Application Note, V1.1, Aug 2010 A N - E V A L 3 A 1 0 6 5 EL J 15W 5.0V SMPS Evaluation Board with CoolSET® F 3 I C E 3 A 1 0 6 5 E L J Power Management & Supply N e v e r s t o p t h i n k i n g . Edition 2010-08-11 Published by Infineon Technologies Asia Pacific, 168 Kallang Way, 349253 Singapore, Singapore © Infineon Technologies AP 2008. 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. 15W 5V Demo board using ICE3A1065ELJ on board Revision History: Previous Version: 2010-08-11 V1.1 1.0 Page Subjects (major changes since last revision) 1, 5, 11 Change demo board name to EVAL3A1065ELJ ® 15W 5.0V SMPS Evaluation Board with CoolSET F3 ICE3A1065ELJ: 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-PS0021 15W 5V Demoboard using ICE3A1065ELJ on board Table of Contents Page 1 Abstract..........................................................................................................................................5 2 Evaluation Board...........................................................................................................................5 3 List of Features .............................................................................................................................6 4 Technical Specifications ..............................................................................................................6 5 Circuit Diagram .............................................................................................................................7 6 6.1 6.2 PCB Layout ....................................................................................................................................9 Component side component legend ...............................................................................................9 Solder side copper & component legend ........................................................................................9 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.8.1 7.8.2 7.8.3 7.9 7.9.1 7.9.2 Circuit Description ......................................................................................................................11 Introduction....................................................................................................................................11 Line Input.......................................................................................................................................11 Start up & auxiliary supply circuit ..................................................................................................11 RCD Clamper circuit .....................................................................................................................11 Peak primary current control circuit ..............................................................................................11 Output Stage of secondary side....................................................................................................11 Feedback and regulation...............................................................................................................12 Particular features .........................................................................................................................12 Blanking Window for Load Jump & Active Burst Mode.................................................................12 Active Burst Mode .........................................................................................................................12 Frequency jitter mode ...................................................................................................................12 Protection modes ..........................................................................................................................13 Auto restart mode..........................................................................................................................13 Latch off mode...............................................................................................................................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 Electrostatic Discharge Test (ESD)...............................................................................................20 Lightning Surge Test .....................................................................................................................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 Waveforms and scope plots ......................................................................................................22 Startup @ low and high AC line input voltage and 15W load .......................................................22 Drain to source voltage and current during 15W load operation ..................................................23 Load transient response (Load jump from 10% to 100%) ............................................................23 AC output ripple during 15W .........................................................................................................24 Active Burst Mode @ light load .....................................................................................................25 Vcc overvoltage protection (latch off mode)..................................................................................26 Overload protection without/with extended blanking time (auto restart mode).............................27 Open loop protection (auto restart mode) .....................................................................................28 Vcc under voltage/Short optocoupler protection (auto restart mode) ...........................................28 External latch off enable................................................................................................................29 Frequency Jittering........................................................................................................................29 12 12.1 Appendix ......................................................................................................................................30 Slope compensation for CCM operation .......................................................................................30 13 References ...................................................................................................................................30 Application Note 4 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 1 Abstract This document is an engineering report that describes a universal input power supply designed in a 5V 15W ®1 off line SMPS flyback converter topology that utilizes the ICE3A1065ELJ CoolSET . The application board is designed for discontinuous conduction mode (DCM) with current mode controller IC and running at 100 kHz switching frequency. It has one output voltage with secondary control regulation. It is especially suitable for small power supply such as DVD player, set-top box, game console, charger and auxiliary power for high ® power system, etc. The ICE3A1065ELJ is an enhanced version of the F3 CoolSET especially in robustness ® to the system noise such as ESD, lightning surge, etc. Besides having the basic features of the F3 CoolSET such as Active Burst Mode, propagation delay compensation, soft gate drive, latch off protection for serious fault (Vcc OVP, OTP and short winding) and auto-restart protection for general fault (OLP and Open loop), etc., it also has the BiCMOS technology design, built-in soft start time, built-in and extendable blanking time, frequency jitter feature with built-in jitter period and external latch enable pin, etc. The particular good features are the extremely low standby input power, the low EMI performance and the robustness to the system noise. 2 Evaluation Board Figure 1 – EVAL3A1065ELJ This document contains the list of features, the power supply specification, schematic, bill of material and the transformer construction drawing. Typical operating characteristics are presented at the rear of the report and it consists of performance curves and scope waveforms. 1 ® ® CoolSET is a current mode PWM control IC and the power MOSFET CoolMOS within one package designed for low cost switch mode power supplies (SMPS). Application Note 5 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 3 List of Features ® 650V avalanche rugged CoolMOS with built-in Startup Cell Active Burst Mode for lowest Standby Power Fast load jump response in Active Burst Mode 100kHz internally fixed switching frequency Built-in latched Off Mode for Overtemperature, Overvoltage & Short Winding Detection Auto Restart Mode for Overload, Open Loop & VCC Undervoltage Built-in Soft Start Built-in and extendable blanking Window for short duration high current External latch 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 driving for low EMI Robustness to system noise such as ESD, lightning surge, etc. 4 Technical Specifications Input voltage 85VAC~265VAC Input frequency 50Hz, 60Hz Input Standby Power <100mW @ no load; < 0.8W @ 0.5W load Output voltage and current 5V +/- 2% Output current 3.0A Output power 15W Efficiency >75% at full load Output ripple voltage < 50mVp-p Application Note 6 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 5 Circuit Diagram Figure 2 – 15W 5.0V ICE3A1065ELJ power supply Schematic Application Note 7 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ ® N.B. : In order to get the optimized performance of the CoolSET , the grounding of the PCB layout must be connected very carefully. From the circuit diagram above, it indicates that the grounding for the ® CoolSET can be split into several groups; signal ground, Vcc ground, Current sense resistor ground and EMI return ground. All the split grounds should be connected to the bulk capacitor ground separately. ® • Signal ground includes all small signal grounds connecting to the CoolSET GND pin such as filter capacitor ground, C6, C7, C8 and optocoupler ground. • Vcc ground includes the Vcc capacitor ground, C9 and the auxiliary winding ground, pin 2 of the power transformer. • Current Sense resistor ground includes current sense resistor R4 and R4A. • EMI return ground includes Y capacitor, C4. Application Note 8 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 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 4 – Solder side copper – View from Component Side Application Note 9 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ Figure 5 – Solder side component Legend – View from Component Side Application Note 10 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 7 Circuit Description 7.1 Introduction The EVAL3A1065ELJ demoboard is a low cost off line flyback switch mode power supply (SMPS) using the ® ICE3A1065ELJ system IC from the CoolSET -F3 family. The circuit, shown in Figure 2, details a 5.0V, 15W 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 line input side comprises the input fuse F1 as over-current protection. The common mode choke L1, X2-capacitor C1 and Y1-capacitor C4 act as EMI suppressors. Spark gap device SG1 and SG2 can absorb high voltage stress during lightning surge test. After the bridge rectifier BR1 and the input bulk capacitor C2, a voltage of 100 to 380 VDC is present which changed with input voltage. 7.3 Start up & auxiliary supply circuit Since there is a built-in startup cell in the ICE3A1065ELJ, there is no need for external start up resistor. The startup cell is connecting the Drain pin of the IC. Once the voltage is built up at the Drain pin of the ICE3A1065ELJ, the startup cell will charge up the Vcc capacitor C5 and C6. 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. During operation, the Vcc pin is supplied via a separate transformer winding with associated rectification D2 and buffering C5 and C6. Resistor R3 & R5 is used for current limiting. In order not to exceed the maximum voltage at Vcc pin an external zenor diode ZD1 and resistor R6 are added. The Soft-Start is a built-in function and is set at 20ms. There is no need for extra components. 7.4 RCD Clamper circuit ® While turning off the internal CoolMOS , the clamper circuit R2, C3 and D1 absorbs the current caused by transformer leakage inductance once the voltage exceeds clamper circuit voltage. Then the Drain to Source 1 ® voltage is well below the maximum break down voltage (V(BR)DSS = 650V ) of internal CoolMOS . 7.5 Peak primary current control circuit ® The drain to source current of the internal CoolMOS is sensed via external shunt resistors R4 and R4A. An accurate value of the shunt together with the IC’s propagation delay compensation control can effectively improve the peak power control between high line and low line which is shown in the peak power limitation curve in the rear part of the report. 7.6 Output Stage of secondary side On the secondary side of the system the power is coupled out by a schottky diode D21. The capacitor C21 provides energy buffering following with the LC filter L21 and C22 to reduce the output voltage ripple considerably. Storage capacitor C21 is a high ripple current electrolytic capacitor which has a very low ESR and can reduce the output voltage ripple. L22 and C24 can help to suppress the high transient voltage spike during Electrostatic Discharge (ESD) test. 1 V(BR)DSS = 650V @ Tj = 110°C Application Note 11 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 7.7 Feedback and regulation The output voltage is controlled using a TL431 reference diode IC (IC3). This device incorporates the voltage reference as well as the error amplifier and a driver stage. Compensation network Cc1, Cc2, Rc1, Rc2, Rc3, Rc3A and Rc4 constitute the external circuitry of the error amplifier of IC3. 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 Rc5 and Rc6. Optocoupler IC2 is used for floating transmission of the control signal to the “Feedback” input via capacitor C8 of the ICE3A1065ELJ control device. The selected optocoupler meets DIN VDE 884 requirements for a wider creepage distance. C8 is a noise filtering capacitor. It should be as small as possible so that it can reduce the noise and at the same time provide fast response to the output. 7.8 Particular features 7.8.1 Blanking Window for Load Jump & Active Burst Mode In case of Load Jumps the Controller provides a Blanking Window before activating the Over Load Protection. 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, it should go to the extendable mode, where a capacitor, C7 should be added to BL pin. The extended blanking time can be achieved by charging the C7 at BL pin from 0.9V to 4.0V with an internal 8.4uA constant current source. Thus the overall blanking time is the addition of 20ms and the extended time. For example, C7=10nF, IBK (internal current source)=8.4uA. The voltage at Feedback pin will rise up to exceed 4.5V without switching off the IC under over load condition when it is within the blanking time frame. At that period the transferred power is limited to the maximum peak current defined by the value of the current sense resistor, R4 and R4A. Blanking time (total) = 20ms + C7 X (4-0.9)/IBK = 23.7ms Note: A noise filtering capacitor ( at least 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 mistriggered and the system may not be working properly. The blanking time to enter the Active Burst Mode is built-in 20ms with no extension. If a low load condition is detected when VFB is falling below 1.35V, the system will only enter Active Burst Mode after 20ms blanking time while VFB is still below 1.35V. 7.8.2 Active Burst Mode At light load condition, the SMPS enters into Active Burst Mode. The controller is always active at this state. VCC must be designed higher than the Vcc switch off threshold VCCoff ≥ 10.5V. While supporting low ripple on VOUT and fast response on load jump, efficiency also increased significantly during Active Burst Mode. When the voltage level at FB falls below 1.35V, the internal blanking timer starts to count. When it reaches 20ms and the FB voltage is still below 1.35V, it will enter Active Burst Mode. The Blanking Window is generated to avoid a sudden entering of Burst Mode due to load jump. During Active Burst Mode the current sense voltage limit is reduced from 1V to 0.31V so as to reduce the conduction losses. 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 3.61V. To leave Burst Mode, FB voltage must exceed 4.5V. It will reset the Active Burst Mode and turn the SMPS into Normal Operating Mode. Maximum current can then be provided to stabilize VOUT. 7.8.3 Frequency jitter mode The ICE3A1065ELJ 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. Application Note 12 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 7.9 Protection modes There are two kinds of protection modes for the device; auto-restart mode and the latch-off mode. The autorestart mode is for the general fault and the latch off mode is for the serious fault. 7.9.1 Auto restart mode In the auto-restart mode, the gate switching is stopped and the Vcc voltage will drop. When it drops to 10.5V, the startup cell will turn on and charge up the Vcc capacitor to 18V. Then the startup cell turns off and the device will start the start up phase from soft start. However, if the fault persists, the device will enter the autorestart mode again. If the fault is removed, the device will return to normal mode in the next start up phase. A list of auto restart mode protections and the failure conditions are showed in the below table. Protection function Failure condition Over-load / Open loop VFB > 4.5V and VBL > 4.0V (Blanking time counted from charging VBA from 0.9V to 4.0V together with the basic 20ms) Protection Mode Auto Restart Vcc Under-voltage / short Optocoupler Vcc < 10.5V Auto Restart 7.9.2 Latch off mode The operation of latch-off mode is very similar to auto-restart mode but there is no startup phase when the Vcc reach 18V. Since there is no switching energy from the auxiliary winding, the Vcc voltage will then drop to 10.5V. Then the startup cell charge sequence repeats again. The Vcc waveform during latch-off mode likes a saw-tooth shape. The latch-off mode can be reset if the Vcc voltage is lower than 6.23V. A list of latch off mode protections and the failure conditions are showed in the below table. Protection function Failure condition Vcc Over-voltage Vcc > 24V & VFB > 4.5V Latch Off Over-temperature (controller junction) TJ > 130°C Latch Off Short Winding/Short Diode VCS > 1.66V Latch Off External latch enable VBL < 0.1V Latch Off Application Note Protection Mode 13 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 8 Items 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 Component List Part BR1 C1 C2 C3 C4 C6 C7 C8 C9 C21 C22 C24 Cc1 Cc2 D1 D2 D21 F1 IC1 IC2 IC3 J1, J2, J3, J4, J5, J6 L1 L21 L22 R2 R3 R4 R4A R5 R6 Rc1 Rc2 Rc3 Rc4 Rc5 Rc6 TR1 ZD1 Application Note Type RS207, 2A 1000V 0.22uF/275V, X2 capacitor 47uF/400V 2n2F/400V 2.2nF/250V, Y1 capacitor 0.1u/50V 10nF/50V 1nF/50V 22u/50V 2200uF/35V 470uF/35V 0.1uF/50V 1uF/50V 1nF/50V UF4005 1N4148 MBR745 1A 250V ICE3A1065ELJ SFH617A-3 1 TL431CLP Jumper 2 x 27mH, 0.7A 1.5uH 2 x 100µH,(µi=10000,T38,R 6.30) 150K, 2W, 5% 0R, (SMD 0805) R4 1.2R, 0.5W, 1% 27R, 0.1W, 5% ( 0805 SMD ) 560R, 0.1W, 5% ( 0805 SMD ) 39R, 0.1W, 5% ( 0805 SMD ) 10K, 0.25W, 1% 510R,0.25W, 1% 10K, 0.25W, 1% 6.8K, 0.25W, 5% 1K, 5% ( 0805 SMD ) 100R, 5% ( 0805 SMD ) EF20, N87, Lp=520uH 22V zener diode 14 Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Manufacturer EPCOS EPCOS EPCOS Murata EPCOS EPCOS Murata Murata EPCOS Infineon EPCOS NEC-Tokin EPCOS ROHM ROHM ROHM ROHM ROHM ROHM EPCOS - 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 9 Transformer Construction Core and material: EF20/10/6, N87 Bobbin: Horizontal type Primary Inductance, Lp = 520µH measured between pin 4 and pin 5 (Gapped to Inductance) Transformer structure: Figure 6 – Transformer structure and top view of transformer complete Wire size requirement: Application Note Start 2 Stop 1 No. of turns 10 Wire size 2XAWG#32 3 9 4 6 25 4 1XAWG#32 3XAWG#26 /2 Primary Secondary 5 3 25 1XAWG#32 1 15 Layer Auxiliary 1 /2 Primary 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 10 Test Results 10.1 Efficiency Efficiency versus AC Line Input Voltage Efficien cy [ % ] 85.00 80.00 78.7 78.3 77.4 78.5 78.2 75.6 75.00 70.00 85 115 150 180 230 265 AC Line Input Voltage [ Vac ] Efficiency @ 15W output power Figure 7 – Efficiency versus AC Line Input Voltage Efficiency versus Output Power 85.00 79.8 78.8 78.7 Efficiency [%] 80.00 75.8 78.1 78.9 3.75 7.5 78.4 75.6 75.00 78.5 77.4 70.00 0 11.25 15 Output Power [ W ] Vin=115Vac Vin=230Vac Figure 8 – Efficiency vs. Output Power @ 115 & 230 Vac Application Note 16 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 10.2 Input Standby Power Stanby Power @ no-load versus AC Line Input Voltage Input Power [ mW ] 50 35.07 40 30 20 17.51 17.91 85 115 18.74 19.47 150 180 23.30 10 0 230 265 AC Line Input Voltage [ Vac ] Po = 0W Figure 9 – Input Standby Power @ no load vs. AC Line Input Voltage ( measured by Yokogawa WT210 power meter – integration mode ) Standby Pow er @ 0.3W & 0.5W load versus AC Line Input Voltage Input Power [ W ] 1.00 0.67 0.50 0.41 0.71 0.68 0.68 0.41 0.42 0.42 0.43 0.44 115 150 180 230 265 0.67 0.67 0.00 85 AC Line Input Voltage [ Vac ] Po=0.3W Po=0.5W Figure 10 – Input Standby Power @ 0.3 and 0.5W load vs. AC Line Input Voltage ( measured by Yokogawa WT210 power meter – integration mode ) Application Note 17 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ Standby Pow er Efficiency @ 0.3W & 0.5W load versus AC Line Input Voltage 80 Efficiency [ % ] 76.28 75.78 75.44 75.58 74.68 75 72.11 74.47 73.93 73.43 73.07 71.55 70 69.42 65 85 115 150 180 230 265 AC Line Input Voltage [ Vac ] Po=0.3W Po=0.5W Figure 10 – Input Standby Power efficiency @ 0.3 and 0.5W load vs. AC Line Input Voltage 10.3 Line Regulation Line Regulation : Vo versus AC Line Input Voltage @ 15W load Output Voltage [ V ] 5.50 5.02 5.03 5.03 5.03 5.03 5.03 85 115 150 180 230 265 5.00 4.50 AC Line Input Voltage [ Vac ] Vo @ 15W load Figure 11 – Line Regulation vs. AC Line Input Voltage Application Note 18 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 10.4 Load Regulation Load Regulation: Vout versus Load @ Vin = 230Vac Ouput Voltage [ V ] 5.50 5.1 5.08 5.07 5.05 5.03 3.75 7.5 11.25 15 5.00 4.50 0 Output Pow er [ W ] Output Voltage Figure 12 – Load Regulation vs. AC Line Input Voltage 10.5 Max. Overload Output Power Max. Overload Output Power [ W ] Max. Overload Output & Input Pow er ( Peak Pow er ) versus AC Line Input Voltage 25 Pin=22.63W±1.4% & Po=16.9W±3.25% 22.96 22.51 22.33 22.31 22.61 22.95 20 16.35 16.75 16.85 16.95 17.20 17.45 150 180 230 265 15 85 115 AC Line Input Voltage [ V ] Peak Output Power Peak Input Power Figure 13 – Maximum Overload Output & Input Power vs. AC Line Input Voltage Application Note 19 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 10.6 Electrostatic Discharge Test (ESD) Pass 20kV ESD test (EN61000-4-2) in contact discharge. 10.7 Lightning Surge Test Pass 8kV lightning surge test (EN61000-4-5) in Line to Earth. * With the addition of SG1 & SG2 (DSP-301N-S008). 10.8 Conducted EMI Test Pass CISPR 22 Class B EMI test. The conducted EMI was measured by Schaffner (SMR4503) receiver under CISPR 22 class B test standard. The demo board was tested with maximum load (15W) with input voltage of 115Vac and 230Vac. 80 EN_V_QP 70 EN_V_AV QP Pre AV Pre 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 -20 f / MHz Figure 14 – Max. Load (15W) with 115 Vac (Line) Application Note 20 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 80 EN_V_QP 70 EN_V_AV QP Pre AV Pre 60 50 dBµV 40 30 20 10 0 -10 0.1 1 10 100 -20 f / MHz Figure 15 – Max. Load (15W) with 230 Vac (Neutral) Application Note 21 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11 Waveforms and scope plots All waveforms and scope plots were recorded with a LeCroy 6050 oscilloscope 11.1 Startup @ low and high AC line input voltage and 15W load C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) C3 Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) Startup time = 0.52s Startup time = 0.52s Figure 16 – Startup @ Vin=85Vac and 15W load Figure 17 – Startup @ Vin=265Vac and 15W load C1 C1 C2 C2 C3 C4 C3 C4 Z4 Z4 C4 Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Current sense voltage (VCS) Channel Z4; Zoom of Channel 4 Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Supply Voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Current sense voltage (VCS) Channel Z4; Zoom of Channel 4 Soft start time = 20ms Soft start time = 20ms Figure 18 – Soft Start @ Vin=85Vac and 15W load Figure 19 – Soft Start @ Vin=265Vac and 15W load Application Note 22 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.2 Drain to source voltage and current during 15W load operation C1 C1 C2 C2 Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Drain to source current (IDS) Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Drain to source current (IDS) Duty cycle = 41.34% Duty cycle = 13.03% Figure 16 – Operation @ Vin = 85Vac and 15W load Figure 17–Operation @ Vin = 265Vac and 15W load 11.3 Load transient response (Load jump from 10% to 100%) C1 C1 C2 C2 Channel 1; C1 : Output voltage (Vo) Channel 2; C2 : Output current (Io) Channel 1; C1 : Output voltage (Vo) Channel 2; C2 : Output current (Io) Current step slew rate = 0.4A/us Current step slew rate = 0.4A/us Figure 18– Load jump @ Vin=85Vac from 1.5W to 15W load Figure 19 – Load jump @ Vin=265Vac from 1.5W to 15W load Application Note 23 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.4 AC output ripple during 15W C1 C1 Channel 1; C1 : Output ripple voltage Channel 1; C1 : Output ripple voltage Vo_ripple_pk_to_pk = 40mV Vo_ripple_pk_to_pk = 40mV Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 10uF(Electrolytic), 20MHz filter Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 10uF(Electrolytic), 20MHz filter Figure 20 – AC output ripple @ Vin=85Vac and 15W load Figure 21 – AC output ripple @ Vin=265Vac and 15W load Application Note 24 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.5 Active Burst Mode @ light load C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Current sense voltage (VCS) Channel 1; C1 : Drain to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Current sense voltage (VCS) Blanking time to enter burst mode : 19.4ms Blanking time to enter burst mode : 19.4ms Figure 22 – Active burst mode @ Vin=85Vac and step from 3A Figure 23 – Active burst mode @ Vin=265Vac and step from 3A to 0.05A load to 0.05A load C1 C1 Channel 1; C1 : Output ripple voltage Channel 1; C1 : Output ripple voltage Vo_ripple_pk_to_pk = 40mV Vo_ripple_pk_to_pk = 40mV Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 10uF(Electrolytic), 20MHz filter Probe terminal end with decoupling capacitor of 0.1uF(ceramic) + 10uF(Electrolytic), 20MHz filter Figure 24 – Output ripple at active burst mode @ Vin=85Vac Figure 25 – Output ripple at active burst mode @ Vin=265Vac and 0.25W load and 0.25W load Application Note 25 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.6 Vcc overvoltage protection (latch off mode) C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to 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 to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) System enters latch-off mode when VCC>24V & VFB > 4.5V System enters latch-off mode when VCC>24V & VFB > 4.5V Figure 26 – Vcc overvoltage protection @ Vin=85Vac; Rc1 disconnected at startup with light load.( CBL =100pF, remove ZD1) Figure 27 – Vcc overvoltage protection @ Vin=265Vac; Rc1 Application Note 26 disconnected at startup with light load.(CBL=100pF, remove ZD1) 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.7 Overload protection without/with extended blanking time (auto restart mode) C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to 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 to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) Blanking time to enter auto-restart mode: 20ms; System enters auto-restart when VFB>4.5V, VBL > 4V with basic mode blanking time. Blanking time to enter auto-restart mode: 20ms; System enters auto-restart when VFB>4.5V, VBL > 4V with basic mode blanking time. Figure 30 – Over load protection without extended blanking Figure 31 – Over load protection without extended blanking time; CBL =100pF @ Vin=265Vac and output power step from 0A to 4A load time; CBL =100pF @ Vin=85Vac and output power step from 0A to 4A load C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to 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 to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) Blanking time to enter auto-restart mode: 23ms; System enters auto-restart when VFB>4.5V, VBL > 4V with extended blanking time. Blanking time to enter auto-restart mode: 23ms; System enters auto-restart when VFB>4.5V, VBL > 4V with extended blanking time. Figure 30 – Over load protection with extended blanking time; CBL = 10nF @ Vin=85Vac and output power step from 3A to 4A load Figure 31 – Over load protection with extended blanking time; CBL = 10nF @ Vin=265Vac and output power step from 3A to 4A load Application Note 27 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.8 Open loop protection (auto restart mode) C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to 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 to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) Blanking time to enter auto-restart mode : 20ms; System enters auto-restart when VFB>4.5V, VBL > 4V with defined blanking time. Blanking time to enter auto-restart mode : 20ms; System enters auto-restart when VFB>4.5V, VBL > 4V with defined blanking time. Figure 32 – Open loop protection @ Vin=85Vac; Rc1 is Figure 33 – Open loop protection @ Vin=85Vac; Rc1 is disconnected during system operation @ 3A load(CBL =100pF) disconnected during system operation @ 3A load(CBL =100pF) 11.9 Vcc under voltage/Short optocoupler protection (auto restart mode) C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to 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 to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) System enters auto-restart protection when Vcc < 10.5V System enters auto-restart protection when Vcc < 10.5V Figure 32 – Vcc overvoltage protection @ Vin=85Vac; Short Figure 33 – Vcc overvoltage protection @ Vin=265Vac; Short optocoupler is done by shorting the transistor (primary side) of the optocoupler (CBL =100pF). optocoupler is done by shorting the transistor (primary side) of the optocoupler (CBL=100pF). Application Note 28 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 11.10 External latch off enable C1 C1 C2 C2 C3 C3 C4 C4 Channel 1; C1 : Drain to 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 to source voltage (VDS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : BL voltage (VBL) System enters latch-off mode when VBL< 0.1V System enters latch-off mode when VBL< 0.1V Figure 34 – Latch-off enable by triggering BL pin @ Vin=85Vac, Figure 35 – Latch-off by triggering latch enable pin @ Vin=265Vac, short the BL pin to ground short the BL pin to ground 11.11 Frequency Jittering Channel 1; C1 : Drain to source voltage (VDS) Channel 1; C1 : Drain to source voltage (VDS) Frequency changing from 94.5kHz ~ 102.06KHz, Jitter period is set at 4ms internally Frequency changing from 93.5kHz ~ 101.5KHz, Jitter period is set at 4ms internally Figure 36 – Frequency change shown at VDS @ Vin=85Vac and 15W load Application Note 29 Figure 37 – Frequency change shown at VDS @ Vin=265Vac and 15W load 2010-08-11 15W 5V Demoboard using ICE3A1065ELJ 12 Appendix 12.1 Slope compensation for CCM operation This demo board is designed in Discontinuous Conduction Mode (DCM) operation. If the application is designed in Continuous Conduction Mode (CCM) operation where the maximum duty cycle exceeds the 50% threshold, it needs to add the slope compensation network. Otherwise, the circuitry will be unstable. In that case, three extra components (2 ceramic capacitors C17 & C18 and one resistor R19) are needed to add as shown in the circuit diagram below (red block). Figure 38 – Circuit Diagram Switch Mode Power Supply with Slope Compensation More information regarding how to calculate the additional components, see in the application note AN_SMPS_ICE2xXXX – available on the internet: www.infineon.com/CoolSET CoolSET F2. 13 References ® [1] Infineon Technologies, Datasheet “CoolSET -F3 ICE3A1065ELJ Off-Line SMPS Current Mode ® Controller with Integrated 650V CoolMOS and Startup Cell ( Latch and Frequency Jitter Mode )” [2] Kyaw Zin Min, Eric Kok Siu Kam, Infineon Technologies, Application Note “ICE3Axx65ELJ CoolSET F3 latch & Jitter version Design Guide, AN-PS0030“ [3] Harald Zoellinger, Rainer Kling, Infineon Technologies, Application Note “AN-SMPS-ICE2xXXX-1, ® CoolSET ICE2xXXXX for Off-Line Switching Mode Power supply (SMPS )” Application Note 30 ® 2010-08-11