Application Note, V1.0, 25 JUNE 2008 Application Note AN- EVALQRS-ICE2QS02G-80W 80W Evaluation Board with Quasi-Resonant PWM Controller ICE2QS02G Power Management & Supply N e v e r s t o p t h i n k i n g . Published by Infineon Technologies AG 81726 Munich, Germany © 2007 Infineon Technologies AG All Rights Reserved. Legal Disclaimer The information given in this document shall in no event be regarded as a guarantee of conditions or characteristics. With respect to any examples or hints given herein, any typical values stated herein and/or any information regarding the application of the device, Infineon Technologies hereby disclaims any and all warranties and liabilities of any kind, including without limitation, warranties of non-infringement of intellectual property rights of any third party. Information For further information on technology, delivery terms and conditions and prices, please contact the nearest Infineon Technologies Office (www.infineon.com). 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Title Revision History: Previous Version: Page 25 JUNE 2008 none Subjects (major changes since last revision) 80W Evaluation Board with Quasi-Resonant PWM Controller ICE2QS02G License to Infineon Technologies Asia Pacific Pte Ltd Mao Mingping [email protected] He Yi [email protected] Jeoh Meng kiat [email protected] We Listen to Your Comments Any information within this document that you feel is wrong, unclear or missing at all? Your feedback will help us to continuously improve the quality of this document. Please send your proposal (including a reference to this document) to: [email protected] V1.0 AN-PS0018 EVALQRS-ICE2QS02G-80W Table of Contents 1 Content ............................................................................................................... 5 2 Evaluation Board ............................................................................................... 5 3 List of Features .................................................................................................. 6 4 Technical Specifications ................................................................................... 6 5 Circuit Description............................................................................................. 6 5.1 Mains Input and Rectification ......................................................................................................6 5.2 PWM Control..................................................................................................................................6 5.3 Snubber Network ..........................................................................................................................6 5.4 Output Stage..................................................................................................................................6 5.5 Feedback Loop..............................................................................................................................6 6 Circuit Operation ............................................................................................... 7 6.1 Startup Operation..........................................................................................................................7 6.2 Normal Mode Operation ...............................................................................................................7 6.3 Digital Frequency Reduction .......................................................................................................7 7 Protection Features ........................................................................................... 7 7.1 Vcc under voltage protection ......................................................................................................7 7.2 Foldback point protection ............................................................................................................7 7.3 Open loop/over load protection...................................................................................................7 7.4 Adjustable output overvoltage protection..................................................................................8 7.5 Short winding protection..............................................................................................................8 7.6 Mains undervoltage protection....................................................................................................8 8 Circuit diagram .................................................................................................. 9 8.1 PCB Topover layer ......................................................................................................................10 8.2 PCB Bottom Layer ......................................................................................................................11 9 Component List ............................................................................................... 12 10 Transformer Construction .............................................................................. 13 11 Test Results ..................................................................................................... 14 11.1 Efficiency .....................................................................................................................................14 12 References ....................................................................................................... 16 Application Note 4 25 June 2008 EVALQRS-ICE2QS02G-80W 1 Content The demo-board described here is an 80W power supply using quasi-resonant flyback converter topology. The PWM controller ICE2QS02G is a second generation quasi-resonant controller IC developed by Infineon Technologies. Its application is mainly focused on power supplies which has auxiliary converter working during standby mode, such as power supplies used in LCD TV, home audio or printer applications. The required VCC voltage for the IC is here drawn from the additional auxiliary power supply. In normal operation, the digital frequency reduction with decreasing load enables a quasi-resonant operation till very low load. As a result, the system efficiency, over the entire load range, is significantly improved compared to conventional free running quasi resonant converter implemented with only maximum switching frequency limitation. In addition, numerous asjustable protection functions have been implemented in ICE2QS02G to protect the system and customize the IC for the chosen application. In case of failure modes, like open control-loop/over load, output overvoltage, and transformer short winding, the device switches into Auto Restart Mode or Latch-off Mode. By means of the cycle-by-cycle peak current limitation plus foldback point correction, the dimension of the transformer and the secondary diode can be lower which leads to more cost effective design. 2 Evaluation Board Figure 1-EVALSQ-80W-ICE2QS02G Application Note 5 25 June 2008 EVALQRS-ICE2QS02G-80W 3 List of Features Quasi-resonant operation Digital frequency reduction with decreasing load Cycle-by-cycle peak current limitation with foldback point correction Built-in digital soft-start Direct current sensing with internal Leading Edge Blanking Time VCC undervoltage protection: IC stop operation, recover with softstart Main undervoltage protection: Block gate and recover with soft start Openloop/Overload protection: Auto Restart with adjustable blanking time and adjustable restart time Output overvoltage protection: Latch-off with adjustable threshold Short-winding protection: Latch-off 4 Technical Specifications Input voltage Input frequency Output voltage and current Output power Efficiency Minimum switching frequency at full load, minimum input voltage 5 85VAC~265VAC 50Hz, 60Hz 20V 4A 80W >86% at full load 65kHz Circuit Description 5.1 Mains Input and Rectification The AC line input side comprises the input fuse FUSE1 as overcurrent protection. The X2 Capacitors CX1, CX2 and Choke L1 and Y1 capacitors CY1 and CY2 forms a main filter to minimize the feedback of RFI into the main supply. After the bridge rectifier BR1, together with a smoothing capacitor C1, provide a voltage of 80VDC to 380 VDC depending on mains input voltage. RT1 is placed in series with input to limit the initial peak inrush current whenever the power supply is switched on when C1 is fully discharged. 5.2 PWM Control The PWM pulse is generated by the 8-pin Quasi Resonant PWM curremt-mode Controller ICE2QS02G. It comprises the complete control for quasi-resonant flyback switch mode power supply especially in LCD TV, home audio and Printer applications. The PWM switch-on is determined by the zero-crossing input signal and the value of the up/down counter. The PWM switch-off is determined by the feedback signal VFB and the current sensing signal VCS. ICE2QS02G also performs all necessary protection functions in flyback converters. Details about the information mentioned above are illustrated in the product datasheet. 5.3 Snubber Network A snubber network R1, C2 and D1 dissipate the energy of the leakage Inductance and to suppress ringing on the SMPS transformer. 5.4 Output Stage On the secondary side, 20V output, the power is coupled out via a dual schottky diode D2. The capacitors C4, C5 and C6 provide energy buffering followed by the L-C filters to reduce the output ripple and prevent interference between SMPS switching frequency and line frequency considerably. Storage capacitors C4, C5 and C6 are designed to have an internal resistance as small as possible (ESR). This is to minimize the output voltage ripple caused by the triangular current. 5.5 Feedback Loop Application Note 6 25 June 2008 EVALQRS-ICE2QS02G-80W For feedback, the output is sensed by the voltage divider of R15, R16 and R17 and compared to TL431 internal reference voltage. C15, C16 and R14 comprise the compensation network. The output voltage of TL431 is converted to the current signal via Optocoupler and two resistors R12 and R13 for regulation control. 6 Circuit Operation 6.1 Startup Operation When VCC reaches the turn on voltage threshold 12V, the IC begins with a soft start which is realized internally with a built-in digital block. The maximum soft start time is 20ms. During this period, feedback voltage will be generated internally, which is 1.8V at the first step and increases step by step with preset voltage at a time interval of 4ms. In such a way, the primary peak current and the gate drive pulse width are both gradually increased during the soft start. 6.2 Normal Mode Operation The secondary output voltage is built up after startup. The secondary regulation control is adopted with TL431 and optocoupler. The compensation network C15, C16 and R14 constitutes the external circuitry of the error amplifier of TL431. This circuitry allows the feedback to be precisely controlled to dynamically varying load conditions, therefore providing stable control. 6.3 Digital Frequency Reduction During normal operation, the switching frequency for ICE2QS02G is digitally reduced with decreasing load. At light load, the MOSFET will be turned on not at the first minimum drain-source voltage time, but on the nth. The counter is in range of 1 to 7, which depends on feedback voltage in a time-base. The feedback voltage decreases when the output power requirement decreases, and vice versa. Therefore, the counter is set by monitoring voltage VFB. The counter will be increased with low VFB and decreased with high VFB. The thresholds are preset inside the IC. 7 Protection Features 7.1 Vcc under voltage protection During normal operation, the VCC voltage is continuously monitored. When the Vcc voltage falls below the under voltage lock out level (VCCoff), the IC is off and gate signal is disabled. 7.2 Foldback point protection For a quasi-resonant flyback converter, the maximum possible output power is increased when a constant current limit value is used for all the mains input voltage range. This is usually not desired as this will increase additional cost on transformer and output diode incase of output over power conditions. The internal fold back protection is implemented to adjust the VCS voltage limit according to the bus voltage. Here, the input line voltage is sensed using the current flowing out of ZC pin, during the MOSFET on-time. As the result, the maximum current limit will be lower at high input voltage and the maximum output power can be well limited versus the input voltage. 7.3 Open loop/over load protection In case of open control loop, feedback voltage is pulled up with internally block. After an adjustable blanking time, the IC enters Auto restart mode. In case of secondary short-circuit or overload, regulation voltage VFB will also be pulled up, same protection will be applied and IC will enters Auto restart mode. The charging time and the discharging time of the capacitor C8, determines respectively the openloop/overload protection blanking time and the restart time of the IC. This allows the system to face a sudden power surge for a Application Note 7 25 June 2008 EVALQRS-ICE2QS02G-80W short period of time fixed by the charging time of C8 without triggering the overload protection. Once the protection triggered, the IC will restart using the internal soft-start circuit, after a period of time fixed by the discharging time of C8. 7.4 Adjustable output overvoltage protection During off-time of the power switch, the voltage at the zero-crossing pin ZC is monitored for output overvoltage detection. If the voltage is higher than the preset threshold for a preset period, the IC is latched off. 7.5 Short winding protection The source current of the MOSFET is sensed via two shunt resistors R11 and R19 in parallel. If the voltage at the current sensing pin is higher than the preset threshold VCSSW of 1.68V during the on-time of the power switch, the IC is latched off. This constitutes a short winding protection. To avoid an accidental latch off, a spike blanking time of 190ns is integrated in the output of internal comparator. 7.6 Mains undervoltage protection Finally, this IC has an adjustable main undervoltage detection system. Once the Voltage at pin VINS drops below 1.25V, the protection is triggered. For a stable operation, a hysteresis operation is ensured using an internal current source. When the VINS exceeds the hysteresis point, the system resumes its operation with a soft-start. Application Note 8 25 June 2008 EVALQRS-ICE2QS02G-80W 8 Circuit diagram Figure 2 – Schematics Application Note 9 25 June 2008 EVALQRS-ICE2QS02G-80W 8.1 PCB Topover layer Figure 3 – Component side Component Legend – View from Component Side Application Note 10 25 June 2008 EVALQRS-ICE2QS02G-80W 8.2 PCB Bottom Layer Figure 1 Solder side copper – View from component side Application Note 11 25 June 2008 EVALQRS-ICE2QS02G-80W 9 Component List Table 1– Component List Items Part Type Quantity 1 BR1 KBU6G,4A/400V 1 2 C1 330uF/400V 1 3 C2 15nF/630V 1 4 C3 47pF/1kV 1 5 C4 1000uF/35V 1 6 C5 1000uF/35V 1 7 C6 1000uF/35V 1 8 C7 470uF/35V 1 9 C8 1uF/50V 1 10 C9 100pF/50V 1 11 C10 100nF/50V 1 12 C11 47uF/50V 1 13 C12 1.5nF/50V 1 14 C13 100pF/50V 1 15 C14 47pF/1kV 1 16 C15 22pF/50V 1 17 C16 0.1uF/50V 1 18 C17 470pF/1kV 1 19 CX1 0.33uF/275VAC 1 20 CX2 0.33uF/275VAC 1 21 CY1 2.2nF/250VAC 1 22 CY2 2.2nF/250VAC 1 23 CY3 2.2nF/250VAC 1 24 D1 UF4006 1 25 D2 MBR20100 1 26 D3 IN4148 1 27 FUSE1 4A 1 28 IC1 ICE2QS02 1 29 IC2 SFH617-3 1 30 IC2 TL431 1 31 L1 2*3.3mH/4.6A 1 32 L2 1.5uH 1 33 Q1 IPA60R199CP 1 34 R1 33k/2W 1 Application Note 12 25 June 2008 EVALQRS-ICE2QS02G-80W 10 35 R2 62k 1 36 R3 1.0M 1 37 R4 1.0M 1 38 R5 1.0M 1 39 R6 620k 1 40 R7 10k 1 41 R8 24k 1 42 R9 110 1 43 R10 27 1 44 R11 0.47/1W 1 45 R12 680 1 46 R13 1.1k 1 47 R14 22k 1 48 R15 120k,1% 1 49 R16 20k, 1% 1 50 R17 20k, 1% 1 51 R18 200k 1 52 R19 0.47/1W 1 53 RT1 S237/5 1 54 VR1 S10K275 1 55 TR1 E36/18/11_N87 1 Transformer Construction Core and material: E 36/18/11, N87 Bobbin: Horizontal Version Primary Inductance, Lp=220uH, measured between pin 1 and pin 4 (Gapped to Inductance) Figure 5 – Transformer structure Application Note 13 25 June 2008 EVALQRS-ICE2QS02G-80W Pin 16 Pin 15 Pin 14 Pin 13 Pin 12 Pin 11 Pin 10 Pin 9 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Figure 6 – Transformer complete – top view 11 Test Results 11.1 Efficiency Table 2 – Load condition Full load 20V/4A Med load 20V/2A Light load 20V/0.4A Table 3 – Efficiency vs. AC line voltage Vin(AC) 85 110 220 265 Application Note Pin(W) Vout(V) Iout(A) Pout(W) Efficiency Full load 92.20 20.01 3.985 79.73 86.48% Med load 46.10 20.01 1.993 39.880 86.50% Light load 9.40 20.01 0.388 7.764 82.59% Full load 90.32 20.01 3.985 79.740 88.28% Med load 44.96 20.01 1.993 39.880 88.70% Light load 9.18 20.01 0.390 7.804 85.00% Full load 89.50 19.99 3.985 79.660 89.00% Med load 44.88 19.99 1.993 39.840 88.77% Light load 9.74 20.01 0.390 7.804 80.12% Full load 90.10 20.00 3.986 79.720 88.47% Med load 45.15 20.01 1.993 39.880 88.32% Light load 10.13 20.01 0.390 7.804 77.03% 14 25 June 2008 EVALQRS-ICE2QS02G-80W Figure 7 – Efficiency vs. AC line voltage Table 4 – Efficiency vs. output power at 220Vac line voltage Pin(W) Vout(V) Iout(A) Pout(W) Efficiency 9.74 20.01 0.390 7.804 80.12% 18.51 20.00 0.795 15.900 85.89% 27.35 20.01 1.198 23.972 87.64% 35.91 19.99 1.589 31.764 88.45% 44.88 19.99 1.993 39.840 88.77% 53.81 19.99 2.398 47.936 89.08% 62.45 19.99 2.787 55.712 89.21% 71.40 19.98 3.193 63.796 89.35% 80.90 19.99 3.596 71.884 88.85% 89.50 19.99 3.985 79.660 89.00% Figure 8 – Efficiency vs. output power at 220Vac line voltage Application Note 15 25 June 2008 EVALQRS-ICE2QS02G-80W 12 References [1] ICE2QS01 datasheet, Infineon Technologies AG, 2006 [2] ICE2QS02G datasheet, Infineon Technologies AG, 2008 [3] AN-ICE2QS01, 25W Evaluation Board with Quasi –Resonant PWM Controller ICE2QS01, Infineon Technologies AG, 2006 [4] CoolMOS® IPA60R199CP datasheet Rev 1.3, Infineon Technologies AG, 2007 [5] Converter Design Using the Quasi-Resonant PWM Controller ICE2QS01, Infineon Technologies AG, 2006 Application Note 16 25 June 2008