Design Note for Charger and Adapter 10W

Version 1.0 , August 2001
Design Note
DN-Charger_Adapter 10W
CoolSET
10W Charger / Adapter with ICE2A165
Author:
Harald Zöllinger
Published by Infineon Technologies AG
http://www.infineon.com
Power Management & Supply
N e v e r
s t o p
t h i n k i n g
10W Board with ICE2A165
Contents:
10W Board with ICE2A165 ...................................................................................... 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
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V1.0
10W Board with ICE2A165
10W Board with ICE2A165
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 ICE2A165 chip used 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 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.
Fig: board
Other output voltages can also be implemented very easily by simple modification of the transformer
and the output circuitry.
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V1.0
10W Board with ICE2A165
Technical specifications:
Input Voltage Range
Input Frequency
Output Voltage
Output Power
Line Regulation (85 ...270V)
Load Regulation (10% ... 100%)
Efficiency
Output Ripple Voltage
Input Power @ noload
Switching Frequency
Temperature Range
85 ... 270V AC
50, 60 Hz
5V +-5%
14W
< 1%
< 1%
> 70%
< 100mV
<400mW
21...100 kHz
0 ... 70°C
Circuit description:
Introduction
The ICE2A165 chip used here was specially designed for 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 input fuse F1 as overcurrent protection as well as choke L5 and X2
capacitor C8 as radio interference suppressors. After bridge rectifier BR1 and input capacitor C3, a
voltage of 90 to 380 VDC depending on input voltage is available.
ICE2A165 Power Supply
Startup
From this voltage, the chip's starting current supply is derived using resistors R6 and R7. Because of
the low current drain of <55 uA, high-value resistors can be used. Series connection of the resistors is
necessary for reasons of dielectric strength of the individual resistors.
Operation Mode
During operation, the VCC pin is supplied via a separate transformer winding with associated
rectification D2 and buffering C4, C13. Resistor R8 is used for current limiting during charging of C4.
In order not to exceed the maximum voltage at VCC pin an external zenerdiode D4 limits this voltage.
During noload condition the switching frequency is reduced down to 21kHz in order to reduce the
switching losses.
Softstart
The Soft-Start function is realised by an internal resistor and the external capacitor C14.
Primary Current – CoolMOS
Snubber Network
R10, C12 and D3 are dissipate the energy of the leakage inductance.
Limitation of primary current
The CoolMOS source current is sensed with an external shunt resistor R17. When the voltage at R17
exceeds the internal Current-Limit threshold the gate driver is shut off immediately.
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10W Board with ICE2A165
Output Stage
Output Voltage
Power is coupled out on the secondary side via a fast-acting diode D1 with low forward voltage.
Capacitor C5 performs energy buffering, a following filter L3, C9 considerably reduces the output
voltage ripple.
Storage capacitor C5 is designed to exhibit as small an internal resistance as possible (ESR) in order
to minimize the output voltage ripple caused by the triangular current characteristic. The output
voltage is set with resistors R1, R2.
Regulation
The output voltage is controlled using a type TL431 reference diode.
This device incorporates the voltage reference as well as the error amplifier and a driver stage.
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 using resistors R3, R4.
Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input of the
ICE2A165 control device. The optocoupler used meets DIN VDE 884 requirements.
Design calculations for the components and the transformer were performed in accordance with
Application Note “AN–SMPS–ICE2AXXX for OFF – Line Switch Mode Power Supplies”.
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10W Board with ICE2A165
Schematic:
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DN-Charger_Adapter 10W
V1.0
10W Board with ICE2A165
Component Legend:
Board Layout:
Component side shown
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DN-Charger_Adapter 10W
V1.0
10W Board with ICE2A165
Component List:
Part List
ICE2A165 Evaluation Board 5V/ 10W
Pos.
Part
1
BR1
2
C1
4
C2
5
C3
6
C4
7
C5
8
C6
9
C7
10
C8
11
C9
12
C12
13
C13
14
C14
15
D1
16
D2
17
D3
18
D4
19
F1
20
IC1
21
IC11
22
IC2
23
L3
24
L5
25
R1
26
R2
27
R3
28
R4
29
R5
30
R6
31
R7
32
R8
33
R9
34
R10
35
R16
36
R17
37
R18
38
TR1
39
TR1
40
X1
41
X2
* = not assembled
Type
B500 C1500
470nF, 50V
10nF, 50V
47uF, 400V
22uF, 50V
1000uF, 25V
4,7nF, 50V
2,2nF,250V, Y1
0,1uF, 275V, X2
1000uF, 25V
1nF, 400V
100nF, 50V
220nF, 50V
SB540
1N4148
1N4937
ZPD18
Microfuse 3,15A
SFH617A-3X016
ICE2A165
TL431CLP
1uH, 3,7A
27mH, 0,4A
4,7k, 1%
4,7k, 1%
180R
1k
4,7k
360k
360k
4,7R
22R
100k, 1W
*
1,4R, 0,6W, 1%,
*
E20 Coil Former
E20/10/6, 0,5 N27
Connector 2pol.
Connector 2pol.
8 of 12
07.08.2001
Comment
DN-Charger_Adapter 10W
V1.0
10W Board with ICE2A165
Transformer Construction
Core Material: E20/10/6; N27
gap: 0,5mm
Al = 103nH
Lp = 692uH
Coil former: horizontal version
41 turns 0,25 mm
5 turns 2 x 0,8mm
11 turns 0,25 mm
1/2 Prim.
Pin 1
Pin 2
Sec .
Pin 8
Pin 10
Aux.
Pin 5
Pin 4
1/2 Prim
41 turns 0,25 mm
Pin 2
Pin 3
center
meens one layer Makrofol
Primary winding
41 + 41 turns
Aux. winding
11
turns
Secondary winding 5
turns
Top view
0,25 mm Ø
0,25 mm Ø
2 x 0,80 mm Ø
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
with triple Insulation
Pin 10
Pin 9
Pin 8
Pin 7
Pin 6
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DN-Charger_Adapter 10W
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10W Board with ICE2A165
Measurements:
No-load Input Power
Pin [mW]
Efficiency [%]
Efficiency
100
90
80
70
60
50
40
30
20
10
0
0
1
2
3
4
5
6
7
8
9
10
50
Pout [W]
[email protected]
400
350
300
250
200
150
100
50
0
100
150
200
250
300
Vacin [V]
[email protected]
Max. Output Power Vs Input Voltage
16
14
Power
12
10
8
6
4
2
0
85
100
150
200
230
270
Voltage
Note:
The built-in transformer does not comply with EN60950 safety requirements
in respect of electrical isolation.
References:
[1]
ICE2AXXX for OFF-Line Switch Mode Power Supplies
Application Note, Infineon Technologies
[2]
CoolSET-II
Off-line SMPS Current Mode Controller with 650V/800V CoolMOS on Board
Datasheet, Infineon Technologies
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DN-Charger_Adapter 10W
V1.0
10W Board with ICE2A165
Revision History
Application Note AN-EVAL-ICE2A165-1
Actual Release: V1.1 Date:07.08.2001
Previous Release: V1.0
Page of
actual
Rel.
Page of
Subjects changed since last release
prev. Rel.
12
12
12
12
First Issue
Part List, Transformer Construction
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.
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DN-Charger_Adapter 10W
V1.0
10W Board with ICE2A165
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DN-Charger_Adapter 10W
V1.0
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