Demoboard for Charger and Adapter 40W

Version 1.2 , August 2001
Application Note
AN-EVAL-ICE2A365-1
CoolSET
40W Evaluation Board with ICE2A365
Author:
Harald Zöllinger
Published by Infineon Technologies AG
http://www.infineon.com
3RZHU0DQDJHPHQW6XSSO\
N e v e r
s t o p
t h i n k i n g
40W Evaluation Board with ICE2A365
Contents:
40W Evaluation Board with ICE2A365..................................................3
Technical specifications: .......................................................................4
Circuit description: ................................................................................4
Schematic:............................................................................................6
Component Legend: .............................................................................7
Board Layout: .......................................................................................7
Component List:....................................................................................8
Transformer Construction .....................................................................9
Measurements: ...................................................................................10
References: ........................................................................................10
Seite 2 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
40W Evaluation Board with ICE2A365
The board described here was designed as a typical power supply in flyback converter topology with
one output voltage and secondary control. This type of switch mode power supply is particularly
suitable as an AC/DC power supply for battery chargers, video games, satellite decoders, etc.
The switch mode power supply ICE2A365 chip used for this application is a current-controlled pulse
width modulator with integrated CoolMOS power switch. Special efforts have been made to
compensate temperature dependency and to achieve a very high accuracy of the switching frequency.
Furthermore, overload and open loop protection is implemented by controlling the feedback line. In
case of overload or open loop, the IC is working in hiccup mode.
Evaluation board
Other output voltages can also be implemented very easily by a simple modification of the transformer
and the output circuitry.
Seite 3 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Technical specifications:
Input Voltage Range
Input Frequency
Output Voltage
Peak Output Power
Line Regulation (85 ...270V)
Load Regulation (10% ... 100%)
Efficiency
Output Ripple Voltage
Switching Frequency
Stby Power with Burst Mode @ noload
EMI
Temperature Range
85 ... 270V AC
50, 60 Hz
16V +-5%
54W
< 1%
< 1%
> 80 %
< 200mV
21...100 kHz
<400mW
EN55022B
0 ... 50°C
Circuit description:
Introduction
The ICE2A365 chip used here was particularly designed for the use in flyback converters. As shown
on the circuit diagram (p. 3), only a few additional components are required to create an AC/DC power
supply.
Line Input
The AC line input side comprises the input fuse F1 as overcurrent protection the choke L5 and X2capacitors C8 and C22 as radio interference suppressors. After the bridge rectifier BR1 and the input
capacitor C3, a voltage of 90 to 380 VDC depending on input voltage is available.
ICE2A365 Power Supply
Startup
From the DC input voltage, the chip's starting current supply is derived using the resistors R6 and R7.
Because of the low current drain of <85 uA, high-value resistors can be used. Series connection of the
resistors is necessary for reasons of insufficient dielectric strength of the individual resistors.
Mode of Operation
During operation, the VCC pin is supplied via a separate transformer winding with associated
rectification D2 and buffering C4, C13. The Resistor R8 is used for current limiting during the charging
of C4. In order to not exceed the maximum voltage at the VCC pin, an external zenerdiode D4 is
applied for voltage limitation.
Softstart
The Soft-Start function is realised by an internal resistor and the external capacitor C14.
Primary Current – CoolMOS
Clamping Network
R10, C12 and D3 dissipate the energy of the leakage inductance.
Limitation of primary current
The CoolMOS source current is sensed by an external shunt resistor R17. When the voltage at R17
exceeds the internal current-limit threshold, the gate driver is shut off immediately.
Seite 4 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Output Stage
Output Voltage
On the secondary side the power is coupled out via a fast-acting diode D1 with low forward voltage.
The capacitors C5, C9, C20 provide energy buffering, a filter L3, C23 reduces the output voltage ripple
considerably.
Storage capacitors C5, C9,and C20 are designed to have an internal resistance as small as possible
(ESR). This minimizes the output voltage ripple caused by the triangular current characteristic. The
output voltage level is set by resistors R1, R2.
Regulation
The output voltage is controlled using a type TL431 reference diode.
This device incorporates the voltage reference the error amplifier, and a driver stage. The
compensation network C1, C2, R1, R5 constitutes the external circuitry of the error amplifier of IC2.
This circuitry allows the feedback to be precisely matched to dynamically varying load conditions,
thereby providing stable control. The maximum current through the optocoupler diode and the voltage
reference is set by the resistors R3 and R4.
Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input of the
ICE2A365 control device. The optocoupler meets DIN VDE 884 requirements.
Design calculations for the components and the transformer were performed in accordance with the
Application Note “AN–SMPS–ICE2AXXX for OFF – Line Switch Mode Power Supplies”.
Seite 5 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Schematic:
Seite 6 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Component Legend:
Board Layout:
Component side shown
Seite 7 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Component List:
Part List
ICE2A365 Evaluation Board 16V/ 40W
Pos.
Part
1
BR1
2
C1
3
C2
4
C3
5
C4
6
C5
7
C6
8
C7
9
C8
10
C9
11
C12
12
C13
13
C14
14
C20
15
C22
16
C23
17
C24
18
C25
19
D1
20
D2
21
D3
22
D4
23
F1
24
IC1
25
IC3
26
IC2
27
L3
28
L5
29
R1
30
R2
31
R3
32
R4
33
R5
34
R6
35
R7
36
R8
37
R9
38
R10
39
R16
40
R17
41
R18
42
R20
43
TR1
44
TR1
45
D1
46
X1
47
X2
* = not assembled
Type
B500 C1500
330nF, 50V
1nF, 50V
150uF, 400V
68uF, 35V
1000uF, 35V
2,2nF, 50V
*
0,1uF, 275V, X2
*
2,2nF, 400V
100nF, 50V
1uF, 50V
1000uf, 35V
0,22uF, 275V, X2
470uF, 35V
2,2nF, 250V Y1
2,2nF, 250V Y1
DSS10-01A
1N4148
1N4937
ZPD18
Microfuse 3,15A
SFH617A-3X016
ICE2A365
TL431CLP
1uH, 3,7A
27mH, 0,9A
24k, 1%
4,3k, 1%
680R
1,2k
150k
430k
430k
4,7R
22R
39k, 2W
*
0,43R, 0,6W, 1%,
*
wire
E25 Coil Former
E25/13/7, 0,75 N27
Heatsink, 18K/W
Connector 2pol.
Connector 2pol.
19.09.2001
Grid
Ordering Code
Manuf.
5mm
5mm
10mm
2,5mm
5mm
5mm
B43501-A9157-M
B41821-A7476-M
KZE35VB1000MK25
B37979-G5222-J
Epcos
Epcos
Epcos
Epcos
(NCC) Alfatec
Epcos
15mm
B81130-C1104-M
7,5mm
5mm
5mm
5mm
15mm
5mm
12,5mm
12,5mm
5mm
10mm
10mm
10mm
5mm
B32520-C6222-K
B37987-F5104-K
B37984-M5105-K
KZE35VB1000MK25
B81130-C1224-M
KZE35VB470MJ20
WKP 2n2 M
WKP 2n2 M
Epcos
Epcos
Epcos
Epcos
(NCC) Alfatec
Epcos
(NCC) Alfatec
Wima
Wima
IXYS
Infineon
5mm
822LY-1R0M
B82732-R2901-B30
Componex
Epcos
10mm
10mm
10mm
10mm
10mm
10mm
10mm
10mm
10mm
10mm
10mm
10mm
see also Transformer Construction
FK224
Fischer
Seite 8 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Transformer Construction
Note:
The built-in transformer does not comply with EN60950 safety requirements
in respect of electrical isolation.
Seite 9 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Measurements:
Efficiency [%]
Efficiency
Frequency Reduction
100
90
80
70
60
50
40
30
20
10
0
0
5
10
15
20
25
30
35
40
110
100
90
80
70
60
50
40
30
20
10
0
5
10
15
20
25
30
35
40
Pout [W]
Pout [W]
[email protected]
[email protected]
[email protected]
Output Power Limitationvs Input Voltage
No-load Input Power
60
40
Pin [mW]
Pout [W]
50
30
20
10
0
85
100
150
200
250
[email protected]
400
350
300
250
200
150
100
50
0
265
0
50
100
150
200
250
300
Vacin [V]
Vacin[V]
References:
[1]
ICE2AXXX for OFF-Line Switch Mode Power Supplies
Application Note, Infineon Technologies
[2]
CoolSET-II
Off-line SMPS Current Mode Controller with High Voltage CoolMOS on Board
Datasheet, Infineon Technologies
Seite 10 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
Revision History
Application Note AN-EVAL-ICE2A365-1
Actual Release: V1.2 Date:16.08.2001
Previous Release: V1.1
Page of
actual
Rel.
Page of
Subjects changed since last release
prev. Rel.
12
12
14
12
First Issue
Part List
For questions on technology, delivery and prices please contact the Infineon Technologies Offices in Germany or the Infineon
Technologies Companies and Representatives worldwide:
see the address list on the last page or our webpage at
http://www.infineon.com
CoolMOS and CoolSET are trademarks of Infineon Technologies AG.
We listen to Your Comments
Any information within this dokument that you feel is wrong, unclear or missing at all?
Your feedback will help us to continously improve the quality of this dokument.
Please send your proposal (including a reference to this dokument) to:
[email protected]
Edition 2000--05--09
Published by Infineon Technologies AG,
St.-Martin-Strasse 53,
D-81541 München
© Infineon Technologies AG 2000.
All Rights Reserved.
Attention please!
The information herein is given to describe certain components and shall not be considered as warranted characteristics.
Terms of delivery and rights to technical change reserved.
We hereby disclaim any and all warranties, including but not limited to warranties of non-infringement, regarding circuits, descriptions and charts
stated herein.
Infineon Technologies is an approved CECC manufacturer.
Information
For further information on technology, delivery terms and conditions and prices please contact your nearest Infineon Technologies Office in
Germany or our Infineon Technologies Representatives worldwide (see address list).
Warnings
Due to technical requirements components may contain dangerous substances. For information on the types in question please contact your
nearest Infineon Technologies Office.
Infineon Technologies Components may only be used in life-support devices or systems with the express written approval of Infineon
Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system, or to affect the
safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body, or to support
and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be
endangered.
Seite 11 von 12
AN-EVAL-ICE2A365-1
V1.2
40W Evaluation Board with ICE2A365
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AN-EVAL-ICE2A365-1
V1.2
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