Design Note for Server Standby

Version 1.0 , November 2001
Design Note
DN-Server Standby-1
CoolSET
20W Server Standby with ICE2A265
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
20W Server Standby with ICE2A265
Table of Contents
INTRODUCTION ..................................................................................................................................... 3
LIST OF FEATURES............................................................................................................................... 4
POWER SUPPLY SPECIFICATION ....................................................................................................... 4
SCHEMATIC............................................................................................................................................ 5
DESCRIPTION ........................................................................................................................................ 6
Introduction ....................................................................................................................................... 6
PRIMARY SIDE ........................................................................................................................................ 6
Line Input .......................................................................................................................................... 6
Startup .............................................................................................................................................. 6
Operation Mode ................................................................................................................................ 6
Softstart ............................................................................................................................................ 6
Snubber Network .............................................................................................................................. 6
Limitation of primary current ............................................................................................................. 6
Feedback Network............................................................................................................................ 6
SECONDARY SIDE................................................................................................................................... 7
Output Voltage.................................................................................................................................. 7
Regulation......................................................................................................................................... 7
EMI FILTER ............................................................................................................................................ 7
PCB LAYOUT.......................................................................................................................................... 8
BILL OF MATERIAL EVALS-ICE2A265 ................................................................................................ 9
TRANSFORMER CONSTRUCTION DOCUMENTATION.................................................................... 10
PERFORMANCE DATA........................................................................................................................ 11
EFFICIENCY .......................................................................................................................................... 11
FREQUENCY REDUCTION ...................................................................................................................... 12
NO-LOAD INPUT POWER ........................................................................................................................ 12
REGULATION AND POWER LIMITING ....................................................................................................... 13
OUTPUT VOLTAGE DURING STARTUP ...................................................................................................... 15
STARTUP BEHAVIOR SOFTSTART PHASE................................................................................................ 16
REFERENCES ...................................................................................................................................... 17
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Introduction
This document is an engineering report that describes a universal input power supply designed in a
typical off line flyback converter topology that utilizes the ICE2A265 CoolSETä
ä. The application
operates in discontinous current mode using the normal 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 a DC standby power supply for PCs.
The switch mode power supply ICE2A265 chip used is a current-controlled pulse width modulator with
an internal CoolMOS
 power switch.
Figure 1 Server Standby
This board was designed to allow testing and demonstrates the basic performance features of
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 ICE2A265
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 the European Commission
Table 1 – List of Features
Power Supply Specification
Description
Input Section
Input Voltage
Line Regulation (120...380V)
Input Frequency
3
No Load Input Power (155VAC)
2
No Load Input Power (325VAC)
Output Section
Output Voltage
3
Output Voltage Ripple (380VAC)
Output Current
Output Power
Total Regulation
Load Regulation (10...100%)
4
Efficiency (120VAC)
Environmental
Conducted EMI
Ambient Temperature
Symbol
Min
Typ
Max
Units
VDCIN
120
380
f
47
155/325
<1
50/60
0.23
0.32
VDC
%
Hz
W
W
VOUT
VRipple
IOUT
POUT
4.75
5.25
4.05
25
η
5.0
0.06
4.00
20
±2
<1
74
TA
0
25
90
3.95
0
64
VDC
VP-P
ADC
W
%
%
%
°C
Table 2 – Server Standby Specification
1
VDSBR at Tj = 110°C
Burst Mode
3
At nominal load
2
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Schematic
Figure 2 Server Standby Schematic
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Description
Introduction
The Server Standby is a low cost flyback switching power supply using the ICE2A265 CoolSET
integrated circuit from the CoolSETä-F2 family. The circuit shown in Figure 2 details a 5.0V, 20W
Server Standby that operates from an input voltage range of 120 to 380 VDC, suitable for applications
requiring either an open frame supply or an enclosed surrounding.
Primary Side
Line Input
Just a ceramic capacitor (C8) is needed for the input voltage stage used as radio interference
suppressors.
Startup
During the startup phase, the chip supply capacitor C4 will be charged by resistors R6 and R7.
Because of the very low start up current of typically 27µA, high-value resistors 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 no load condition (POUT = 0W) the switching frequency is reduced down to 21kHz in
order to reduce the switching losses for a low 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 resistor R17. The very accurate
value of the shunt improves the peak power limitation shown in the curve peak power limitation in the
rear of this report.
Feedback Network
Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input via
resistor R9 and capacitor C6 of the ICE2A265 control device. The optocoupler used meets DIN VDE
884 requirements.
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Secondary Side
Output Voltage
Power is coupled out on the secondary side via a fast-acting diode D1 with low forward voltage.
Capacitors C5, C17 and C20 perform energy buffering, a following filter C9 with one serial choke L3
considerably reduces the output voltage ripple. Storage output capacitors C5, C17 and C20 are
designed to exhibit a low internal resistance as possible (ESR) in order to minimize the output voltage
ripple caused by the triangular current characteristic. The output voltage is set by the voltage divider
R1 and R2. The ceramic capacitor C19 reduces high voltage spikes at the output stage. R20 leads to
a safety operation in normal mode during no load condition.
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,
R1and 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 and R4. Optocoupler IC1 is used for floating transmission of the control signal to the
“Feedback” input via resistor R9 and capacitor C6 of the ICE2A265 control device. The optocoupler
used meets DIN VDE 884 requirements.
EMI Filter
To reduce negative EMI effects, two Y capacitors (C18 & C7) are set in parallel to the transformer.
Note:
Place the Y capacitor as close as possible to the transformer.
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PCB Layout
Figure 3 PCB layout component side shown
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Bill of Material Server Standby
Pos.
Part
1
2
3
4
C1
C2
C4
C5, C17,
C20
C6
C7, C18
C8
C9
C12
C13, C19
C14
D1
D2
D3
D4
IC1
IC3
IC2
L3
R1, R2
R3
R4
R5
R6
R7
R8
R9
R10
R17
R18
R20
TR1
TR1
X1, X2
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Type
Ordering Code
1
1
1
3
470nF, 50V
22nF, 50V
22uF, 50V
470uF, 35V
B37984-M5474-K
B37979-G5223-J
B41821-A6226-M
KZE 35VB470MK20
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2.2nF, 50V
1nF,250V, Y1
0.1uF, 275V, X2
470uF, 25V
1nF, 400V
100nF, 50V
68nF, 50V
MBR745
1N4148
1N4937
ZPD18
SFH617A-3X016
ICE2A265
TL431CLP
1uH, 3,7A
4.7k, 1%
180R
1.2k
2.7k
680k
680k
6.8R
22R
68k, 1W
0.82R, 0.6W, 1%,
*
3.3k
E20 Coil Former
E20/10/6, 0,5 N27
Connector 2pol.
B37979-G5222-J
1
1
1
2
B81133-D1104-M
KZE 25VB1000MK20
B32520-C6102-K
B37987-F5104-K
B37987-F5224-K
Manuf.
Epcos
Epcos
Epcos
(NCC) Alfatec
Epcos
Epcos
(NCC) Alfatec
Epcos
Epcos
Epcos
Infineon
Infineon
822LY-1R0M
Componex
see also Transformer Construction
* Only for multiple output boards
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Transformer Construction Documentation
Figure 4 Transformer Construction Data
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Performance Data
Efficiency
Efficiency versus Input Voltage at nominal Load
100
90
80
Efficiency [%]
70
60
50
40
30
20
10
0
115
165
215
265
315
365
20
25
Input Voltage (VDC)
Efficiency @ nominal load and Tj=25°C
Figure 5 – Efficiency versus Line Input Voltage at Nominal Load
Efficiency versus Output Power
80
Efficiency [%]
75
70
65
60
55
50
0
5
10
15
Output Power [W]
Efficiency @ Vdcin = 120V
Efficiency @ Vdcin = 350V
Figure 6 – Efficiency versus Output Power
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Frequency Reduction
Frequency versus Output Power
120
100
80
60
40
20
0
0
5
10
15
20
Output Power [W]
Vdcin = 120V
Vdcin = 350V
Figure 7 – Frequency versus Output Power
No-load input power
No Load Input Power versus Line Voltage
(Normal Mode)
1,0
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0,0
100
150
200
250
300
350
DC Input Voltage [V]
Input Power @ No Load (Pout = 0W)
Figure 8 – No-load Input Power versus Line Input Voltage in Burst Mode
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Regulation and Power Limiting
Output Voltage versus Line Input Voltage @ nominal Load
6,00
5,00
4,00
3,00
2,00
1,00
0,00
100
150
200
250
300
350
DC Input Voltage [V]
Output Voltage @ nominal load
Figure 9 – Output Voltage versus Line Input Voltage @ Nominal Load
Load Regulation
6
5
4
3
2
1
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
Output Current [ADC]
Output Voltage @ VDcin = 325V
Figure 10 – Load Regulation
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Peak Power versus Input Voltage
30
25
20
15
10
5
0
100
150
200
250
300
350
DC Input Voltage [V]
Peak Power
Figure 11 – Peak Power Limitation versus Line Input Voltage
Loadjump from 10% up to 100% Load
4,5
4
3,5
3
2,5
2
1,5
1
0
0,0005
0,001
0,0015
0,002
0,0025
0,003
0,0035
0,004
Time [s]
Vfb @ 120Vdcin
Vfb @ 380Vdcin
Figure 12 – Feedbackvoltage during Loadjump from 10% up to 100% Load
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Output voltage during startup
Vout during Startup @ Vdcin = 120V
6
16
VC4
14
5
12
4
10
3
8
6
2
4
1
2
VOUT
0
0
0
0,005
0,01
0,015
0,02
0,025
0,03
0,035
0,04
Time [s]
Vout
Vcc
Figure 13 – Startup with full Load Condition at VDCIN = 120V, VC4 and VOUT
Vout during Startup @ Vdcin = 380V
20
6
18
5
16
VC4
14
4
12
3
10
2
8
6
1
VOUT
4
0
0
0,005
0,01
0,015
0,02
0,025
0,03
-1
0,035
2
0,04
0
Time [s]
Vout
Vcc
Figure 14 – Startup with Full Load Condition at VDCIN = 380V, VC4 and VOUT
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Startup Behavior Softstart Phase
Startup @ 120Vdc and nominal Load Condition
VFB
7
6
20
18
VC4
16
5
14
4
12
VSS
3
10
Values at the End of the
Softstart Phase
Vc4 = 15.2V
VFB = 6.4V
VSS = 4.0V
2
1
0
0,015
0,017
0,019
0,021
0,023
0,025
0,027
0,029
-1
8
6
4
2
0
Time [s]
Vfb
Vss
Vcc
Figure 15 Startup Behavior at Nominal Load Condition @ VDCIN = 120V
Startup@ Vacin = 380Vdc and nominal Load Condition
VFB
7
20
18
6
16
5
VC4
14
4
12
3
Values at the End of the
Softstart Phase
Vc4 = 15.6V
VFB = 4.2V
VSS = 4.0V
VSS
2
1
0
0,015
0,017
0,019
0,021
0,023
0,025
0,027
-1
0,029
10
8
6
4
2
0
Time [s]
Vfb
Vss
Vcc
Figure 16 Startup Behavior at Nominal Load Condition @ VDCIN = 380V
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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-Server Standby-1
Previous Release: 1.0
Actual Release: 1.0
Date: 23.11.2001
Page of
actual
Rel.
Date:23.11.2001
Page of
Subjects changed since last release
prev. Rel.
Note:
The built-in transformer does not comply with EN60950 safety requirements
in respect of electrical isolation.
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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
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 2001-11--23
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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PL-03-821 Warszawa
T (+48)22-8 70 91 50
Fax (+48)22-8 70 91 59
ROK
Siemens Ltd.
Asia Tower,10th Floor
726 Yeoksam-dong,Kang-nam Ku
CPO Box 3001
Seoul 135-080
T (+82)2-5 27 77 00
Fax (+82)2-5 27 77 79
RUS
INTECH electronics
ul.Smolnaya,24/1203
RUS-125 445 Moskva
T (+7)0 95 -4 51 97 37
Fax (+7)0 95 -4 51 86 08
S
Siemens Components Scandinavia
Österögatan 1,Box 46
S-164 93 Kista
T (+46)8-7 03 35 00
Fax (+46)8-7 03 35 01
Email:
[email protected]
19 of 19
VRC
Infineon Technologies
Hong Kong Ltd.
Beijing Office
Room 2106,Building A
Vantone New World Plaza
No.2 Fu Cheng Men Wai Da Jie
Jie
100037 Beijing
T (+86)10 –68 57 90 -06,-07
Fax (+86)10 -68 57 90 08
Infineon Technologies
Hong Kong Ltd.
Chengdu Office
Room14J1,Jinyang Mansion
58 Tidu Street
Chengdu,
Sichuan Province 610 016
T (+86)28-6 61 54 46 /79 51
Fax (+86)28 -6 61 01 59
Infineon Technologies
Hong Kong Ltd.
Shanghai Office
Room1101,Lucky Target Square
No.500 Chengdu Road North
Shanghai 200003
T (+86)21-63 6126 18 /19
Fax (+86)21-63 61 11 67
Infineon Technologies
Hong Kong Ltd.
Shenzhen Office
Room 1502,Block A
Tian An International Building
Renim South Road
Shenzhen 518 005
T (+86)7 55 -2 28 91 04
Fax (+86)7 55-2 28 02 17
ZA
Siemens Ltd.
Components Division
P.O.B.3438
Halfway House 1685
T (+27)11-6 52 -27 02
Fax (+27)11-6 52 20 42
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