Version 2.3, August 2002 Design Note DN-EVALSF2-ICE2B765P-1 CoolSET 80W 24V Design Note for Adapter using ICE2B765P Author: Rainer Kling Published by Infineon Technologies AG http://www.infineon.com/CoolSET Power Management & Supply N e v e r s t o p t h i n k i n g 80W 24V Adapter with ICE2B765P on Board Table of Contents TABLE OF CONTENTS.......................................................................................................................... 1 INTRODUCTION ..................................................................................................................................... 2 Application........................................................................................................................................ 2 CoolSET ........................................................................................................................................ 2 LIST OF FEATURES .............................................................................................................................. 3 POWER SUPPLY SPECIFICATION....................................................................................................... 3 SCHEMATIC ........................................................................................................................................... 4 PCB LAYOUT ......................................................................................................................................... 5 DESCRIPTION ........................................................................................................................................ 6 Introduction....................................................................................................................................... 6 Line Input.......................................................................................................................................... 6 Startup .............................................................................................................................................. 6 Operation Mode................................................................................................................................ 6 Softstart ............................................................................................................................................ 6 Snubber Network.............................................................................................................................. 6 Limitation of primary current............................................................................................................. 6 Output Voltage ................................................................................................................................. 7 Regulation ........................................................................................................................................ 7 EMI Behavior .................................................................................................................................... 7 BILL OF MATERIAL ............................................................................................................................... 8 TRANSFORMER CONSTRUCTION DOCUMENTATION ..................................................................... 9 PERFORMANCE DATA ....................................................................................................................... 12 Efficiency ........................................................................................................................................ 12 No-Load Input Power (Standby)..................................................................................................... 13 Regulation and Power Limiting ...................................................................................................... 13 Startup Curves (Low Line) ............................................................................................................. 15 Startup Curves (High Line)............................................................................................................. 16 Loadjump........................................................................................................................................ 17 AC Output Voltage Ripple .............................................................................................................. 18 Drain Source Voltage and Current ................................................................................................. 19 REFERENCES ...................................................................................................................................... 21 www.Infineon.com/CoolSET Page 1 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Introduction Application 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 ICE2B765P CoolSET. The application 1 operates in discontinuous current mode using the frequency reduction during standby condition . The board has one output voltage with secondary regulation. This board demonstrates the basic performance features and the power capability of the latest CoolSET device ICE2B765P of the second generation of CoolSET in a TO220 package with extended creepage distance for higher electrical strength and isolated tab. CoolSET CoolSET is a current mode control IC and the power MOSFET CoolMOS within one standard package designed for low cost power supplies. CoolSET combines the superior technology of CoolMOS and the optimized technology of the control IC with enhanced protection features and improved standby power concept. The integrated propagation delay compensation (patented by Infineon Technologies) prevents a current overshoot, the result is a reduced electrical stress on the MOSFET, the transformer and the output diode. The 650V / 800V high avalanche rugged CoolMOS eliminates or reduces the need for a heatsink and permits a SMPS design with a simple RCD snubber and a low cost standard transformer design. The lowest area specific Rdson leads to a high efficiency and permits an operation at high ambient temperature. CoolSET permits always a safety operation during any error cases due to the integrated protection features. Figure 1– EVALSF2-ICE2B765P This document contains the power supply specification, schematic, bill of material 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 the application note “AN–SMPS–ICE2AXXX for OFF – Line Switch Mode Power Supplies” and FlyCal, a EXCEL based design software according to the application note AN-SMPS-ICE2AXXX. The application note and FlyCal are available on the Internet: www.Infineon.com/CoolSET 1 POUT = 0W www.Infineon.com/CoolSET Page 2 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board List of Features Feature CoolSET Device ICE2B765P External Sense Adjustable Soft Start 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 2 Drain Source Voltage 650V Frequency Reduction Internal Leading Edge Blanking 67 kHz operating frequency TO220 ISODRAIN Package with isolated Tab Standby Power according to European Commission Table 1 – List of Features Power Supply Specification Description Input Voltage Line Regulation (85...270V) Input Frequency No Load Input Power (230VAC) Output Voltage AC Output Voltage Ripple (270VAC) Output Current Output Power Peak Power Standby Power Total Regulation Load Regulation (10...100%) Efficiency (85VAC) @ nominal Load Efficiency (270VAC) @ nominal Load Symbol Min Input Section VACIN 85 f 47 Output Section VOUT 23.5 VRipple IOUT 3.25 POUT 0 POUTmax η η Typ Max Units 115/230 <1 50/60 < 0.9 270 VAC % Hz W 24 <0.1 3.3 80 95 < 1.0 ±2 <1 85 90 24.5 64 3.35 85 VDC VP-P ADC W W W % % % % Environmental Conducted EMI EN55022B Ambient Temperature TA 0 50 75 °C Thermal Consideration @ VACIN = 85V and Dmax = 69% (∆T @ Ta = 25°C) Transformer 40 °C CoolSET 60 °C Output Diode 60 °C Output Capacitors 35 °C Table 2 – Power Supply Specification 2 VDSBR at Tj = 110°C www.Infineon.com/CoolSET Page 3 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Schematic Figure 2 Power Supply Schematic www.Infineon.com/CoolSET Page 4 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board PCB Layout Figure 3 Board Layout - Component Side www.Infineon.com/CoolSET Page 5 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Description Introduction The EVALSF2-ICE2B765P demoboard is a low cost flyback switching power supply using the ICE2B765P integrated circuit from the CoolSET-F2 family. The circuit shown in Figure 2 details a 24V, 80W 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 capacitors C8 and C24 as radio interference suppressors. R19 prevents the application against line shut on spikes. After the bridge rectifier BR1 and input capacitor C3, a voltage from 120 to 380 VDC is present. Only a 220µF input capacitor is required due to the wider duty cycle DCMAX of the ICE-F2-family. Startup From the line input voltage, the current supply which is used to charge up the chip supply capacitor C4 is derived by using resistors R7 and rectifier diode D10. Because of the very low start up current of typically 27µA, a high-value resistor can be used to realize the startup. Note: Improve your standby power via increasing R7. Operation Mode During operation, the VCC pin is supplied via a separate transformer winding with associated rectification D2 and buffering C4 and filter capacitor C20. Resistor R8 is used for current limiting during the charging of C4. In order not to exceed the maximum voltage at the VCC pin an external zener diode D7 limits this voltage. During light or no load condition the switching frequency is reduced down to 21kHz in order to reduce the switching losses without audible noise. Note: In order to improve the standby power, set the board in the burst mode during no load condition via increasing the chip supply resistor R8. Softstart In order to minimize the electrical stress, a Soft-Start function is realized by an internal resistor and the adjustable external capacitor C18. Snubber Network Due to the high avalanche rugged CoolMOS inside, a simple RCD snubber protection can be used. 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 CoolMOS drain source current is sensed via external shunt resistors R20 and R21. An accurate value of the shunt improves the peak power limitation shown in the curve peak power limitation in the rear of this report and minimize the electrical stess on the MOSFET, the Transformer and the output rectifier. www.Infineon.com/CoolSET Page 6 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Output Voltage Power is coupled out on the secondary side via a fast-acting diodes D1 and D9 with low forward voltage. Capacitors C5 and C29 performs energy buffering, a following LC - filter C32 and inductor L9 considerably reduces the output voltage ripple. Storage output capacitors C5 and C29 is designed to exhibit a very low ESR in order to minimize the output voltage ripple caused by the triangular current characteristic. The output voltage is set with resistors R1 and 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 ICE2B765P control device. The optocoupler used meets DIN VDE 884 requirements for a wider creepage distance. EMI Behavior In order to reduce the conducted EMI behavior, capacitor C7 is set in parallel to the transformer TR1. Note: The value should not exceeds 2.2nF in order to guarantee a safety off line switch mode power supply design. www.Infineon.com/CoolSET Page 7 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Bill of Material ICE2B765P Evaluation Board 24V/ 80W Pos. Part Type Number Values Note 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BR1 C1 [nF] C2 [nF] C3 [µF] C4 [µF] C5 [µF] C6 [nF] C7 [nF] C8 [µF] C12 [nF] C18 [nF] C20 [nF] C24 [µF] C29 [µF] C32 [µF] B380 C5000 470 0.15 220 22 1000 2.2 2.2 0.22 4.7 330 100 0.22 1000 330 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 50V 50V 385V 25V 35V 50V 275V 275V 400V 50V 50V 275V 35V 35V 16 D1 MUR1520 1 200V 17 18 19 D2 D3 D7 1N4148 1N4937 ZPD18 1 1 1 200V 18V 20 D9 MUR1520 1 200V 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 D10 F1 F1 IC1 IC2 IC3 L9 [µH] L5 [µH] 1N4007 Microfuse Clip for Fuse SFH617A-3X016 TL431CLP ICE2B765P 1.0 2*27mH R1 [kΩ] 40.0 R2 [kΩ] 4.7 R3 [kΩ] 1.1 R4 [kΩ] 1.6 R5 [kΩ] 180.0 R7 [kΩ] 680 7.5 R8 [Ω] 22.0 R9 [Ω] 10.0 R10 [kΩ] R19 NTC10 R20 [Ω] 0.43 R21 [Ω] 0.39 TR1 ETD39/18/13 Heatsink Heatsink X1, X2 Connector 2pol. www.Infineon.com/CoolSET 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 Ordering Code Low ESR X7R Y1 Cap X2 Cap MKT X7R X7R X2 Cap Low ESR Low ESR 3.15A 6A 1.7A 0.6W 0.6W 0.6W 0.6W 0.6W 0.6W 0.6W 0.6W 2W 1% 1% 0.6W 1% 0.6W 1% 1mm Gap 11 k/W 18 k/W For ICE2B756P For Output Rectifiers Page 8 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Transformer Construction Documentation Al-Value: Gap: Margin: Inductance: Leakage Ind.: 190 nH 1 mm 0 mm 1,49E-04 H 7,7E-06 H (5%) www.Infineon.com/CoolSET Page 9 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board www.Infineon.com/CoolSET Page 10 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board www.Infineon.com/CoolSET Page 11 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Performance Data Efficiency Efficiency vs. Line Input Voltage 100 80W Output 95 Efficiency [%] 90 85 80 75 70 65 60 55 50 80 100 120 140 160 180 200 220 240 260 280 Input Voltage (VAC 50Hz) Figure 4 Efficiency vs. Line Input Voltage Efficiency vs. Output Power 100 95 85 VAC 270 VAC Efficiency [%] 90 85 80 75 70 65 60 55 50 0 10 20 30 40 50 60 70 80 Output Power [W] Figure 5 Efficiency vs. Output Power @ Low and High Line 50Hz www.Infineon.com/CoolSET Page 12 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board No-Load Input Power (Standby) Standby Power versus Line Voltage @ No Load 1,1 1,0 Pout = 0W Input Power [W] 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0,0 80 100 120 140 160 180 200 220 240 260 280 Input Line Voltage (VAC 50Hz) Figure 6 Standby Power vs. Line Input Voltage and No Load Condition (Pout = 0W) Regulation and Power Limiting Line Regulation @ Pout = 80W 25 Output Voltage [VDC] Iout = 3.33 A 24,5 24 23,5 23 80 100 120 140 160 180 200 220 240 260 280 Input Voltage (VAC 50Hz) Figure 7 Regulation vs. Line Input Voltage www.Infineon.com/CoolSET Page 13 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Load Regulation 25 Output Voltage [VDC] 230 VAC 24,5 24 23,5 23 0 10 20 30 40 50 60 70 80 Output Power [W] Figure 8 Regulation vs. Load Maximum Output Power vs. Line Input Voltage Maximum Output Power [W] 100 95 90 85 80 75 70 80 100 120 140 160 180 200 220 240 260 280 AC Line Input Voltage [V] Figure 9 Peak Power (Over Current Shut Off Threshold) vs. Line Input Voltage www.Infineon.com/CoolSET Page 14 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Startup Curves (Low Line) VCC VSS VFB VOUT Figure 10 Startup VACIN = 85V no Load Conditon (POUT = 0W) VCC VSS VFB VOUT Figure 11 Startup @ Vacin = 85V and nominal Load (POUT = 80W) www.Infineon.com/CoolSET Page 15 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Startup Curves (High Line) VCC VSS VFB VOUT Figure 12 Startup @ 270VACIN and no Load Condition (POUT = 0W) VCC VSS VFB VOUT Figure 13 Startup @ Vacin = 270V and nominal Load (POUT = 80W) www.Infineon.com/CoolSET Page 16 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Loadjump VFB Figure 14 Loadjump form 10% up to 100% at VACIN = 85V VFB Figure 15 Loadjump form 10% up to 100% at VACIN = 270V www.Infineon.com/CoolSET Page 17 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board AC Output Voltage Ripple Figure 16 AC Output Voltage Ripple @ VACIN = 85V Figure 17 AC Output Voltage Ripple @ VACIN = 270V www.Infineon.com/CoolSET Page 18 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Drain Source Voltage and Current VDS VSense Figure 18 Drain Source Voltage and Current @ VACIN = 85V VDS VSense Figure 19 Drain Source Voltage and Current @ VACIN = 85V www.Infineon.com/CoolSET Page 19 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board Note: The built-in transformer does not comply with EN60950 safety requirements in respect of electrical isolation. Change service Issue status 1.0 2.1 2.2 2.3 www.Infineon.com/CoolSET Changes First issue BOM Update Performance Data BOM Update Page 20 from 22 Date 02.05.2002 02.08.2002 27.08.2002 08.11.2002 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board 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-EVALSF2-ICE2B765P-01 Actual Release: 2.3 Date: 2002-08-27 Previous Release: V1.0 Page of actual Rel. -- Page of Subjects changed since last release prev. Rel. -- See change service www.Infineon.com/CoolSET Page 21 from 22 EVALSF2-ICE2B765P V2.3 80W 24V Adapter with ICE2B765P on Board 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 2002-05--02 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. www.Infineon.com/CoolSET Page 22 from 22 EVALSF2-ICE2B765P V2.3