35W Brick Adapter Reference Design

AN- REF- 35W ADAPT ER
35W 19V Adapt er Ref er ence Boar d
wit h I CE2Q S03G , I PD60R600 P6
BAS21-03W & 2N7002
Appl icat ion Not e AN - REF- 35W ADAPT ER
V1.0, 2014-07-02
Po wer Manag em ent & Mult im ar k et
Edition 2014-07-02
Published by Infineon Technologies AG,
81726 Munich, Germany.
© 2014 Infineon Technologies AG
All Rights Reserved.
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THIS APPLICATION NOTE.
Information
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Trademarks of Infineon Technologies AG
AURIX™, C6 6™, CanPAK™, CIPOS™, CIPURSE™, EconoPACK™, CoolMOS™, CoolSET™,
CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, EasyPIM™, EconoBRIDGE™, EconoDUAL™,
EconoPIM™, EconoPACK™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, I²RF™,
ISOFACE™, IsoPACK™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OptiMOS™, ORIGA™,
POWERCODE™; PRIMARION™, PrimePACK™, PrimeSTACK™, PRO-SIL™, PROFET™, RASIC™,
ReverSave™, SatRIC™, SIEGET™, SINDRION™, SIPMOS™, SmartLEWIS™, SOLID FLASH™,
TEMPFET™, thinQ!™, TRENCHSTOP™, TriCore™.
Other Trademarks
Advance Design System™ (ADS) of Agilent Technologies, AMBA™, ARM™, MULTI-ICE™, KEIL™,
PRIMECELL™, REALVIEW™, THUMB™, µVision™ of ARM Limited, UK. AUTOSAR™ is licensed by
AUTOSAR development partnership. Bluetooth™ of Bluetooth SIG Inc. CAT-iq™ of DECT Forum.
COLOSSUS™, FirstGPS™ of Trimble Navigation Ltd. EMV™ of EMVCo, LLC (Visa Holdings Inc.). EPCOS™
of Epcos AG. FLEXGO™ of Microsoft Corporation. FlexRay™ is licensed by FlexRay Consortium.
HYPERTERMINAL™ of Hilgraeve Incorporated. IEC™ of Commission Electrotechnique Internationale. IrDA™
of Infrared Data Association Corporation. ISO™ of INTERNATIONAL ORGANIZATION FOR
STANDARDIZATION. MATLAB™ of MathWorks, Inc. MAXIM™ of Maxim Integrated Products, Inc.
MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS
Technologies, Inc., USA. muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of
Applied Wave Research Inc., OmniVision™ of OmniVision Technologies, Inc. Openwave™ Openwave Systems
Inc. RED HAT™ Red Hat, Inc. RFMD™ RF Micro Devices, Inc. SIRIUS™ of Sirius Satellite Radio Inc.
SOLARIS™ of Sun Microsystems, Inc. SPANSION™ of Spansion LLC Ltd. Symbian™ of Symbian Software
Limited. TAIYO YUDEN™ of Taiyo Yuden Co. TEAKLITE™ of CEVA, Inc. TEKTRONIX™ of Tektronix Inc.
TOKO™ of TOKO KABUSHIKI KAISHA TA. UNIX™ of X/Open Company Limited. VERILOG™, PALLADIUM™
of Cadence Design Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™
of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited.
Last Trademarks Update 2011-11-11
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Revision History
AN_201405_PL21_006
Major changes since previous revision
Date
Version
Changed By
Change Description
2 Jul 2014
1.0
Kyaw Zin Min
Release of final version
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Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Table of Contents
Revision History .............................................................................................................................................. 4
Table of Contents ............................................................................................................................................ 5
1
Abstract ........................................................................................................................................ 7
2
Reference board ........................................................................................................................... 7
3
Technical specifications .............................................................................................................. 8
4
List of features (ICE2QS03G) ....................................................................................................... 8
5
5.1
5.2
5.3
5.4
5.5
Circuit description ....................................................................................................................... 9
Mains Input Rectification and Filtering ............................................................................................ 9
PWM Control and switching MOSFET ............................................................................................ 9
Snubber Network ........................................................................................................................... 9
Output Stage.................................................................................................................................. 9
Feedback Loop .............................................................................................................................. 9
6
6.1
6.2
6.3
6.4
6.5
Circuit Operation ........................................................................................................................ 10
Startup Operation......................................................................................................................... 10
Normal Mode Operation ............................................................................................................... 10
Primary side peak current control ................................................................................................. 10
Digital Frequency Reduction......................................................................................................... 10
Burst Mode Operation .................................................................................................................. 10
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Protection Features.................................................................................................................... 11
VCC over voltage and under voltage protection ............................................................................ 11
Over load/Open loop protection .................................................................................................... 11
Auto restart for over temperature protection.................................................................................. 11
Adjustable output overvoltage protection ...................................................................................... 11
Short winding protection ............................................................................................................... 11
Foldback point protection ............................................................................................................. 11
AC line under voltage protection (Brownout mode) by external circuit ........................................... 12
8
Circuit diagram........................................................................................................................... 13
9
9.1
9.2
PCB layout.................................................................................................................................. 14
Top side ....................................................................................................................................... 14
Bottom side .................................................................................................................................. 14
10
Component list ........................................................................................................................... 15
11
Transformer construction .......................................................................................................... 16
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
Test results................................................................................................................................. 17
Efficiency (without 0.11Ω cable) ................................................................................................... 17
Input standby power ..................................................................................................................... 18
Line regulation ............................................................................................................................. 19
Load regulation ............................................................................................................................ 19
Maximum power ........................................................................................................................... 20
ESD immunity (EN61000-4-2) ...................................................................................................... 20
Electrical fast transient / Burst immunity (EN61000-4-4) ............................................................... 20
Surge immunity (EN61000-4-5) .................................................................................................... 20
Conducted emissions (EN55022 class B) ..................................................................................... 21
Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
13.11
13.12
Waveforms and scope plots ...................................................................................................... 23
Start up at low/high AC line input voltage with maximum load ....................................................... 23
Soft start ...................................................................................................................................... 23
Drain voltage and current at maximum load .................................................................................. 24
Zero crossing point during normal operation ................................................................................. 24
Load transient response (Dynamic load from 10% to 100%) ......................................................... 25
Output ripple voltage at maximum load......................................................................................... 25
Output ripple voltage during burst mode at 1 W load..................................................................... 26
Active Burst mode operation......................................................................................................... 26
Over load protection (Auto restart mode) ...................................................................................... 27
Output overvoltage protection (Latched off mode) ........................................................................ 27
VCC under voltage/Short optocoupler protection (Auto restart mode) ............................................. 28
Brown out protection .................................................................................................................... 28
14
References ................................................................................................................................. 29
Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Abstract
1
Abstract
This application note is an engineering report of a very small form factor reference design for universal input
35W 19V adapter. The adapter is using ICE2QS03G, a second generation current mode control quasi-resonant
flyback topology controller and IPD60R600P6, a seventh generation of high voltage power CoolMOS™. The
distinguishing features of this reference design are very small form factor, best in class low standby power, high
efficiency, good EMI performance and various modes of protection for high reliable system.
2
Reference board
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.
Figure 1 – REF-ICE2QSO3G & IPD60R600P6 35W ADAPTER [Dimensions L x W x H: 89mm x 35mm x 27mm]
Figure 2A – REF-ICE2QSO3G & IPD60R600P6 35W ADAPTER (Top Side)
IPD60R600P6
2N7002
BAS21-03W
ICE2QS03G
Figure 2B – REF-ICE2QSO3G & IPD60R600P6 35W ADAPTER (Bottom Side)
Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Technical specifications
3
Technical specifications
Input voltage
90Vac~264Vac
Input frequency
47~63Hz
Output voltage
19V
Full load output current
1.84A
Full load output power
35W
Brownout detect/reset voltage @ full load
80/87Vac
Output over voltage protection
21~22V
Over current protection
2.3~3.3A
No-load power consumption
<75mW (comply with EU CoC Version 5, Tier 2 and
EPS of DOE USA)
Active mode four point average efficiency
(25%,50%,75% & 100%load)
>88.22% (comply with EU CoC Version 5, Tier 2 and
EPS of DOE USA)
Active mode at 10% load efficiency
>78.22% (comply with EU CoC Version 5, Tier 2)
Form factor case size (L x W x H)
(89 x 35 x 27) mm3
4
List of features (ICE2QS03G)
Quasi resonant operation till very low load
Active burst mode operation at light/no load for low standby input power (< 100mW)
Digital frequency reduction with decreasing load
HV startup cell with constant charging current
Built-in digital soft-start
Foldback correction and cycle-by-cycle peak current limitation
Auto restart mode for VCC Overvoltage protection
Auto restart mode for VCC Undervoltage protection
Auto restart mode for Overload /Openloop protection
Auto restart mode for Over temperature protection
Latch-off mode for adjustable output overvoltage protection
Latch-off mode for Short Winding
Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Circuit description
5
Circuit description
5.1
Mains Input Rectification and Filtering
The AC line input side comprises the input fuse F1 as over-current protection. The choke L2, X-capacitors C7
and Y-capacitor C11, C18 and C19 act as EMI suppressors. PCB spark gap and varistor VR1 can absorb high
voltage stress during lightning surge test. After the bridge rectifier D3 and the input bulk capacitor C1, a voltage
of 90 to 373 VDC is present which depends on input line voltage.
5.2
PWM Control and switching MOSFET
The PWM pulse is generated by the Quasi Resonant PWM current-mode Controller ICE2QS03G and this PWM
pulse drives the high voltage power MOSFETs, IPD60R600P6 (CoolMOS™ P6). P6 is Infineon’s seventh
generation of high voltage power MOSFETs designed according to the revolutionary Superjunction (SJ)
principle. The new CoolMOS™ P6 series combines our experience as the leading SJ MOSFET supplier with
innovation focusing on high efficiency solutions. The resulting P6 technology is tailored to provide high
performance in hard & soft switching topologies while not sacrificing the ease of use. P6 achieves extremely low
conduction and switching losses especially in light load condition enabling switching applications to work more
efficient and be designed more compact, lighter and cooler. The PWM switch-on is determined by the zerocrossing input signal and the value of the up/down counter. The PWM switch-off is determined by the feedback
signal VFB and the current sensing signal VCS. ICE2QS03G also performs all necessary protection functions in
flyback converters. Details about the information mentioned above are illustrated in the product datasheet.
5.3
Snubber Network
A snubber network R22, R23, C13 and D1 dissipate the energy of the leakage inductance and suppress ringing
on the SMPS transformer. Due to the resonant capacitor (MOSFET’s drain source capacitance), the overshoot
is relatively smaller than fixed frequency flyback converter. Thus the snubber resistor can be used with a larger
one which will reduce the snubber loss.
5.4
Output Stage
On the secondary side, 19V output, the power is coupled out via a schottky diode D2. The capacitors C2
provides energy buffering following with the LC filter L1 and C3 to reduce the output ripple and prevent
interference between SMPS switching frequency and line frequency considerably. Storage capacitor C2 is
designed to have an internal resistance (ESR) as small as possible. This is to minimize the output voltage ripple
caused by the triangular current.
5.5
Feedback Loop
For feedback, the output is sensed by the voltage divider of R3 and R4 and compared to TL431 internal
reference voltage. C4 and R5 comprise the compensation network. The output voltage of TL431 is converted to
the current signal via optocoupler OT1 and two resistors R8 and R10 for regulation control.
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Circuit Operation
6
Circuit Operation
6.1
Startup Operation
Since there is a built-in startup cell in the ICE2QS03G, there is no need for external start up resistor, which can
improve standby performance significantly. When VCC reaches the turn on voltage threshold 18V, the IC begins
with a soft start. The soft-start implemented in ICE2QS03G is a digital time-based function. The preset soft-start
time is 12ms with 4 steps. If not limited by other functions, the peak voltage on CS pin will increase step by step
from 0.32V to 1V finally. After IC turns on, the Vcc voltage is supplied by auxiliary windings of the transformer.
6.2
Normal Mode Operation
The secondary output voltage is built up after startup. The secondary regulation control is adopted with TL431
and optocoupler. The compensation network C4 and R5 constitutes the external circuitry of the error amplifier of
TL431. This circuitry allows the feedback to be precisely controlled with respect to dynamically varying load
conditions, therefore providing stable control.
6.3
Primary side peak current control
The MOSFET drain source current is sensed via external resistor R15 and R16. Since ICE2QS03G is a current
mode controller, it would have a cycle-by-cycle primary current and feedback voltage control which can make
sure the maximum power of the converter is controlled in every switching cycle.
6.4
Digital Frequency Reduction
During normal operation, the switching frequency for ICE2QS03G is digitally reduced with decreasing load. At
light load, the CoolMOS™ IPD60R600P6 will be turned on not at the first minimum drain-source voltage time,
but on the nth. The counter is in range of 1 to 7, which depends on feedback voltage in a time-base. The
feedback voltage decreases when the output power requirement decreases, and vice versa. Therefore, the
counter is set by monitoring voltage VFB. The counter will be increased with low VFB and decreased with high
VFB. The thresholds are preset inside the IC.
6.5
Burst Mode Operation
At light load condition, the SMPS enters into Active Burst Mode. At this stage, the controller is always active
but the Vcc must be kept above the switch off threshold. During active burst mode, the efficiency increase
significantly and at the same time it supports low ripple on Vout and fast response on load jump.
For determination of entering Active Burst Mode operation, three conditions apply:
1. The feedback voltage is lower than the threshold of VFBEB(1.219V). Accordingly, the peak current sense
voltage across the shunt resistor is 0.1667;
2. The up/down counter is 7;
3. And a certain blanking time (tBEB=24ms).
Once all of these conditions are fulfilled, the Active Burst Mode flip-flop is set and the controller enters Active
Burst Mode operation. This multi-condition determination for entering Active Burst Mode operation prevents mistriggering of entering Active Burst Mode operation, so that the controller enters Active Burst Mode operation
only when the output power is really low during the preset blanking time.
During active burst mode, the maximum current sense voltage is reduced from 1V to 0.34V so as to reduce the
conduction loss and the audible noise. At the burst mode, the FB voltage is changing like a sawtooth between
3.0 and 3.6V.
The feedback voltage immediately increases if there is a high load jump. This is observed by one comparator.
As the current limit is 34% during Active Burst Mode a certain load is needed so that feedback voltage can
exceed VLB (4.19V). After leaving active burst mode, maximum current can now be provided to stabilize V O. In
addition, the up/down counter will be set to 1 immediately after leaving Active Burst Mode. This is helpful to
decrease the output voltage undershoot.
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Protection Features
7
Protection Features
7.1
VCC over voltage and under voltage protection
During normal operation, the Vcc voltage is continuously monitored. When the Vcc voltage increases up to
VVCCOVP or Vcc voltage falls below the under voltage lock out level VVCCoff, the IC will enter into autorestart mode.
7.2
Over load/Open loop protection
In case of open control loop, feedback voltage is pulled up with internally block. After a fixed blanking time, the
IC enters into auto restart mode. In case of secondary short-circuit or overload, regulation voltage VFB will also
be pulled up, same protection is applied and IC will auto restart.
7.3
Auto restart for over temperature protection
The IC has a built-in over temperature protection function. When the controller’s temperature reaches 140 °C,
the IC will shut down switch and enters into auto restart. This can protect power MOSFET from overheated.
7.4
Adjustable output overvoltage protection
During off-time of the power switch, the voltage at the zero-crossing pin ZC is monitored for output overvoltage
detection. If the voltage is higher than the preset threshold 3.7V for a preset period 100μs, the IC is latched off.
7.5
Short winding protection
The source current of the MOSFET is sensed via external resistor R15 and R16. If the voltage at the current
sensing pin is higher than the preset threshold VCSSW of 1.68V during the on-time of the power switch, the IC is
latched off. This constitutes a short winding protection. To avoid an accidental latch off, a spike blanking time of
190ns is integrated in the output of internal comparator.
7.6
Foldback point protection
For a quasi-resonant flyback converter, the maximum possible output power is increased when a constant
current limit value is used for all the mains input voltage range. This is usually not desired as this will increase
additional cost on transformer and output diode in case of output over power conditions.
The internal foldback protection is implemented to adjust the VCS voltage limit according to the bus voltage.
Here, the input line voltage is sensed using the current flowing out of ZC pin, during the MOSFET on-time. As
the result, the maximum current limit will be lower at high input voltage and the maximum output power can be
well limited versus the input voltage.
Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Protection Features
7.7
AC line under voltage protection (Brownout mode) by external circuit
When the AC line input voltage is lower than the specified voltage range, brownout mode is detected by sensing
the voltage level at U2 (TL431)’s REF pin (VRef_Typ =2.5V) through the voltage divider resistors (R12, R13, R14
and R17 in Fig.3) from bulk capacitor C1. Q2 acts as a switch to enter or leave brownout mode by controlling FB
pin voltage. Q3 together with R17 act as voltage hysteresis for the brownout circuit and U2 (TL431) as a
comparator. The system enters the brownout mode by controlling FB pin voltage of U1 to 0V (when the voltage
level at VRef drop down to 2.5V, then the MOSFET switch Q2 and Q3 on and VFB drop down to 0V). It is until the
input level goes back to input voltage range, VRef increase to 2.5V (then the switch Q2 and Q3 off) and the Vcc
hits 18V, the brownout mode is released. The calculation for brownout circuit as below,
Vbulkcap_enterbrownout
( R12  R13  R14) Vref
Vbulkcap_enterbrownout 85.39V
R14
 R14R17   R12  R13 Vref



 R14  R17 

Vbulkcap_leavebrownout
 R14R17 


 R14  R17 
Application Note AN-REF-35W ADAPTER
12
Vbulkcap_leavebrownout 122.028V
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Circuit diagram
8
Circuit diagram
Figure 3 – 35W 19V ICE2QSO3G power supply schematic
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
PCB layout
9
PCB layout
Figure 4 – Bottom side copper and component legend
9.1
Top side
Figure 5A – Top side component legend
9.2
Bottom side
Figure 5B – Bottom side component legend
Application Note AN-REF-35W ADAPTER
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35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Component list
10
Component list
No.
Reference
Part value
1
Supplier
Description
Package
Electrolytic Cap
Φ18*25mm,P=10mm
Chip Cap
0603
C1
E-CAP,82uF,400V,105℃
2
C10
1nF/50V/X7R
3
C11
Y2 Cap,2.2nF/250Vac
Ceramic Cap
9*5mm,P=10mm
4
C12
47PF/1000V
Chip Cap
6*3mm P=4mm
5
C13
4.7nF/630V/X7R
MURATA
Chip Cap
1206
6
MURATA
C15
220nF/16V/X7R
MURATA
Chip Cap
0603
7
C16
100pF/50V/X7R
MURATA
Chip Cap
0603
8
C17,C21,C22
2.2uF/25V/X7R
MURATA
Chip Cap
1206
Ceramic Cap
9*5mm,P=10mm
9
C18,C19
Y2 Cap,220pF/250Vac
10
C2
E-CAP,470uF,25V
EPCOS
Electrolytic Cap
Φ10*16mm,P=5.0mm
11
MURATA
Chip Cap
1206
Electrolytic Cap
Φ6.3*11.5mm,P=5.0mm
C24
1nF/630V/X7R
12
C3
E-CAP,100uF,25V
13
C4
22nF/X7R/50V
MURATA
Chip Cap
0603
14
C5,C20
100nF/X7R/50V
MURATA
Chip Cap
0603
15
C6
47uF/25V/105℃
EPCOS
Electrolytic Cap
X2 CAP,0.33uF,305VAC
EPCOS
X2 CAP
Φ5*10mm,P=2.5mm
6.0*12.0*13.0mm,P=10m
m
16
17
C7
C9
NC
Chip Cap
18
D1
ES1006FL
Diode
SOD123
19
D2
100V,10A,0.64V
Diode
TO-220AC
Bridge Rectifier
KBPM
Diode
SOD323
8*4mm,P=5mm
20
D3
600V,2A,1.1V
21
D4
200V,250mA (BAS21-03W)
22
Infineon
F1
T2.0A/250V
Fuse
23
JP1
Φ0.6mm,L=10mm
Jumper wire
24
JP2
Φ0.6mm,L=14mm
Jumper wire
25
JP3
Φ0.6mm,L=20mm
Jumper wire
26
L1
4.7uH/4.2A,
Wurth
Inductance
Φ6*8.5mm,P=2.5mm
Wurth
Inductance
15mm*7.5mm*18mm
LED
Φ3*mm,P=2.5mm
27
L2
10mH,350mohm,0.7A
28
LED1
NC
29
OT1
Q1
PHOTOCOUPLER,VOS617A
30
N MOSFET,600V,0.6Ohm (IPD60R600P6)
Infineon
MOSFET
DPAK
31
Infineon
Optocoupler
Q2,Q3
N MOSFET,60V,300mA,(2N7002)
MOSFET
SOT23
32
R3
4.99K/0603, ±1%
Chip Resistor
0603
33
R10
0603
R12,R13
2K/0603, ±1%
4.99M/1206, ±1%
Chip Resistor
34
Chip Resistor
1206
Chip Resistor
0603
35
R14
301K/0603, ±1%
36
R17
681K/0603, ±1%
Chip Resistor
0603
37
R18
51.1K/0603, ±1%
Chip Resistor
0603
38
R19,R24
200K/0603, ±1%
Chip Resistor
0603
39
R2
39.2K/0603, ±1%
Chip Resistor
0603
40
R20,R21,R31
NC
Chip Resistor
0603
41
R22,R23
27.4K/1206, ±1%
Chip Resistor
1206
42
R25,R26
0/0603, ±1%
Chip Resistor
0603
43
R27
27R/1206, ±1%
Chip Resistor
1206
44
R4
33.2K/0603, ±1%
Chip Resistor
0603
45
R5
100K/0603, ±1%
Chip Resistor
0603
46
R6,R8,R11
10K/0603, ±1%
Chip Resistor
0603
47
R7,R15,R16
1R0/1206, ±1%
Chip Resistor
1206
Application Note AN-REF-35W ADAPTER
15
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Transformer construction
48
R9
10R/1206, ±1%
Chip Resistor
1206
49
T1
RM-8 (N87) Lp=900 μH
EPCOS
Transformer
RM-8
50
Infineon
IC
SO-8
Regulator
SOT-23
Leaded varistors
7*4.3mm,P=5mm
U1
ICE2QS03G
51
U2,U3
TL431
52
VR1
S05K275,
53
Heatsink
22*15*10mm
heatsink
54
PCB
80*30.5*1.6mm,one layer
PCB
55
Case
89*35*27mm
Case
Connector input
The plum blossom socket,ST-A04
socket
56
11
EPCOS
Transformer construction
Core and material: RM8 N87
Bobbin: RM8 with 6 pin
Primary Inductance, Lp=900 ±30 μH, measured between pin 1 and pin 3
Manufacturer and part number: EPCOS
Figure 6 – Transformer structure
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Test results
12
Test results
12.1
Efficiency (without 0.11Ω cable)
Vin(Vac)
90
115
230
264
Pin(W)
Vo(Vdc)
Io(A)
VO_ripple (mV)
Po(W)
η(%)
0.04360
4.31000
9.92000
19.82000
29.70000
39.71000
0.04600
4.34000
9.90000
19.66000
29.48000
39.10000
0.05938
4.21000
10.12000
19.64000
29.32000
38.68000
0.06720
4.21000
10.24000
19.74000
29.42000
38.79000
19.03
19.04
19.04
19.04
19.04
19.05
19.03
19.04
19.04
19.04
19.04
19.05
19.03
19.04
19.04
19.04
19.04
19.05
19.03
19.04
19.04
19.04
19.04
19.05
0.000
0.184
0.460
0.920
1.380
1.840
0.000
0.184
0.460
0.920
1.380
1.840
0.000
0.184
0.460
0.920
1.380
1.840
0.000
0.184
0.460
0.920
1.380
1.840
96.40
15.00
27.20
46.30
34.60
72.10
99.80
15.80
25.40
49.60
33.50
42.70
98.00
144.10
22.30
39.60
29.60
32.10
100.60
131.90
21.80
39.70
36.80
31.10
0.00
3.50
8.76
17.52
26.28
35.05
0.00
3.50
8.76
17.52
26.28
35.05
0.00
3.50
8.76
17.52
26.28
35.05
0.00
3.50
8.76
17.52
26.28
35.05
81.28
88.29
88.38
88.47
88.27
0.00
80.72
88.47
89.10
89.13
89.65
0.00
83.22
86.55
89.19
89.62
90.62
0.00
83.22
85.53
88.74
89.31
90.36
Average η (%)
88.35
89.09
88.99
88.49
Active-Mode Efficiency versus AC Line Input Voltage
95.00
Efficiency [ % ]
93.00
90.62
91.00
89.00
90.36
89.65
88.35
88.27
89.09
88.99
115
230
87.00
88.49
85.00
90
264
AC Line Input Voltage [ Vac ]
Full load Efficiency
Average Efficiency(25%,50%,75% & 100%)
Figure 7 – Efficiency vs AC line input voltage
Application Note AN-REF-35W ADAPTER
17
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Test results
Efficiency versus Output Power
Efficiency [ % ]
85.00
89.19
88.47
90.00
89.62
89.13
89.10
83.22
90.62
89.65
86.55
80.00
80.72
75.00
70.00
10
25
50
75
100
Output Power [%]
Vin=115Vac
Vin=230Vac
Figure 8 – Efficiency vs output power @ low and high line
12.2
Input standby power
Standby Power @ no-load versus AC Line Input Voltage
Input Power [ mW ]
100
80
67.20
59.38
60
46.00
43.60
40
20
0
90
115
230
264
AC Line Input Voltage [ Vac ]
Po = 0W
Figure 9 – Input standby power @ no load vs AC line input voltage (measured by Yokogawa WT210 power
meter - integration mode)
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Test results
12.3
Line regulation
Line Regulation: Output voltage @ max. load versus AC line input voltage
Output Voltage [ V ]
19.5
19.3
19.05
19.1
19.05
19.05
19.05
115
230
264
18.9
18.7
18.5
90
AC Line Input Voltage [ Vac ]
Vo @ maximum load
Figure 10 – Line regulation Vo @ full load vs AC line input voltage
12.4
Load regulation
Load Regulation: Vout versus output power
Output Voltage [ V ]
19.50
19.30
19.10
18.90
19.03
19.03
19.04
19.04
19.04
19.04
19.04
19.04
19.05
19.05
18.70
18.50
2.8
25
50
75
100
Output Power [%]
Output voltage @ 115Vac
Output voltage @ 230Vac
Figure 11 – Load regulation Vo vs output power
Application Note AN-REF-35W ADAPTER
19
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Test results
12.5
Maximum power
70
65
60
55
50
45
Pin=58.15 11.78% W
65.00
62.80
6
56.80
51.30
2.99
2.66
2.36
3.09
4
2
90
115
230
Peak Output Current (A)
Peak Input Power(OLP) [ W ]
Peak input power(OLP)/Peak output current versus AC Line Input Voltage
264
AC Line Input Voltage [ Vac ]
Peak Input Power
Peak Output Current
Figure 12 – Maximum output power (before over-load protection) vs AC line input voltage
12.6
ESD immunity (EN61000-4-2)
Pass EN61000-4-2 level 3 (±6kV) contact discharge
12.7
Electrical fast transient / Burst immunity (EN61000-4-4)
Pass EN61000-4-4 level 3 (±2kV)
(Note: output common is connected to ground during test)
12.8
Surge immunity (EN61000-4-5)
Pass EN61000-4-5 Installation class 3 (1kV: differential mode & 2kV: common mode)
(Note: output common is connected to ground during test)
Application Note AN-REF-35W ADAPTER
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Test results
12.9
Conducted emissions (EN55022 class B)
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 (35W) with input voltage of 115Vac and 230Vac.
Figure 13 – Max. Load (35W) with 115 Vac (Line)
Figure 14 – Max. Load (35W) with 115 Vac (Neutral)
Application Note AN-REF-35W ADAPTER
21
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Test results
Figure 15 – Max. Load (35W) with 230 Vac (Line)
Figure 16 – Max. Load (35W) with 230 Vac (Neutral)
Pass EN55022 class B conducted emissions with > 10dB margin for QP.
Application Note AN-REF-35W ADAPTER
22
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Waveforms and scope plots
13
Waveforms and scope plots
All waveforms and scope plots were recorded with a LeCroy 6050 oscilloscope
13.1
Start up at low/high AC line input voltage with maximum load
1.2s
1.2s
Channel
Channel
Channel
Channel
1; C1 : Drain voltage (VDrain)
2; C2 : Supply voltage (VCC)
3; C3 : Feedback voltage (VFB)
4; C4 : Zero crossing voltage (VZC)
Channel
Channel
Channel
Channel
1; C1 : Drain voltage (VDrain)
2; C2 : Supply voltage (VCC)
3; C3 : Feedback voltage (VFB)
4; C4 : Zero crossing voltage (VZC)
Startup time = 1.2s
Startup time = 1.2s
Figure 17 – Startup @ 90Vac & max. load
Figure 18 – Startup @ 264Vac & max. load
13.2
Soft start
13ms
Channel 1; C1 : Current sense voltage (VCS)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : Zero crossing voltage (VZC)
Soft Star time = 13ms
Figure 19 – Soft Start @ 90Vac & max. load
Application Note AN-REF-35W ADAPTER
23
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Waveforms and scope plots
13.3
Drain voltage and current at maximum load
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Current sense voltage (VCS)
VDrain_peak = 322V
Figure 20 – Operation @ 90Vac and max. load
13.4
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Current sense voltage (VCS)
VDrain_peak = 576V
Figure 21 – Operation @ 264Vac and max. load
Zero crossing point during normal operation
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Current sense voltage (VCS)
Figure 22 – Operation @ 90Vac and 2nd zero
crossing
Application Note AN-REF-35W ADAPTER
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Current sense voltage (VCS)
Figure 23 – Operation @ 90Vac and 7th zero
crossing
24
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Waveforms and scope plots
13.5
Load transient response (Dynamic load from 10% to 100%)
Channel 1; C1 : Output ripple voltage (Vo)
Channel 2; C2 : Output current (Io)
Vripple_pk_pk=840mV (Load change from10% to
100%,100Hz,0.4A/μS slew rate)
Probe terminal end with decoupling capacitor of
0.1μF(ceramic) & 1μF(Electrolytic), 20MHz filter
Channel 1; C1 : Output ripple voltage (Vo)
Channel 2; C2 : Output current (Io)
Vripple_pk_pk=834mV (Load change from10% to
100%,100Hz,0.4A/μS slew rate)
Probe terminal end with decoupling capacitor of
0.1μF(ceramic) & 1μF(Electrolytic), 20MHz filter
Figure 24 – Load transient response @ 90Vac
Figure 25 – Load transient response @ 264Vac
13.6
Output ripple voltage at maximum load
Channel 1; C1 : Output ripple voltage (Vo)
Channel 1; C1 : Output ripple voltage (Vo)
Vripple_pk_pk=78.8mV
Probe terminal end with decoupling capacitor of
0.1μF(ceramic) & 1μF(Electrolytic), 20MHz filter
Vripple_pk_pk = 38.9mV
Probe terminal end with decoupling capacitor of
0.1μF(ceramic) & 1μF(Electrolytic), 20MHz filter
Figure 26 – AC output ripple @ 90Vac and max.
load
Figure 27 – AC output ripple @ 264Vac and max.
load
Application Note AN-REF-35W ADAPTER
25
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Waveforms and scope plots
13.7
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=99.9mV
Probe terminal end with decoupling capacitor of
0.1μF(ceramic) & 1μF(Electrolytic), 20MHz filter
Vripple_pk_pk = 124.5mV
Probe terminal end with decoupling capacitor of
0.1μF(ceramic) & 1μF(Electrolytic), 20MHz filter
Figure 28 – AC output ripple @ 90Vac and 1W
load
Figure 29 – AC output ripple @ 264Vac and 1W
load
13.8
Active Burst mode operation
th
6
th
7
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : Zero crossing voltage (VZC)
Condition: VFB<1.219V, NZC=7 and tblanking =25ms
(load change form full load to 1W load)
Figure 30 – Entering active burst mode @ 90Vac
Application Note AN-REF-35W ADAPTER
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : Zero crossing voltage (VZC)
Condition: VFB>4.19V
(load change from 1W to full load)
Figure 31 – Leaving active burst mode @ 90Vac
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V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Waveforms and scope plots
13.9
Over load protection (Auto restart mode)
built-in 30ms blanking
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : Zero crossing voltage (VZC)
Over load protection with built-in 30ms blanking
time
(output load change from full load to short load)
Figure 32 – Over load protection with extended
blanking time @ 90Vac)
13.10
Channel
Channel
Channel
Channel
Output overvoltage protection (Latched off mode)
1; C1 : Output voltage (Vo)
2; C2 : Supply voltage (VCC)
3; C3 : Feedback voltage (VFB)
4; C4 : Zero crossing voltage (VZC)
Condition: VO >21.9V (VZC>3.7V)
(R10 disconnected during system operation at no
load)
Figure 33 – Output overvoltage protection @ 90Vac
Application Note AN-REF-35W ADAPTER
27
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
Waveforms and scope plots
13.11
VCC under voltage/Short optocoupler protection (Auto restart mode)
Enter autorestart
Channel
Channel
Channel
Channel
Exit autorestart
1; C1 : Drain voltage (VDrain)
2; C2 : Supply voltage (VCC)
3; C3 : Feedback voltage (VFB)
4; C4 : Zero crossing voltage (VZC)
VCC under voltage/short optocoupler protection
(short the transistor of optocoupler during system
operating @ full load & release)
Figure 34 – Vcc under voltage/short optocoupler
protection @ 90Vac
13.12
Brown out protection
123Vdc
87Vdc
87Vdc
123Vdc
Channel 1; C1 : Drain voltage (VDrain)
Channel 2; C2 : Supply voltage (VCC)
Channel 3; C3 : Feedback voltage (VFB)
Channel 4; C4 : Bulk voltage (VBulk)
Channel
Channel
Channel
Channel
Brownout reset: Vbulk= 123Vdc(87Vac)
Brownout detect: Vbulk= 87Vdc(80Vac)
Brownout reset: Vbulk= 123Vdc(87Vac)
Brownout detect: Vbulk= 87Vdc(62Vac)
Figure 35 – Brownout mode with max. load
Figure 36 – Brownout mode with no load
Application Note AN-REF-35W ADAPTER
28
1; C1 : Drain voltage (VDrain)
2; C2 : Supply voltage (VCC)
3; C3 : Feedback voltage (VFB)
4; C4 : Bulk voltage (VBulk)
V1.0, 2014-07-02
35W 19V Adapter Reference Board with ICE2QS03G, IPD60R600P6
References
14
References
[1]
ICE2QS03G data sheet, Infineon Technologies AG
[2]
IPD60R600P6 data sheet, 600V CoolMOS™ P6 Power Transistor
[3]
BAS21-03W data sheet, Infineon Technologies AG
[4]
2N7002 data sheet, Infineon Technologies AG
[5]
Converter Design Using the Quasi-Resonant PWM Controller ICE2QS01, Infineon Technologies AG,
2006. [ANPS0003]
[6]
Design tips for flyback converters using the Quasi-Resonant PWM controller ICE2QS01, Infineon
Technologies, 2006. [ANPS0005]
[7]
Determine the switching frequency of Quasi-Resonant flyback converters designed with ICE2QS01,
Infineon Technologies, 2006. [ANPS0004]
[8]
ICE2QS03G design guide. [ANPS0027]
[9]
36W Evaluation Board with Quasi-Resonant PWM Controller ICE2QS03G, 2011. [AN-PS0040]
Application Note AN-REF-35W ADAPTER
29
V1.0, 2014-07-02
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