Version 1.2 , August 2001 Application Note AN-EVAL-ICE2A365-1 CoolSET 40W Evaluation Board with ICE2A365 Author: Harald Zöllinger Published by Infineon Technologies AG http://www.infineon.com 3RZHU0DQDJHPHQW6XSSO\ N e v e r s t o p t h i n k i n g 40W Evaluation Board with ICE2A365 Contents: 40W Evaluation Board with ICE2A365..................................................3 Technical specifications: .......................................................................4 Circuit description: ................................................................................4 Schematic:............................................................................................6 Component Legend: .............................................................................7 Board Layout: .......................................................................................7 Component List:....................................................................................8 Transformer Construction .....................................................................9 Measurements: ...................................................................................10 References: ........................................................................................10 Seite 2 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 40W Evaluation Board with ICE2A365 The board described here was designed as a typical power supply in flyback converter topology with one output voltage and secondary control. This type of switch mode power supply is particularly suitable as an AC/DC power supply for battery chargers, video games, satellite decoders, etc. The switch mode power supply ICE2A365 chip used for this application is a current-controlled pulse width modulator with integrated CoolMOS power switch. Special efforts have been made to compensate temperature dependency and to achieve a very high accuracy of the switching frequency. Furthermore, overload and open loop protection is implemented by controlling the feedback line. In case of overload or open loop, the IC is working in hiccup mode. Evaluation board Other output voltages can also be implemented very easily by a simple modification of the transformer and the output circuitry. Seite 3 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Technical specifications: Input Voltage Range Input Frequency Output Voltage Peak Output Power Line Regulation (85 ...270V) Load Regulation (10% ... 100%) Efficiency Output Ripple Voltage Switching Frequency Stby Power with Burst Mode @ noload EMI Temperature Range 85 ... 270V AC 50, 60 Hz 16V +-5% 54W < 1% < 1% > 80 % < 200mV 21...100 kHz <400mW EN55022B 0 ... 50°C Circuit description: Introduction The ICE2A365 chip used here was particularly designed for the use in flyback converters. As shown on the circuit diagram (p. 3), only a few additional components are required to create an AC/DC power supply. Line Input The AC line input side comprises the input fuse F1 as overcurrent protection the choke L5 and X2capacitors C8 and C22 as radio interference suppressors. After the bridge rectifier BR1 and the input capacitor C3, a voltage of 90 to 380 VDC depending on input voltage is available. ICE2A365 Power Supply Startup From the DC input voltage, the chip's starting current supply is derived using the resistors R6 and R7. Because of the low current drain of <85 uA, high-value resistors can be used. Series connection of the resistors is necessary for reasons of insufficient dielectric strength of the individual resistors. Mode of Operation During operation, the VCC pin is supplied via a separate transformer winding with associated rectification D2 and buffering C4, C13. The Resistor R8 is used for current limiting during the charging of C4. In order to not exceed the maximum voltage at the VCC pin, an external zenerdiode D4 is applied for voltage limitation. Softstart The Soft-Start function is realised by an internal resistor and the external capacitor C14. Primary Current – CoolMOS Clamping Network R10, C12 and D3 dissipate the energy of the leakage inductance. Limitation of primary current The CoolMOS source current is sensed by an external shunt resistor R17. When the voltage at R17 exceeds the internal current-limit threshold, the gate driver is shut off immediately. Seite 4 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Output Stage Output Voltage On the secondary side the power is coupled out via a fast-acting diode D1 with low forward voltage. The capacitors C5, C9, C20 provide energy buffering, a filter L3, C23 reduces the output voltage ripple considerably. Storage capacitors C5, C9,and C20 are designed to have an internal resistance as small as possible (ESR). This minimizes the output voltage ripple caused by the triangular current characteristic. The output voltage level is set by resistors R1, R2. Regulation The output voltage is controlled using a type TL431 reference diode. This device incorporates the voltage reference the error amplifier, and a driver stage. The compensation network C1, C2, R1, R5 constitutes the external circuitry of the error amplifier of IC2. This circuitry allows the feedback to be precisely matched to dynamically varying load conditions, thereby providing stable control. The maximum current through the optocoupler diode and the voltage reference is set by the resistors R3 and R4. Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input of the ICE2A365 control device. The optocoupler meets DIN VDE 884 requirements. Design calculations for the components and the transformer were performed in accordance with the Application Note “AN–SMPS–ICE2AXXX for OFF – Line Switch Mode Power Supplies”. Seite 5 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Schematic: Seite 6 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Component Legend: Board Layout: Component side shown Seite 7 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Component List: Part List ICE2A365 Evaluation Board 16V/ 40W Pos. Part 1 BR1 2 C1 3 C2 4 C3 5 C4 6 C5 7 C6 8 C7 9 C8 10 C9 11 C12 12 C13 13 C14 14 C20 15 C22 16 C23 17 C24 18 C25 19 D1 20 D2 21 D3 22 D4 23 F1 24 IC1 25 IC3 26 IC2 27 L3 28 L5 29 R1 30 R2 31 R3 32 R4 33 R5 34 R6 35 R7 36 R8 37 R9 38 R10 39 R16 40 R17 41 R18 42 R20 43 TR1 44 TR1 45 D1 46 X1 47 X2 * = not assembled Type B500 C1500 330nF, 50V 1nF, 50V 150uF, 400V 68uF, 35V 1000uF, 35V 2,2nF, 50V * 0,1uF, 275V, X2 * 2,2nF, 400V 100nF, 50V 1uF, 50V 1000uf, 35V 0,22uF, 275V, X2 470uF, 35V 2,2nF, 250V Y1 2,2nF, 250V Y1 DSS10-01A 1N4148 1N4937 ZPD18 Microfuse 3,15A SFH617A-3X016 ICE2A365 TL431CLP 1uH, 3,7A 27mH, 0,9A 24k, 1% 4,3k, 1% 680R 1,2k 150k 430k 430k 4,7R 22R 39k, 2W * 0,43R, 0,6W, 1%, * wire E25 Coil Former E25/13/7, 0,75 N27 Heatsink, 18K/W Connector 2pol. Connector 2pol. 19.09.2001 Grid Ordering Code Manuf. 5mm 5mm 10mm 2,5mm 5mm 5mm B43501-A9157-M B41821-A7476-M KZE35VB1000MK25 B37979-G5222-J Epcos Epcos Epcos Epcos (NCC) Alfatec Epcos 15mm B81130-C1104-M 7,5mm 5mm 5mm 5mm 15mm 5mm 12,5mm 12,5mm 5mm 10mm 10mm 10mm 5mm B32520-C6222-K B37987-F5104-K B37984-M5105-K KZE35VB1000MK25 B81130-C1224-M KZE35VB470MJ20 WKP 2n2 M WKP 2n2 M Epcos Epcos Epcos Epcos (NCC) Alfatec Epcos (NCC) Alfatec Wima Wima IXYS Infineon 5mm 822LY-1R0M B82732-R2901-B30 Componex Epcos 10mm 10mm 10mm 10mm 10mm 10mm 10mm 10mm 10mm 10mm 10mm 10mm see also Transformer Construction FK224 Fischer Seite 8 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Transformer Construction Note: The built-in transformer does not comply with EN60950 safety requirements in respect of electrical isolation. Seite 9 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Measurements: Efficiency [%] Efficiency Frequency Reduction 100 90 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 110 100 90 80 70 60 50 40 30 20 10 0 5 10 15 20 25 30 35 40 Pout [W] Pout [W] Vin@85V Vin@270V Vin@85V Output Power Limitationvs Input Voltage No-load Input Power 60 40 Pin [mW] Pout [W] 50 30 20 10 0 85 100 150 200 250 Vin@270V 400 350 300 250 200 150 100 50 0 265 0 50 100 150 200 250 300 Vacin [V] Vacin[V] References: [1] ICE2AXXX for OFF-Line Switch Mode Power Supplies Application Note, Infineon Technologies [2] CoolSET-II Off-line SMPS Current Mode Controller with High Voltage CoolMOS on Board Datasheet, Infineon Technologies Seite 10 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Revision History Application Note AN-EVAL-ICE2A365-1 Actual Release: V1.2 Date:16.08.2001 Previous Release: V1.1 Page of actual Rel. Page of Subjects changed since last release prev. Rel. 12 12 14 12 First Issue Part List For questions on technology, delivery and prices please contact the Infineon Technologies Offices in Germany or the Infineon Technologies Companies and Representatives worldwide: see the address list on the last page or our webpage at http://www.infineon.com CoolMOS and CoolSET are trademarks of Infineon Technologies AG. We listen to Your Comments Any information within this dokument that you feel is wrong, unclear or missing at all? Your feedback will help us to continously improve the quality of this dokument. Please send your proposal (including a reference to this dokument) to: [email protected] Edition 2000--05--09 Published by Infineon Technologies AG, St.-Martin-Strasse 53, D-81541 München © Infineon Technologies AG 2000. All Rights Reserved. Attention please! The information herein is given to describe certain components and shall not be considered as warranted characteristics. Terms of delivery and rights to technical change reserved. We hereby disclaim any and all warranties, including but not limited to warranties of non-infringement, regarding circuits, descriptions and charts stated herein. Infineon Technologies is an approved CECC manufacturer. Information For further information on technology, delivery terms and conditions and prices please contact your nearest Infineon Technologies Office in Germany or our Infineon Technologies Representatives worldwide (see address list). Warnings Due to technical requirements components may contain dangerous substances. For information on the types in question please contact your nearest Infineon Technologies Office. Infineon Technologies Components may only be used in life-support devices or systems with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system, or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body, or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered. Seite 11 von 12 AN-EVAL-ICE2A365-1 V1.2 40W Evaluation Board with ICE2A365 Infineon Technologies AG sales offices worldwide – partly represented by Siemens AG A F J RC Siemens AG Österreich Erdberger Lände 26 A-1031 Wien T (+43)1-17 07-3 56 11 Fax (+43)1-17 07-5 59 73 Infineon Technologies France, 39/47,Bd.Ornano F-93527 Saint-Denis CEDEX2 T (+33)1-49 22 31 00 Fax (+33)1-49 22 28 01 AUS FIN Siemens Ltd. 885 Mountain Highway Bayswater,Victoria 3153 T (+61)3-97 21 21 11 Fax (+61)3-97 21 72 75 Siemens Components Scandinavia P.O .Bo x 6 0 FIN-02601 Espoo (Helsinki) T (+3 58)10-5 11 51 51 Fax (+3 58)10-5 11 24 95 Email: [email protected] Siemens Components K.K. Talanawa Park Tower 12F &17F 3-20-14,Higashi-Gotanda, Shinagawa-ku Tokyo T (+81)3-54 49 64 11 Fax (+81)3 -54 49 64 01 Infineon Technologies Asia Pacific Pte.Ltd. Taiwan Branch 10F,No.136 Nan King East Road Section 23,Taipei T (+8 86)2-27 73 66 06 Fax (+8 86)2-27 71 20 76 MAL SGP Infineon Technologies AG Sdn Bhd Bayan Lepas Free Industrial Zone1 11900 Penang T (+60)4 -6 44 99 75 Fax (+60)4 -6 41 48 72 Infineon Technologies Asia Pacific,Pte.Ltd. 168 Kallang Way Singapore 349 253 T (+65)8 40 06 10 Fax (+65)7 42 62 39 GB N USA Infineon Technologies Siemens House Oldbury GB-Bracknell,Berkshire RG12 8FZ T (+44)13 44-39 66 18 Fax (+44)13 44-39 66 32 Siemens Components Scandinavia Østre Aker vei 24 Postboks 10,Veitvet N-0518 Oslo T (+47)22-63 30 00 Fax (+47)22-68 49 13 Email: [email protected] Infineon Technologies Corporation 1730 North First Street San Jose,CA 95112 T (+1)4 08-5 01 60 00 Fax (+1)4 08-5 01 24 24 Siemens Components,Inc. Optoelectronics Division 19000 Homestead Road Cupertino,CA 95014 T (+1)4 08-2 57 79 10 Fax (+1)4 08-7 25 34 39 Siemens Components,Inc. Special Products Division 186 Wood Avenue South Iselin,NJ 08830-2770 T (+1)7 32-9 06 43 00 Fax (+1)7 32-6 32 28 30 B Siemens Electronic Components Benelux Charleroisesteenweg 116/ Chaussée de Charleroi 116 B-1060 Brussel/Bruxelles T (+32)2-5 36 69 05 Fax (+32)2-5 36 28 57 Email:[email protected] BR Siemens Ltda. Semiconductores Avenida Mutinga,3800-Pirituba 05110-901 São Paulo-SP T (+55)11-39 08 25 64 Fax (+55)11-39 08 27 28 CDN Infineon Technologies Corporation 320 March Road,Suite 604 Canada,Ontario K2K 2E2 T (+1)6 13-5 91 63 86 Fax (+1)6 13-5 91 63 89 CH Siemens Schweiz AG Bauelemente Freilagerstrasse 40 CH-8047 Zürich T (+41)1-4 953065 Fax (+41)1-4 955050 D Infineon Technologies AG Völklinger Str.2 D-40219 Düsseldorf T (+49)2 11-3 99 29 30 Fax (+49)2 11-3 99 14 81 Infineon Technologies AG Werner-von-Siemens-Platz 1 D-30880 Laatzen (Hannover) T (+49)5 11-8 77 22 22 Fax (+49)5 11-8 77 15 20 Infineon Technologies AG Von-der-Tann-Straße 30 D-90439 Nürnberg T (+49)9 11-6 54 76 99 Fax (+49)9 11-6 54 76 24 Infineon Technologies AG Weissacher Straße 11 D-70499 Stuttgart T (+49)7 11-1 37 33 14 Fax (+49)7 11-1 37 24 48 D Infineon Technologies AG Halbleiter Distribution Richard-Strauss-Straße 76 D-81679 München T (+49)89-92 21 40 86 Fax (+49)89-92 21 20 71 DK Siemens A/S Borupvang 3 DK-2750 Ballerup T (+45)44 77-44 77 Fax (+45)44 77-40 17 E Siemens S.A. Dpto.Componentes Ronda de Europa,5 E-28760 Tres Cantos-Madrid T (+34)91-5 14 71 51 Fax (+34)91-5 14 70 13 H Simacomp Kft. Lajos u.103 H-1036 Budapest T (+36)1-4 57 16 90 Fax (+36)1-4 57 16 92 NL Siemens Electronic Components Benelux Postbus 16068 NL-2500 BB Den Haag T (+31)70-3 33 20 65 Fax (+31)70-3 33 28 15 Email:[email protected] HK Infineon Technologies Hong Kong Ltd. Suite 302,Level 3, Festival Walk, 80 Tat Chee Avenue, Yam Yat Tsuen, Kowloon Tong Hong Kong T (+8 52)28 32 05 00 Fax (+8 52)28 27 97 62 NZ Siemens Auckland 300 Great South Road Greenland Auckland T (+64)9-5 20 30 33 Fax (+64)9-5 20 15 56 I P Siemens S..A. Semiconductor Sales Via Piero e Alberto Pirelli,10 I-20126 Milano T (+39)02-66 76 -1 Fax (+39)02-66 76 43 95 Siemens S.A. an Componentes Electronicos R.Irmaos Siemens,1 Alfragide P-2720-093 Amadora T (+351)1-4 17 85 90 Fax (+351)1-4 17 80 83 IND Siemens Ltd. Components Division No.84 Keonics Electronic City Hosur Road Bangalore 561 229 T (+91)80-8 52 11 22 Fax (+91)80-8 52 11 80 Siemens Ltd. CMP Div,5th Floor 4A Ring Road,IP Estate New Delhi 110 002 T (+91)11-3 31 99 12 Fax (+91)11-3 31 96 04 Siemens Ltd. CMP Div,4th Floor 130,Pandurang Budhkar Marg, Worli Mumbai 400 018 T (+91)22-4 96 21 99 Fax (+91)22-4 96 22 01 IRL Siemens Ltd. Electronic Components Division 8,Raglan Road IRL-Dublin 4 T (+3 53)1-2 16 23 42 Fax (+3 53)1-2 16 23 49 IL Nisko Ltd. 2A,Habarzel St. P.O.Box 58151 61580 Tel Aviv –Isreal T (+9 72)3 -7 65 73 00 Fax (+9 72)3 -7 65 73 33 PK Siemens Pakistan Engineering Co.Ltd. PO Box 1129,Islamabad 44000 23 West Jinnah Ave Islamabad T (+92)51-21 22 00 Fax (+92)51-21 16 10 PL Siemens SP.z.o.o. ul.Zupnicza 11 PL-03-821 Warszawa T (+48)22-8 70 91 50 Fax (+48)22-8 70 91 59 ROK Siemens Ltd. Asia Tower,10th Floor 726 Yeoksam-dong,Kang-nam Ku CPO Box 3001 Seoul 135-080 T (+82)2-5 27 77 00 Fax (+82)2-5 27 77 79 RUS INTECH electronics ul.Smolnaya,24/1203 RUS-125 445 Moskva T (+7)0 95 -4 51 97 37 Fax (+7)0 95 -4 51 86 08 S Siemens Components Scandinavia Österögatan 1,Box 46 S-164 93 Kista T (+46)8-7 03 35 00 Fax (+46)8-7 03 35 01 Email: [email protected] Seite 12 von 12 VRC Infineon Technologies Hong Kong Ltd. Beijing Office Room 2106,Building A Vantone New World Plaza No.2 Fu Cheng Men Wai Da Jie Jie 100037 Beijing T (+86)10 -68 57 90 -06,-07 Fax (+86)10 -68 57 90 08 Infineon Technologies Hong Kong Ltd. Chengdu Office Room14J1,Jinyang Mansion 58 Tidu Street Chengdu, Sichuan Province 610 016 T (+86)28-6 61 54 46 /79 51 Fax (+86)28 -6 61 01 59 Infineon Technologies Hong Kong Ltd. Shanghai Office Room1101,Lucky Target Square No.500 Chengdu Road North Shanghai 200003 T (+86)21-63 6126 18 /19 Fax (+86)21-63 61 11 67 Infineon Technologies Hong Kong Ltd. Shenzhen Office Room 1502,Block A Tian An International Building Renim South Road Shenzhen 518 005 T (+86)7 55 -2 28 91 04 Fax (+86)7 55-2 28 02 17 ZA Siemens Ltd. Components Division P.O.B.3438 Halfway House 1685 T (+27)11-6 52 -27 02 Fax (+27)11-6 52 20 42 AN-EVAL-ICE2A365-1 V1.2