Design Note for DVD Application 35W

Version 1.0 , Nov. 2001
Design Note
DN-EVALMF2ICE2A265-1
CoolSET
35W DVD Power Supply with ICE2A265
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
35W DVD Power Supply ICE2A265
Contents:
35W Multi Output Evaluation Board for DVD Supply with ICE2A265 ........................................... 3
Technical specifications: .................................................................................................................. 4
Circuit description: ............................................................................................................................ 4
Schematic: .......................................................................................................................................... 6
Board Layout; Component Legend: ................................................................................................ 7
Component List: ................................................................................................................................ 8
Transformer Construction: ............................................................................................................... 9
Mesurements:................................................................................................................................... 10
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
35W Multi Output Evaluation Board for DVD Supply with ICE2A265
The board described here was designed as a typical power supply in flyback converter topology with
six output voltages and secondary control. This type of switch mode power supply is particularly
suitable as an AC/DC power supply for DVD supply, video games, satellite decoders, etc.
The switch mode power supply ICE2A265 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 auto restart mode.
Fig: Evaluation board
Note:
Other output voltages can also be implemented very easily by a simple modification of the
transformer and the output circuitry.
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Technical specifications:
Input Voltage Range
Input Frequency
Output Voltage 1
Output Voltage 2
Output Voltage 3
Output Voltage 4
Output Voltage 5
Output Voltage 6 (isolated)
Line Regulation (190 ...270V)
Load Regulation (10% ... 100%)
Efficiency
Switching Frequency
Temperature Range
190 ... 264V AC
50, 60 Hz
+5V +-3%; 1,5A peak
+16V +-8%; 1,5A peak
+12V +-8%;
70mA
-12V +-8%;
70mA
-22V +-8%;
50mA
+5V +-5%;
40mA
< 1% @ 5V
< 1% @ 5V
>80%
21....100 kHz
0 ... 50°C
Circuit description:
Introduction
The ICE2A265 chip used here was particularly designed for the use in flyback converters. As shown
on the circuit diagram (p. 6), 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 L1 and X2capacitors C13 and C18 as radio interference suppressors. After the bridge rectifier D12...D15 and the
input capacitor C1, a voltage of 200 to 380 VDC depending on input voltage is available.
ICE2A265 Power Supply
Startup
From the DC input voltage, the chip's starting current supply is derived using the resistors R6 and
diode D11. 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 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 D10 and buffering C2, C21. The Resistor R8 is used for current limiting during the
charging of C2. In order to not exceed the maximum voltage at the VCC pin, an external zenerdiode
D9 is applied for voltage limitation.
Softstart
The Soft-Start function is realised by an internal resistor and the external capacitor C14.
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Primary Current – CoolMOS
Clamping Network
R12, C19 and D1 dissipate the energy of the leakage inductance.
Limitation of primary current
The CoolMOS source current is sensed by an external shunt resistor R7. When the voltage at R7
exceeds the internal current-limit threshold, the gate driver is shut off immediately.
Output Stage
On the secondary side the power is coupled out via a fast-acting diodes D2, D3, D4, D5, D7, D8 with
low forward voltage. The capacitors C3, C4, C5, C9, C11, C26 provide energy buffering, a filter L2,
C6; L3, C7; L4, C8; L5, C10; L6, C12 reduces the output voltage ripple considerably.
All storage capacitors 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 for the +5V output.
Regulation
The output voltage is controlled using a type TL431 IC2 reference diode.
This device incorporates the voltage reference the error amplifier, and a driver stage. The
compensation network C15, C16, 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 U1 is used for floating transmission of the control signal to the “Feedback” input of the
ICE2A265 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”.
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Schematic:
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Board Layout; Component Legend:
Component side shown
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Component List:
Part List
35W DVD Supply
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
C1
C2
C3, C4, C6,
C7
C5, C9, C26
C8, C10, C27
C11
C12
C13, C18
C14, C15
C16, C20
C17
C19
C21, C22,
C23, C24,
C25, C30, C31
C28, C29,
C34, C35
C33
D1
D2
D8
D3, D4, D5,
D7
D9
D10
Pcs.
Type
1
47uF, 400V
1
47uF, 35V
Grid
10mm
2,5mm
Ordering Code
B43501B41821-
Manuf.
EPCOS
EPCOS
4
1000uF, 25V
5mm
KZE25VB1000MK20
NCC
3
3
1
1
2
2
2
5mm
5mm
5mm
5mm
15mm
5mm
5mm
KZE25VB220MH11
KZE25VB100MF11
KZE35VB220MH15
KZE35VB150MH11
B81130B37984B37979-
NCC
NCC
NCC
NCC
EPCOS
EPCOS
EPCOS
1
220uF, 25V
100uF, 25V
220uF, 35V
150uF, 35V
0,1uF, 275V, X2
470nF, 50V
2,2nF, 50V
*
2,2nF, 400V
7,5mm
B32520-
EPCOS
7
100nF, 50V
5mm
B37987-
EPCOS
5mm
B37984-
EPCOS
4
1uF, 50V
1
1
2
1
1nF, 250V, Y1
1N4937
MUR420
MBR540
12,5mm
10mm
15mm
15mm
4
MUR120
12,5mm
1
1
BZX 79/B18
1N4148
22
D11, D12,
D13, D14, D15
5
1N4007
23
24
25
26
27
28
29
D16, D18
D17
D19
F1
IC2
IC3
U1
2
1
1
1
1
1
1
*
*
*
Fuse 3,15A
TL431CLP
ICE2A265
SFH617A-3X016
30
K1, K2, K3,
K4, K5, K6, K7
7
Connector 2
3
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
wire
27mH, 0,9A
1uH, 3,7A
2,2uH, 0,6A
4k92, 1%
4k7, 1%
750R
1,2k
47k
330k
0,68R 1%
4,7R
22R
47k
SMT1 coil former
ED29/ 0,98mm gap
31
Br1, Br2, Br3
32
L1
33
L2, L3, L4
34
L5, L6
35
R1
36
R2
37
R3
38
R4
39
R5
40
R6
41
R7
42
R8, R11
43
R9
44
R12
45
TR1
46
TR1
* = not assembled
08.06.2003
WKP 1n M
Wima
10mm
10mm
12,5mm
10mm
10mm
10mm
SOT-54
DIP8
2,5mm
Infineon
10mm
5mm
10mm
10mm
10mm
10mm
10mm
10mm
10mm
12,5mm
10mm
10mm
12,5mm
4mm
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B82732822LY-1R0M
B82141-
see also Winding
Instruction
EPCOS
Componex
EPCOS
Orega
Orega
DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Transformer Construction:
9 of 12
DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Mesurements:
10 of 12
DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
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
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DN-EVALMF2ICE2A265 V1.0
35W DVD Power Supply ICE2A265
Revision History
Design Note DN-EVALM-ICE2A265-1
Actual Release: V1.0 Date: 11.04.2002
Previous Release: V1.0
Page of Page of Subjects changed since last release
prev.
actual
Rel.
Rel.
12
-New 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:
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Edition 2000-05--15
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-EVALMF2ICE2A265 V1.0
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