Design Note for Charger and Adapter 40W

Version 3.0 , August 2001
Design Note
DN-Charger_Adapter 40W-1
CoolSET
40W 12V Board with ICE2A365
Author:
Rainer Kling
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
40W Charger Adapter using ICE2A365
Table of Contents
INTRODUCTION ..................................................................................................................................... 2
LIST OF FEATURES............................................................................................................................... 3
POWER SUPPLY SPECIFICATION ....................................................................................................... 3
SCHEMATIC............................................................................................................................................ 4
PCB LAYOUT.......................................................................................................................................... 4
DESCRIPTION ........................................................................................................................................ 5
Introduction ....................................................................................................................................... 5
Line Input .......................................................................................................................................... 5
Startup .............................................................................................................................................. 5
Operation Mode ................................................................................................................................ 5
Softstart ............................................................................................................................................ 5
Snubber Network .............................................................................................................................. 5
Limitation of primary current ............................................................................................................. 5
Output Voltage.................................................................................................................................. 5
Regulation......................................................................................................................................... 5
BILL OF MATERIAL ............................................................................................................................... 6
TRANSFORMER CONSTRUCTION DOCUMENTATION...................................................................... 7
REFERENCES ........................................................................................................................................ 9
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Introduction
This document is an engineering report that describes an universal input power supply designed in a
typical off line flyback converter topology that utilizes the ICE2A365 CoolSETä
ä. The application
operates in discontinous current mode using the burst mode during standby condition. The board has
one output voltage with secondary regulation.
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 auto restart mode.
The integrated energy saving concept causes a very low standby power during no load and light load
condition.
This type of switch mode power supply is also suitable as an AC/DC power supply for laptops,
palmtops, battery chargers, video games, satellite decoders, settop and cable boxes, color TV etc. in
the power range up to approx. 60 W.
The switch mode power supply ICE2A365 chip used is a current-controlled pulse width modulator with
an internal CoolMOS
 power switch.
Figure 1 Charger_Adapter 40W
This board was designed to allow testing and demonstrates the basic performance features and the
increased power capability of the new ICE - CoolSETä
ä.
This document contains the power supply specification, schematic, bill of materials and the
transformer construction documentation. Typical operating characteristics are presented at the rear of
the report and consist of performance curves and scope waveforms.
Note:
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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List of Features
Feature
CoolSETä Device ICE2A365
External Sense
Adjustable Softstart
Modulated Gatedrive
Over Load Protection with auto restart
Over Current Protection with auto restart
Over Temperature Shut Down with auto restart
Open Loop Protection with auto restart
Under Voltage Lock Out with auto restart
1
Drain Source Voltage 650V
Frequency Reduction
Internal Leading Edge Blanking
100 kHz working frequency
DIP8 Package
Standby Power according to European Comission
Table 1 – List of Features
Power Supply Specification
Description
Input Section
Input Voltage
Line Regulation (85...270V)
Input Frequency
3
No Load Input Power (90VAC)
2
No Load Input Power (230VAC)
Output Section
Output Voltage
Output Voltage Ripple (90VAC)
Output Current
Output Power
Total Regulation
Load Regulation (10...100%)
Efficiency (90VAC)
Efficiency (270VAC)
Environmental
Conducted EMI
Ambient Temperature
Symbol
Min
Typ
Max
Units
VACIN
85
270
f
47
115/230
<1
50/60
200
0.6
VAC
%
Hz
mW
W
VOUT
VRipple
IOUT
POUT
11.5
12
100
3.4
40
±2
<1
81
85
12.5
3.38
0
η
η
TA
0
25
64
3.42
51
50
VDC
mVP-P
ADC
W
%
%
%
%
EN55022B
°C
Table 2 – Power Supply Specification
1
2
VDSBR at Tj = 110°C
Burst Mode
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Schematic
Figure 2 – 40W 12V ICE2A365 Power Supply Schematic
PCB Layout
Figure 3 – PCB Layout Component Side shown
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Description
Introduction
The Charger_Adapter 40W is a low cost flyback switching power supply using the ICE2A365
integrated circuit from the CoolSETä-F2 family. The circuit shown in Figure 2 details a 12V, 40W
supply that operates from an line input voltage range of 85 to 265VAC, suitable for applications
requiring either an open frame supply or an enclosed adapter.
Line Input
The AC line input side comprises of an input fuse F1 as line input over current protection as well as
choke L5 and the X2 capacitor C8 as radio interference suppressors. The NTC resistor R20 limits the
switch on peak current. After bridge rectifier BR1 and input capacitor C3, a voltage of 90 to 380 VDC,
depending on input voltage, is available. Only a 150 µF input capacitor is required due to the wider
duty cycle DCMAX of the ICE-F2-family.
Startup
From this voltage, the chip starting the current supply is derived using resistors R6 and R7. Because
of the very low start up current of typically 27µA, a high-value resistor can be used.
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 the charging of
C4. In order not to exceed the maximum voltage at VCC pin an external zener diode D4 limits this
voltage. During light load condition (POUT = W) the switching frequency is reduced down to 21kHz in
order to reduce the switching losses.
Note:
During no load condition, the board creates a burst mode situation to improve the standby power.
Softstart
The Soft-Start function is realized by an internal resistor and the adjustable external capacitor C14.
Snubber Network
The network R10, C12 and D3 clamp the DRAIN voltage spike caused by transformer leakage
inductance to a safe value below the drain source break down voltage VDSBR = 650V maximum.
Limitation of primary current
The CoolMOSä drain source current is sensed via external shunt resistors R17. The very accurate
value of the shunt due to the two parallel resistors improve the peak power limitation shown in the
curve peak power limitation in the rear of this report.
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 C23 with a choke L3 and C23 considerably
reduces the output voltage ripple. Storage output 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
via resistor R9 and capacitor C6 of the ICE2A365 control device. The optocoupler used meets DIN
VDE 884 requirements.
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Bill of Material
ICE2A365 Charger Adapter 12V/ 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
IC2
26
IC3
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
680nF, 50V
1,2nF, 50V
150µF, 400V
68µF, 35V
1000µF, 35V
2,2nF, 50V
*
0,1µF, 275V, X2
1000µF, 35V
2,2nF, 400V
100nF, 50V
1µF, 50V
1000µF, 35V
0,22µF, 275V, X2
470µF, 35V
2,2nF, 250V Y1
2,2nF, 250V Y1
DSS10-01A
1N4148
1N4937
ZPD18
Microfuse 3,15A
SFH617A-3X016
TL431CLP
ICE2A365
1µH, 3,7A
27mH, 0,9A
18k, 1%
4,7k, 1%
510R
1,5k
44k
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.
05.11.2001
Grid
5mm
5mm
10mm
2,5mm
5mm
5mm
15mm
5mm
7,5mm
5mm
5mm
5mm
15mm
5mm
12,5mm
12,5mm
5mm
10mm
10mm
10mm
5mm
Ordering Code
Manuf.
B43501-A9157-M
B41821-A7476-M
KZE35VB1000MK25
B37979-G5222-J
Epcos
Epcos
Epcos
Epcos
(NCC) Alfatec
Epcos
B81130-C1104-M
KZE35VB1000MK25
B32520-C6222-K
B37987-F5104-K
B37984-M5105-K
KZE35VB1000MK25
B81130-C1224-M
KZE35VB470MJ20
WKP 2n2 M
WKP 2n2 M
Epcos
(NCC) Alfatec
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
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Transformer Construction Documentation
Note:
The built-in transformer does not comply with EN60950 safety requirements
in respect of electrical isolation.
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Change service
Issue status
1.0
2.0
3.0
Changes
First issue
Page 6, BOM Pos. 4 / 10 / 13
Page 7 Transformerdata
Page 6, BOM Pos. 25 and 26
8 of 11
Date
30.08.2001
01.10.2001
05.11.2001
Charger_Adapter 40W
V3.0
40W Charger Adapter using ICE2A365
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
Revision History
Application Note AN-Charger_Adapter
Actual Release: 3.0 Date: 2001-11-05
Page of
actual
Rel.
--
40W-03
Previous Release: V1.0
Page of
Subjects changed since last release
prev. Rel.
--
See change service
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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/CoolSET
CoolMOS and CoolSET are trademarks of Infineon Technologies AG.
Edition 2001-08--30
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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Charger_Adapter 40W
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