Version 1.0 , August 2001 Design Note DN-Charger_Adapter 10W CoolSET 10W Charger / Adapter with ICE2A165 Author: Harald Zöllinger Published by Infineon Technologies AG http://www.infineon.com Power Management & Supply N e v e r s t o p t h i n k i n g 10W Board with ICE2A165 Contents: 10W Board with ICE2A165 ...................................................................................... 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 2 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 10W Board with ICE2A165 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 ICE2A165 chip used 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 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. Fig: board Other output voltages can also be implemented very easily by simple modification of the transformer and the output circuitry. 3 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Technical specifications: Input Voltage Range Input Frequency Output Voltage Output Power Line Regulation (85 ...270V) Load Regulation (10% ... 100%) Efficiency Output Ripple Voltage Input Power @ noload Switching Frequency Temperature Range 85 ... 270V AC 50, 60 Hz 5V +-5% 14W < 1% < 1% > 70% < 100mV <400mW 21...100 kHz 0 ... 70°C Circuit description: Introduction The ICE2A165 chip used here was specially designed for 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 input fuse F1 as overcurrent protection as well as choke L5 and X2 capacitor C8 as radio interference suppressors. After bridge rectifier BR1 and input capacitor C3, a voltage of 90 to 380 VDC depending on input voltage is available. ICE2A165 Power Supply Startup From this voltage, the chip's starting current supply is derived using resistors R6 and R7. Because of the low current drain of <55 uA, high-value resistors can be used. Series connection of the resistors is necessary for reasons of dielectric strength of the individual resistors. Operation Mode During operation, the VCC pin is supplied via a separate transformer winding with associated rectification D2 and buffering C4, C13. Resistor R8 is used for current limiting during charging of C4. In order not to exceed the maximum voltage at VCC pin an external zenerdiode D4 limits this voltage. During noload condition the switching frequency is reduced down to 21kHz in order to reduce the switching losses. Softstart The Soft-Start function is realised by an internal resistor and the external capacitor C14. Primary Current – CoolMOS Snubber Network R10, C12 and D3 are dissipate the energy of the leakage inductance. Limitation of primary current The CoolMOS source current is sensed with an external shunt resistor R17. When the voltage at R17 exceeds the internal Current-Limit threshold the gate driver is shut off immediately. 4 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Output Stage Output Voltage Power is coupled out on the secondary side via a fast-acting diode D1 with low forward voltage. Capacitor C5 performs energy buffering, a following filter L3, C9 considerably reduces the output voltage ripple. Storage capacitor C5 is designed to exhibit as small an internal resistance as possible (ESR) in order to minimize the output voltage ripple caused by the triangular current characteristic. The output voltage is set with resistors R1, R2. Regulation The output voltage is controlled using a type TL431 reference diode. This device incorporates the voltage reference as well as the error amplifier and a driver stage. Compensation network C1, C2, R1, R5 constitutes the external circuitry of the error amplifier of IC2. This circuitry allows the feedback to be precisely matched to dynamically varying load conditions, thereby providing stable control. The maximum current through the optocoupler diode and the voltage reference is set by using resistors R3, R4. Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input of the ICE2A165 control device. The optocoupler used meets DIN VDE 884 requirements. Design calculations for the components and the transformer were performed in accordance with Application Note “AN–SMPS–ICE2AXXX for OFF – Line Switch Mode Power Supplies”. 5 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Schematic: 6 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Component Legend: Board Layout: Component side shown 7 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Component List: Part List ICE2A165 Evaluation Board 5V/ 10W Pos. Part 1 BR1 2 C1 4 C2 5 C3 6 C4 7 C5 8 C6 9 C7 10 C8 11 C9 12 C12 13 C13 14 C14 15 D1 16 D2 17 D3 18 D4 19 F1 20 IC1 21 IC11 22 IC2 23 L3 24 L5 25 R1 26 R2 27 R3 28 R4 29 R5 30 R6 31 R7 32 R8 33 R9 34 R10 35 R16 36 R17 37 R18 38 TR1 39 TR1 40 X1 41 X2 * = not assembled Type B500 C1500 470nF, 50V 10nF, 50V 47uF, 400V 22uF, 50V 1000uF, 25V 4,7nF, 50V 2,2nF,250V, Y1 0,1uF, 275V, X2 1000uF, 25V 1nF, 400V 100nF, 50V 220nF, 50V SB540 1N4148 1N4937 ZPD18 Microfuse 3,15A SFH617A-3X016 ICE2A165 TL431CLP 1uH, 3,7A 27mH, 0,4A 4,7k, 1% 4,7k, 1% 180R 1k 4,7k 360k 360k 4,7R 22R 100k, 1W * 1,4R, 0,6W, 1%, * E20 Coil Former E20/10/6, 0,5 N27 Connector 2pol. Connector 2pol. 8 of 12 07.08.2001 Comment DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Transformer Construction Core Material: E20/10/6; N27 gap: 0,5mm Al = 103nH Lp = 692uH Coil former: horizontal version 41 turns 0,25 mm 5 turns 2 x 0,8mm 11 turns 0,25 mm 1/2 Prim. Pin 1 Pin 2 Sec . Pin 8 Pin 10 Aux. Pin 5 Pin 4 1/2 Prim 41 turns 0,25 mm Pin 2 Pin 3 center meens one layer Makrofol Primary winding 41 + 41 turns Aux. winding 11 turns Secondary winding 5 turns Top view 0,25 mm Ø 0,25 mm Ø 2 x 0,80 mm Ø Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 with triple Insulation Pin 10 Pin 9 Pin 8 Pin 7 Pin 6 9 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Measurements: No-load Input Power Pin [mW] Efficiency [%] Efficiency 100 90 80 70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 50 Pout [W] Vin@85V 400 350 300 250 200 150 100 50 0 100 150 200 250 300 Vacin [V] Vin@270V Max. Output Power Vs Input Voltage 16 14 Power 12 10 8 6 4 2 0 85 100 150 200 230 270 Voltage Note: The built-in transformer does not comply with EN60950 safety requirements in respect of electrical isolation. References: [1] ICE2AXXX for OFF-Line Switch Mode Power Supplies Application Note, Infineon Technologies [2] CoolSET-II Off-line SMPS Current Mode Controller with 650V/800V CoolMOS on Board Datasheet, Infineon Technologies 10 of 12 DN-Charger_Adapter 10W V1.0 10W Board with ICE2A165 Revision History Application Note AN-EVAL-ICE2A165-1 Actual Release: V1.1 Date:07.08.2001 Previous Release: V1.0 Page of actual Rel. Page of Subjects changed since last release prev. Rel. 12 12 12 12 First Issue Part List, Transformer Construction 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). 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