematic 2015-02-13 2.0 KLING Section 4: Complete Update 2015-02-13 2.0 KLING Section 4.4: EMI Test (NEW) 2015-02-13 2.0 KLING Section 5: Surge, Flicker and Burst (NEW) 2015-02-13 2.0 KLING Section 7: Board Layout (Update) 2015-02-13 2.0 KLING Section 8: Bill of Material BOM (Update) 2015-02-19 2.0 KLING Improved Resolution of Figure: 2 / 29 / 30 / 31 2015-02-19 2.0 KLING Section 4.1.2: Start-Up Time, Update of Figure 4 until Figure 9 2015-02-24 2.1 KLING Schematic Update Figure: 2 2015-03-02 2.1 KLING LLC Transformer Figure: 28 / Resolution 2015-03-04 2.1 KLING Resonant Choke Figure: 27 / Resolution 2015-02-05 2.1 KLING Schematic Update Figure: 2 / BOM Update 2015-03-04 2.1 KLING PFC Choke Figure: 26 / Resolution 2015-04-13 2.1 KLING Update BOM / including Supplier and Part Number 2015-06-19 2.1 KLING Typo Correction 2015-07-24 2.1 KLING Figure 11 update / Figure 12 new 2015-07-27 2.1 KLING Add THD description for stable and vary load condition 2015-07-27 2.1 KLING Add Surge protection feature 2015-09-19 2.2 KLING BOM & Schematic correction: L8: Value / C30 + D1 Partnr. 2015-09-19 2.2 KLING Overall correction Application Note 34 Revision 2.2, 2015-09-22 Trademarks of Infineon Technologies AG AURIX™, C166™, CanPAK™, CIPOS™, CIPURSE™, CoolGaN™, CoolMOS™, CoolSET™, CoolSiC™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, DrBLADE™, EasyPIM™, EconoBRIDGE™, EconoDUAL™, EconoPACK™, EconoPIM™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, ISOFACE™, IsoPACK™, iWafer™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OmniTune™, OPTIGA™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™, PrimeSTACK™, PROFET™, PRO-SIL™, RASIC™, REAL3™, ReverSave™, SatRIC™, SIEGET™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, SPOC™, 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. ANSI™ of American National Standards Institute. AUTOSAR™ of AUTOSAR development partnership. Bluetooth™ of Bluetooth SIG Inc. CATiq™ of DECT Forum. COLOSSUS™, FirstGPS™ of Trimble Navigation Ltd. EMV™ of EMVCo, LLC (Visa Holdings Inc.). EPCOS™ of Epcos AG. FLEXGO™ of Microsoft Corporation. HYPERTERMINAL™ of Hilgraeve Incorporated. MCS™ of Intel Corp. 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™ of Openwave Systems Inc. RED HAT™ of Red Hat, Inc. RFMD™ of 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 2014-07-17 www.infineon.com Edition 2015-09-22 Published by Infineon Technologies AG 81726 Munich, Germany © 2016 Infineon Technologies AG. All Rights Reserved. Do you have a question about any aspect of this document? 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