Application Note, V1.0, May 2009 AN-EVALSF3-ICE3AS03LJG 65W 19.5V SMPS Evaluation Board with F3 PWM controller ICE3AS03LJG Power Management & Supply N e v e r s t o p t h i n k i n g . Edition 2009-05-15 Published by Infineon Technologies Asia Pacific, 8 Kallang Sector, 349282 Singapore, Singapore © Infineon Technologies AP 2009. All Rights Reserved. Attention please! The information herein is given to describe certain components and shall not be considered as a guarantee of 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. Information For further information on technology, delivery terms and conditions and prices please contact your nearest Infineon Technologies Office (www.infineon.com). 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. 65W 19.5V Demo board using ICE3AS03LJG on board Revision History: Previous Version: Page 2009-5-15 V1.0 none Subjects (major changes since last revision) 65W 19.5V SMPS Evaluation Board with F3 PWM controller ICE3AS03LJG: License to Infineon Technologies Asia Pacific Pte Ltd Kyaw Zin Min Kok Siu Kam Eric 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] AN-PS0037 65W 19.5V Demo board using ICE3AS03LJG on board Table of Contents Page 1 Abstract .......................................................................................................................................5 2 Evaluation Board ........................................................................................................................5 3 List of Features ...........................................................................................................................7 4 Technical Specifications ............................................................................................................7 5 Circuit Diagram ...........................................................................................................................8 6 6.1 6.2 PCB Layout ...............................................................................................................................10 Component side component legend ...........................................................................................10 Solder side copper & component legend ....................................................................................10 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 Circuit Description....................................................................................................................11 Introduction.................................................................................................................................11 Line Input....................................................................................................................................11 Start up.......................................................................................................................................11 Operation mode..........................................................................................................................11 Soft start .....................................................................................................................................11 RCD Clamper circuit ...................................................................................................................11 Main switcher..............................................................................................................................11 Gate drive ...................................................................................................................................12 Peak current control of primary current.......................................................................................12 Output Stage ..............................................................................................................................12 Feedback and regulation ............................................................................................................12 Blanking Window for Load Jump ................................................................................................12 Active Burst Mode.......................................................................................................................12 Jitter mode..................................................................................................................................13 Protection modes........................................................................................................................13 8 Component List ........................................................................................................................14 9 Transformer Construction .......................................................................................................15 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 Test Results ..............................................................................................................................16 Efficiency ....................................................................................................................................16 Input Standby Power ..................................................................................................................17 Line Regulation...........................................................................................................................18 Load Regulation .........................................................................................................................19 Max. Overload Output Power......................................................................................................19 ESD ............................................................................................................................................20 Lightning Surge ..........................................................................................................................20 Conducted EMI test ....................................................................................................................20 11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 Waveforms and Scope Plots....................................................................................................21 Startup waveforms @ full load ....................................................................................................21 Drain-Source voltage and current @ full load .............................................................................21 Frequency jittering ......................................................................................................................22 Load transient response (Load jump from 10% to 100%) ...........................................................22 Output ripple voltage @ Full Load ..............................................................................................23 Output ripple voltage during burst mode @ 1W Load .................................................................23 Active burst mode @ 1W load ....................................................................................................24 Vcc overvoltage protection - Latched Off ....................................................................................24 External protection enable (Mosfet OTP) – Latched Off..............................................................25 Over load protection without/with extended blanking time-Auto Restart......................................26 Open loop protection – Auto Restart...........................................................................................27 Vcc under voltage/Short optocoupler – Auto Restart ..................................................................27 12 References ................................................................................................................................28 Application Note 4 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 1 Abstract This document is an engineering report that describes a universal input power supply designed in a 19.5V 65W off line flyback converter that utilizes the F3 PWM controller ICE3AS03LJG. The application board is operated in discontinuous current mode and running at 100 kHz switching frequency. It has one output voltage with secondary side control regulation. It is especially suitable for AC/DC power supply such as LCD monitors, adapters for printers and notebook computers, DVD players and recorder, Blue-Ray DVD player and recorder, set-top boxes and industrial auxiliary power supplies. The ICE3AS03LJG is a current mode PWM controller. With the 500V startup cell, active burst mode and BiCMOS technologies, the standby power can be <100mW at no load. The frequency jitter mode and the soft gate drive can give a low EMI performance. The built-in 20ms blanking window and the extendable blanking time approach can prevent the IC from entering the auto restart mode due to over load protection unintentionally. The outstanding propagation delay compensation feature can allow a very precise current limit between low line and high line. For this IC, it provides both auto-restart and latch off protection mode. For those serious faults such as Vcc over-voltage, over temperature, short transformer winding, etc, the IC will enter the latched off protection mode. For those less severe case such as the over load, open loop, short opto-coupler, etc, it enters the auto restart protection mode. In case it needs customer defined protection, the external latch off enable feature can fulfill the requirement. By using this feature, an external over temperature protection circuit for the MOSFET is implemented in this evaluation board. 2 Evaluation Board Figure 1a – EVALSF3-ICE3AS03LJG (top view) Application Note 5 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board Figure 1b – EVALSF3-ICE3AS03LJG (bottom view) This document contains the list of features, the power supply specification, schematic, bill of material and the transformer construction drawing. Typical operating characteristics and performance curves with scope waveforms are presented at the rear of the report. Application Note 6 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 3 List of Features 500V Startup Cell switched off after Start Up Active Burst Mode for lowest Standby Power Fast load jump response in Active Burst Mode 100kHz internally fixed switching frequency Built-in Latched Off Protection Mode for Overtemperature, Overvoltage & Short Winding Built-in Auto Restart Protection Mode for Overload, Open Loop,VCC Undervoltage & Short Optocoupler Built-in Soft Start Built-in blanking window with extendable blanking time for short duration high current External latch off enable function Max Duty Cycle 75% Overall tolerance of Current Limiting < ±5% Internal PWM Leading Edge Blanking BiCMOS technology provide wide VCC range Frequency jitter and soft gate driving for low EMI 4 Technical Specifications Input voltage 85VAC~265VAC Input frequency 50Hz, 60Hz Input Standby Power < 100mV @ no load; < 1W @ 0.5W load Output voltage and current 19.5V +/- 2% Output current 3.34A Output power 65W Average Efficiency >85% (115Vac & 230Vac) Output ripple voltage < 130mVp-p Application Note 7 2009-05-15 8 5V ~ 26 5V 2A #VAR Q2 R8 C18 100k 0.1uF R7 27k(1% ) R6 110k(1% ) Q3 R25 0R L2 3.3mH 1.8A #SG 2 L1 27mH 1.7A External OTP #C19 R9 62k(1% ) #R13 C1 #SG 1 C2 0.1uF 100nF C10 C9 24V ZD1 #NTC 1 10R R4 IC1 100R R3 5 HV 8 Gnd 1nF C11 2 FB C8 #C7 4 Gate R23 0R R5 9R1 0R R2 R10 0.47R/0.5W R14 0R R24 0R 1N4148 D4 D3 C6 3 3k /2W 3 4 1N4148 R1 D1 UF4006 C4 10nF/400V SPA07N60C3 Q1 R11 0.51R/0.5W C3 120uF 400V 10uF 35V 3 CS 1 BL ICE3AS03LJG 7 Vcc BR1 4A 600V 65W(19.5V X 3.34A) SMPS Demo Board using ICE3AS03LJG and SPA07N60C3(V 1.1) Kyaw Zin Min, Eric Kok/ 30 Apr 2009 N L 0 .47 uF 3 05 V #R12 3 05 V 0 .33 uF F1 4 70 k NTC 2 BC8 07 8 BC8 17 Application Note 3 2 1 5 6 4 7pF/1 kV IC2 SFH617A-3 2 1 IC3 TL431 R22 820R R21 1.2k R20 39k 470pF *R19 220uF 25V R18 3.6k, 1% C13 68nF R17 470R, 1% R16 24k, 1% C14 C12 C17 L3 1.5uH 2200uF 25V #C15 MBR20H150CT D2 #R15 T1 ER28,98uH(P=24,S=5,A=4) 11 12 C5 2.2nF #C16 #L4 Com 19.5V/3.34A 65W 19.5V Demoboard using ICE3AS03LJG on board 5 Circuit Diagram Figure 2 – 65W 19.5V ICE3AS03LJG power supply schematic 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board N.B.: In order to get the optimized performance of the PWM controller, the grounding of the PCB layout must be taken very carefully. From the circuit diagram above, it shows that the grounding for the PWM controller can be split into several groups; signal ground, Vcc ground and Current sense resistor ground. All the split ground should be connected to the bulk capacitor ground directly. • Signal ground includes all small signal grounds connecting to the PWM controller GND pin such as filter capacitor ground of C9, C10, C11, C7 and opto-coupler ground. • Vcc ground includes the Vcc capacitor ground, C8 and the auxiliary winding ground; pin 6 of the power transformer. • Current Sense resistor ground includes current sense resistor R10 and R11. Application Note 9 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 6 PCB Layout 6.1 Component side component legend Figure 3 – Component side Component Legend – View from Component Side 6.2 Solder side copper & component legend Figure 4a – Solder side copper – View from Component Side Figure 4b – Solder side component legend – View from Component Side Application Note 10 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 7 Circuit Description 7.1 Introduction The EVALSF3-ICE3AS03LJG demo board is an off line flyback switch mode power supply (SMPS) using the ICE3AS03LJG PWM IC from the Infineon PWM controller. The circuit, shown in Figure 2, details a 19.5V, 65W power supply that operates from an AC line input voltage range of 85Vac to 265Vac, suitable for applications requiring either an open frame supply or an enclosed adapter. 7.2 Line Input The AC input side comprises the input fuse F1 as over-current protection. The common mode choke L1 and L2, X2-capacitors C1 and C2 and Y1-capacitor C5 act as EMI suppressors. A varistor VAR (optional) is added to absorb the line transient while a NTC1 (optional) is added to reduce the inrush surge current during start up. Two series resistor, R12 and R13 (optional) are added to discharge the voltage at C1 and C2 after the AC line is removed. A rectified DC voltage (120V ~ 375V) is obtained through the bridge rectifier BR1 and the input bulk capacitor C3. 7.3 Start up Since there is a built-in startup cell in the ICE3AS03LJG, there is no need for external start up resistors. The startup cell is connecting the HV pin of the IC. Once the voltage is built up at the HV pin of the ICE3AS03LJG, the startup cell will charge up the Vcc capacitor C8 and C9. When the Vcc voltage exceeds the UVLO at 18V, the IC starts up. Then the Vcc voltage is bootstrapped by the auxiliary winding to sustain the operation. 7.4 Operation mode During operation, the Vcc pin is supplied via a separate transformer winding with associated rectification D3 and buffering and filtering capacitors C8 and C9. Resistor R2 and R3 are used for current limiting. In order not to exceed the maximum voltage at Vcc pin, an external zener diode ZD1 and R4 is added to clamp the voltage. 7.5 Soft start The Soft-Start time is built-in 10ms. After the Vcc hits UVLO at 18V, it starts the soft-start phase. 7.6 RCD Clamper circuit While turning off the switch Q1, the clamper circuit R1, C4 and D1 absorbs the current caused by transformer leakage inductance once the voltage exceeds clamper circuit voltage. Then drain to source voltage is well below the maximum break down voltage. 7.7 Main switcher Q1 is the main switcher for the system. It has a low Rdson to reduce the conduction loss. An optional drainsource capacitor C6 can be added to the MOSFET to reduce the switching noise so as to get a better EMI performance. Application Note 11 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 7.8 Gate drive The gate drive current is 0.17A push and 0.39A pull. The gate on signal has installed with a slope controlled rising edge feature which make the driving softly. If it needs to optimize the EMI performance, a turn off resistor-diode network (R24 and D4) can be added in parallel with the gate drive resistor (R5) so as to turn the device off faster than it is turned on. 7.9 Peak current control of primary current The power MOSFET drain source current is sensed via external shunt resistors R10 and R11 which determine the tolerance of the current limit control. Since ICE3AS03LJG is a current mode controller, it would have a cycle-by-cycle primary current and feedback voltage control which can make sure the maximum power of the converter is controlled in every switching cycle. Besides, propagation delay compensation is implemented to ensure the maximum input current/power can be controlled in an even tighter manner. The demo board shows app. +/-3.6% (refer to Figure 13). 7.10 Output Stage The power is coupled to the secondary side through schottky diode D2. The capacitor C12 provides energy buffering and the cascading LC filter L2 and C14 is used to reduce the output voltage ripple. The capacitor C12 is selected to have a low internal resistance (ESR) to minimize the output voltage ripple. 7.11 Feedback and regulation The output voltage is controlled by a TL431 reference control IC (IC3). This device incorporates the voltage reference as well as the error amplifier. Compensation network C13, C17, R16, R17, R18, R19 and R20 constitutes the loop compensation circuit. This circuitry allows the feedback to be precisely matched to dynamically varying load conditions and provides stable control. The maximum current through the optocoupler diode and the voltage reference is set by using resistors R21 and R22. Optocoupler IC2 is used to transmit the control signal to the “Feedback” input of the ICE3AS03LJG device. The selected optocoupler should meet DIN VDE 884 requirements for a wider creepage distance. 7.12 Blanking Window for Load Jump In case of Load Jumps the Controller provides a Blanking Window before activating the Over Load Protection and entering the Auto Restart Mode. There are 2 modes for the blanking time setting; basic mode and the extendable mode. If there is no capacitor added to the BL pin, it would fall into the basic mode; i.e. the blanking time is set at 20ms. If a longer blanking time is required, a capacitor, C10 can be added to BL pin to extend it. The extended time can be achieved by an internal 13uA constant current at BL pin to charge C10 from 0.9V to 4.0V. Thus the overall blanking time is the addition of 20ms and the extended time. For example, C10 (external capacitor at BL pin) = 0.22uF, IBK (internal charging current) = 13uA Blanking time (total) = 20ms + C10 X (4-0.9)/IBK = 72.5ms Note: A filter capacitor (e.g. 100pF) may be needed to add to the BL pin if the noises cannot be avoided to enter that pin in the physical PCB layout. Otherwise, some protection features may be mis-triggered and the system may not be working properly. 7.13 Active Burst Mode At light load condition, the SMPS enters into Active Burst Mode. At this stage, the controller is always active but the VCC must be kept above the switch off threshold; i.e. VCCoff ≥ 10.5V. During active burst mode, the efficiency increases significantly and at the same time it supports low ripple on VOUT and fast response on load jump. When the voltage level at FB falls below 1.23V, the internal blanking timer starts to count. When it reaches the built-in 20ms blanking time, it will enter Active Burst Mode. The Blanking Window is generated to avoid sudden entering of Burst Mode due to load jump. Application Note 12 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board During Active Burst Mode the current sense voltage limit is reduced from 1V to 0.25V so as to reduce the conduction losses and audible noise. All the internal circuits are switched off except the reference and bias voltages to reduce the total VCC current consumption to below 0.45mA. At burst mode, the FB voltage is changing like a sawtooth between 3.0 and 3.5V. To leave Burst Mode, FB voltage must exceed 4.2V. It will reset the Active Burst Mode and turn the SMPS into Normal Operating Mode. The maximum current; i.e. current sense voltage limit resume to 1V, can then be provided to stabilize VOUT. 7.14 Jitter mode The ICE3AS03LJG has frequency jittering feature to reduce the EMI noise. The jitter frequency is internally set at 100 kHz (+/-4 kHz) and the jitter period is set at 4ms. 7.15 Protection modes Protection is one of the major factors to determine whether the system is safe and robust. Therefore, sufficient protection is a must. ICE3AS03LJG provides all the necessary protections to ensure the system is operating safely. There are 2 kinds of protection mode; auto-restart and latch off mode. When there are serious faults such as Vcc over-voltage, over temperature and short winding, it enters the latch off mode. For those less severe faults such as over load, open loop, Vcc under-voltage and short optocoupler, it enters the auto-restart mode. In addition, there is an external latch enable feature which is suitable for those tailor-made protection features. An external OTP circuit is implemented to protect the MOSFET surface temperature at 110°C (heatsink temperature at 106°C). A list of protections and the failure conditions are showed in the below table. Protection function Failure condition Vcc Over-voltage Vcc > 25.5V Latch off Over-temperature (controller junction) TJ > 130°C Latch off Short winding / Short diode VCS > 1.66V Latch off External Latch off enable VBL < 0.33V Latch off Over-load / Open loop VFB > 4.2V and VBL > 4.0V and after Blanking time Auto Restart Vcc Under-voltage / short Opto-coupler Vcc < 10.5V Auto Restart Application Note 13 Protection Mode 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 8 Component List No 1 2 3 4 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 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Circuit code BR1 C1 C9,C10,C18 C11 C12 C13 C14 C17 C2 C3 C4 C5 C6 C8 D1 D2 D3,D4 F1 IC1 IC2 IC3 J1 ~ J6,NTC1,R23,R24,R14,L3 L1 L2 L3 NTC2 Q1 Q2 Q3 R1 R10 R11 R16 R17 R18 R2,R25 R20 R21 R22 R3 R4 R5 R6 R7 R8 R9 T1 ZD1 Application Note Component description 4A 600V 0.47uF, 305V 100nF,50V(0603) 1nF, 63V 2200uF, 25V 68nF, 63V 220uF, 25V 470pF, 50V(0603) 0.33uF, 305V 120uF, 400V 10nF, 400V 2.2nF, 250V 47pF, 1kV 10uF, 35V UF4006 MBR20H150CT 1N4148 2A 250V ICE3AS03LJG, SO-8 SFH617 A3 TL431 Jumper 27mH, 1.7A 3.3mH,1.8A 1.5uH 470k(B57891M0474+000) SPA07N60C3 BC807-25 BC817-25 33K, 2W 0.47R, 1/2W,1% 0.51R, 1/2W,1% 24k, 1%, 1/4W 470R, 1%, 1/4W 3.6k, 1%, 1/4W 0R, 0603 39k,0603 1.2k, 0603 820R 100R, 1/4W 10R, (0603) 9R1, 1/4W 110k,1% 27k, (0603),1% 100k(0603) 62k,1% 98uH(P=24,S=5,A=4) 24V 14 Quantity 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 12 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Manufacturer Vishay EPCOS Murata Murata EPCOS EPCOS EPCOS Murata Murata EPCOS Vishay Vishay Vishay Infineon Vishay EPCOS EPCOS NEC-Tokin EPCOS Infineon TDK 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 9 Transformer Construction Core and material: EER28L, PC47 or EER28/34/11, N72 Bobbin: EER28LEC P12 (Vertical type) Primary Inductance, Lp = 98uH measured between pin 1 and pin 3 (Gapped to Inductance) Transformer structure: Figure 5 – Transformer structure and top view of transformer complete Wire size requirement: Start Stop No. of turns Wire size Layer 6 5 4 2XAWG#28 Aux. 2 3 12 3XAWG#28 1 11 12 5 6XAWG#26 Secondary 1 2 12 3XAWG#28 1 Application Note 15 /2 Primary /2 Primary 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 10 Test Results 10.1 Efficiency Active-Mode Efficiency versus AC Line Input Voltage 90.00 Efficiency [ % ] 88.00 86.4 86.0 86.0 86.7 86.6 85.4 85.1 230 265 86.00 83.9 86.0 84.00 85.8 84.7 82.00 82.3 80.00 85 115 150 180 AC Line Input Voltage [ Vac ] Full load Efficiency Average Efficiency(25%,50%,75% & 100%) Figure 6 – Efficiency vs. AC Line Input Voltage Efficiency versus Output Power 95.00 Efficiency [ % ] 90.00 86.4 87.9 86.9 86.7 85.00 80.00 74.4 86.0 85.5 32.5 48.75 84.7 81.8 75.00 71.0 70.00 65.00 0 16.25 65 Output Power [W] Vin=115Vac Vin=230Vac Figure 7 – Efficiency vs. Output Power @ Low and High Line Application Note 16 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 10.2 Input Standby Power Standby Power @ no-load versus AC Line Input Voltage 100 Input Power [ mW ] 90.10 90 84.30 75.36 80 70 72.27 68.07 69.55 85 115 60 150 180 230 265 AC Line Input Voltage [ Vac ] Po = 0W Figure 8 – Input Standby Power @ no load vs. AC Line Input Voltage (Equipment: Yokogawa WT210 power meter – using integration mode) Standby Pow er @ 0.5W load versus AC Line Input Voltage Input Power [ W ] 0.80 0.70 0.67 0.68 85 115 0.68 0.71 0.72 230 265 0.69 0.60 150 180 AC Line Input Voltage [ Vac ] Po=0.5W Figure 9 – Input Standby Power @ 0.5W load vs. AC Line Input Voltage (Equipment: Yokogawa WT210 power meter – using integration mode) Application Note 17 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board Standby Pow er Efficiency @ 0.5W load versus AC Line Input Voltage 80 74.67 74.38 Efficiency [ % ] 75 73.62 72.98 71.02 70.33 70 65 AC Line Input Voltage [ Vac ] Pout=0.5W Figure 10 – Standby Power Efficiency @ 0.5W load vs. AC Line Input Voltage 10.3 Line Regulation Output Voltage [ V ] Line Regulation : Output Voltage @ Full Load versus AC Line Input Voltage 20.50 20.00 19.53 19.53 19.53 19.53 19.53 19.53 85 115 150 180 230 265 19.50 19.00 18.50 AC Line Input Voltage [ Vac ] Vo @ full load Figure 11 – Line Regulation vs. AC Line Input Voltage Application Note 18 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 10.4 Load Regulation Load Regulation: Vout versus Outoput Power Ouput Voltage [ V ] 20.00 19.80 19.67 19.60 19.65 19.67 19.63 19.65 19.58 19.63 19.53 19.58 19.40 19.53 19.20 19.00 0 16.25 32.5 48.75 65 Output Pow er [ W ] Output Voltage @ 230Vac Output Voltage @ 115Vac Figure 12 – Load Regulation vs. AC Line Input Voltage 10.5 Max. Overload Output Power Max. Overload Output & Input Pow er ( Peak Pow er ) versus AC Line Input Voltage Max. Overload Output Power [ W ] Pin=94.70±3.6% & Pout=80.18±5.1% 100 95 90 85 80 75 70 95.7 93 76.08 85 91.29 76.91 115 92.95 91.76 82.19 79.75 78.23 150 180 230 98.12 84.28 265 AC Line Input Voltage [ V ] Peak Output Power Peak Input Power Figure 13 – Overload Output Power (Over Current Shut Off Threshold) vs. AC Line Input Voltage Application Note 19 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 10.6 ESD Pass (EN61000-4-2) 20kV for contact discharge. 10.7 Lightning Surge Pass* (EN61000-4-5) 6kV for line to earth. *Add SG1 & SG2 (DSP-301N-S008) 10.8 Conducted EMI test The conducted EMI was measured by Schaffner (SMR4503) and followed the test standard of EN55022 class B. The demo board was set up at maximum load with input voltage of 115Vac and 230Vac. 80 EN_V_QP EN_V_AV QP AV 70 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 -20 f / MHz Figure 14 – Max. Load (65W) with 115 Vac (Neutral) 80 EN_V_QP EN_V_AV QP AV 70 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 -20 f / MHz Figure 15 – Max. Load (65W) with 230 Vac (Neutral) Application Note 20 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11 Waveforms and Scope Plots All waveforms and scope plots were recorded with a LeCroy 6050 oscilloscope 11.1 Startup waveforms @ full load 0.23s 0.23s 10ms 10ms Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Startup time = 0.23s, Soft start time = 10ms Startup time = 0.23s, Soft start time = 10ms Figure 16 – Startup @ Vin=85Vac and 65W load Figure 17 – Startup @ Vin=265Vac and 65W load 11.2 Drain-Source voltage and current @ full load Channel 1; C1 : Drain Source Voltage (VDS) Channel 2; C2 : Drain Source Current (IDS) Channel 1; C1 : Drain Source Voltage (VDS) Channel 2; C2 : Drain Source Current (IDS) Duty cycle = 41.6% Duty cycle = 10.7% Figure 18 – Operation @ Vin = 85Vac and 65W load Figure 19–Operation @ Vin = 265Vac and 65W load Application Note 21 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11.3 Frequency jittering Channel 1; C1 : Drain Source voltage (VDS) Channel 1; C1 : Drain Source voltage (VDS) Frequency changing from 95.6kHz ~ 102kHz, Jitter period is set at 4ms internally Frequency changing from 95.6kHz ~ 102kHz, Jitter period is set at 4ms internally Figure 20 – Figure 21 – Frequency change shown at VDS @ Vin=85Vac and 65W Load Frequency change shown at Vin=265Vac and 65W Load VDS @ 11.4 Load transient response (Load jump from 10% to 100%) Channel 2; C1 : Output Current (IO) Channel 2; C2 : Output Voltage (VO) Channel 2; C1 : Output Current (IO) Channel 2; C2 : Output Voltage (VO) Vripple_pk_pk= 294mV(Load 10% to 100%,100Hz,0.4A/µS slew rate), No Oscillation Vripple_pk_pk= 294mV(Load 10% to 100%,100Hz,0.4A/µS slew rate), No Oscillation Figure 22– Load jump @ Vin=85Vac from 10% to 100% Figure 23 – Load jump @ Vin=265Vac from 6W to 60W load Application Note 22 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11.5 Output ripple voltage @ Full Load Channel 2; C2 : Output Ripple Voltage (VO) Channel 2; C2 : Output Ripple Voltage (VO) Vripple_pk_pk= 127mV (Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 1uF(Electrolytic),20MHz) Vripple_pk_pk= 127mV (Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 1uF(Electrolytic),20MHz) Figure 24 – Output voltageripple @ 85Vac and 65W load Figure 25 – Output voltageripple @ 265Vac and 65W load 11.6 Output ripple voltage during burst mode @ 1W Load Channel 2; C2 : Output Ripple Voltage (VO) Channel 2; C2 : Output Ripple Voltage (VO) Vripple_pk_pk= 57mV (Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 1uF(Electrolytic),20MHz) Vripple_pk_pk= 73.4mV (Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 1uF(Electrolytic),20MHz) Figure 26 – Output ripple voltage @ Vin=85Vac and 1W load Figure 27 – Output ripple voltage @ Vin=265Vac and 1W load Application Note 23 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11.7 Active burst mode @ 1W load Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Load change from 3.34A to 0.5A, blanking time to enter burst mode is 20ms Figure 28 – Active burst mode @ Vin=85Vac Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Load change from 3.34A to 0.5A, blanking time to enter burst mode is 20ms Figure 29 – Active burst mode @ Vin=265Vac 11.8 Vcc overvoltage protection - Latched Off Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) R16 disconnected during system operating at 0.5A load,System enters to latched off mode due to Vcc OVP R16 disconnected during system operating at 0.5A load,System enters to latched off mode due to Vcc OVP Figure 30 – Vcc overvoltage protection @ Vin=85Vac Figure 31 – Vcc overvoltage protection @ Vin=265Vac Application Note 24 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11.9 External protection enable (Mosfet OTP) – Latched Off Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) DUT is operating at full load and ambient is 80°C, system enters latch off mode when VBL <0.33 (measured heatsink temperature is 103°C & mosfet surface temperature is 107°C) Figure 32 – External latch off enable(Mosfet OTP)@ 85Vac DUT is operating at full load and ambient is 80°C, system enters latch off mode when VBL <0.33 (measured heatsink temperature is 103°C & mosfet surface temperature is 107°C) Figure 33 – External latch off enable(Mosfet OTP) @ 265Vac Application Note 25 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11.10 Over load protection without/with extended blanking time-Auto Restart Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Step load from 3.34 to 4.5A, system enters to auto restart mode when VFB > 4.2V and VBL > 4.0V and 20ms blanking time(Cbl=100pF) Step load from 3.34 to 4.5A, system enters to auto restart mode when VFB > 4.2V and VBL > 4.0V and 20ms blanking time(Cbl=100pF) Figure 34 Figure 35– – Overload protection without extended blanking Overload protection without extended blanking time @ 85Vac time @ 265Vac Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Step load from 3.34 to 4.5A, system enters to auto restart mode when VFB > 4.2V and VBL > 4.0V and 72ms blanking time Step load from 3.34 to 4.5A, system enters to auto restart mode when VFB > 4.2V and VBL > 4.0V and 72ms blanking time Figure 36 – Overload protection with extended blanking time @ 85Vac(Cbl=0.22µF) Figure 37– Application Note 26 Overload protection with extended blanking time @ 265Vac(Cbl=0.22µF) 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 11.11 Open loop protection – Auto Restart Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) R16 disconnected during system operating at 3.34A load, system enters to auto restart mode when VFB > 4.2V and VBL > 4.0V and 20ms blanking time (Over load protection) R16 disconnected during system operating at 3.34A load, system enters to auto restart mode when VFB > 4.2V and VBL > 4.0V and 20ms blanking time (Over load protection) Figure 38 – Open loop protection @ 85Vac Figure 39 – Open loop protection @ 265Vac 11.12 Vcc under voltage/Short optocoupler – Auto Restart Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Channel 1; C1 : Drain Source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL Voltage (VBL) Shorting the transistor of the opto-coupler(IC2), System enters to Auto Restart mode when Vcc<10.5V Shorting the transistor of the opto-coupler(IC2), System enters to Auto Restart mode when Vcc<10.5V Figure 40 – Vcc under voltage/Short optocoupler protection @ Figure 41 85Vac @ 265Vac Application Note 27 – Vcc under voltage/Short optocoupler protection 2009-05-15 65W 19.5V Demoboard using ICE3AS03LJG on board 12 References [1] Infineon Technologies, Datasheet “F3 PWM controller ICE3AS03LJG Off-Line SMPS Current Mode Controller with Integrated 500V Startup Cell (Latched and Frequency Jitter Mode)” [2] Infineon Technologies, Application Note “AN-SMPS-ICE2xXXX-1 CoolSETTM ICE2xXXX for OFFLine Switch Mode Power Supply (SMPS)” [3] Infineon Technologies, Application Note “ICE3BS03LJG F3 Fixed Frequency PWM Controller (Latch & Jitter version) Design Guide” Application Note 28 2009-05-15