Version 3.0 , August 2001 Design Note DN-Charger_Adapter 40W-1 CoolSET 40W 12V Board with ICE2A365 Author: Rainer Kling 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 40W Charger Adapter using ICE2A365 Table of Contents INTRODUCTION ..................................................................................................................................... 2 LIST OF FEATURES............................................................................................................................... 3 POWER SUPPLY SPECIFICATION ....................................................................................................... 3 SCHEMATIC............................................................................................................................................ 4 PCB LAYOUT.......................................................................................................................................... 4 DESCRIPTION ........................................................................................................................................ 5 Introduction ....................................................................................................................................... 5 Line Input .......................................................................................................................................... 5 Startup .............................................................................................................................................. 5 Operation Mode ................................................................................................................................ 5 Softstart ............................................................................................................................................ 5 Snubber Network .............................................................................................................................. 5 Limitation of primary current ............................................................................................................. 5 Output Voltage.................................................................................................................................. 5 Regulation......................................................................................................................................... 5 BILL OF MATERIAL ............................................................................................................................... 6 TRANSFORMER CONSTRUCTION DOCUMENTATION...................................................................... 7 REFERENCES ........................................................................................................................................ 9 1 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 Introduction This document is an engineering report that describes an universal input power supply designed in a typical off line flyback converter topology that utilizes the ICE2A365 CoolSETä ä. The application operates in discontinous current mode using the burst mode during standby condition. The board has one output voltage with secondary regulation. 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 auto restart mode. The integrated energy saving concept causes a very low standby power during no load and light load condition. This type of switch mode power supply is also suitable as an AC/DC power supply for laptops, palmtops, battery chargers, video games, satellite decoders, settop and cable boxes, color TV etc. in the power range up to approx. 60 W. The switch mode power supply ICE2A365 chip used is a current-controlled pulse width modulator with an internal CoolMOS power switch. Figure 1 Charger_Adapter 40W This board was designed to allow testing and demonstrates the basic performance features and the increased power capability of the new ICE - CoolSETä ä. This document contains the power supply specification, schematic, bill of materials and the transformer construction documentation. Typical operating characteristics are presented at the rear of the report and consist of performance curves and scope waveforms. Note: 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”. 2 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 List of Features Feature CoolSETä Device ICE2A365 External Sense Adjustable Softstart Modulated Gatedrive Over Load Protection with auto restart Over Current Protection with auto restart Over Temperature Shut Down with auto restart Open Loop Protection with auto restart Under Voltage Lock Out with auto restart 1 Drain Source Voltage 650V Frequency Reduction Internal Leading Edge Blanking 100 kHz working frequency DIP8 Package Standby Power according to European Comission Table 1 – List of Features Power Supply Specification Description Input Section Input Voltage Line Regulation (85...270V) Input Frequency 3 No Load Input Power (90VAC) 2 No Load Input Power (230VAC) Output Section Output Voltage Output Voltage Ripple (90VAC) Output Current Output Power Total Regulation Load Regulation (10...100%) Efficiency (90VAC) Efficiency (270VAC) Environmental Conducted EMI Ambient Temperature Symbol Min Typ Max Units VACIN 85 270 f 47 115/230 <1 50/60 200 0.6 VAC % Hz mW W VOUT VRipple IOUT POUT 11.5 12 100 3.4 40 ±2 <1 81 85 12.5 3.38 0 η η TA 0 25 64 3.42 51 50 VDC mVP-P ADC W % % % % EN55022B °C Table 2 – Power Supply Specification 1 2 VDSBR at Tj = 110°C Burst Mode 3 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 Schematic Figure 2 – 40W 12V ICE2A365 Power Supply Schematic PCB Layout Figure 3 – PCB Layout Component Side shown 4 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 Description Introduction The Charger_Adapter 40W is a low cost flyback switching power supply using the ICE2A365 integrated circuit from the CoolSETä-F2 family. The circuit shown in Figure 2 details a 12V, 40W supply that operates from an line input voltage range of 85 to 265VAC, suitable for applications requiring either an open frame supply or an enclosed adapter. Line Input The AC line input side comprises of an input fuse F1 as line input over current protection as well as choke L5 and the X2 capacitor C8 as radio interference suppressors. The NTC resistor R20 limits the switch on peak current. After bridge rectifier BR1 and input capacitor C3, a voltage of 90 to 380 VDC, depending on input voltage, is available. Only a 150 µF input capacitor is required due to the wider duty cycle DCMAX of the ICE-F2-family. Startup From this voltage, the chip starting the current supply is derived using resistors R6 and R7. Because of the very low start up current of typically 27µA, a high-value resistor can be used. 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 the charging of C4. In order not to exceed the maximum voltage at VCC pin an external zener diode D4 limits this voltage. During light load condition (POUT = W) the switching frequency is reduced down to 21kHz in order to reduce the switching losses. Note: During no load condition, the board creates a burst mode situation to improve the standby power. Softstart The Soft-Start function is realized by an internal resistor and the adjustable external capacitor C14. Snubber Network The network R10, C12 and D3 clamp the DRAIN voltage spike caused by transformer leakage inductance to a safe value below the drain source break down voltage VDSBR = 650V maximum. Limitation of primary current The CoolMOSä drain source current is sensed via external shunt resistors R17. The very accurate value of the shunt due to the two parallel resistors improve the peak power limitation shown in the curve peak power limitation in the rear of this report. 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 C23 with a choke L3 and C23 considerably reduces the output voltage ripple. Storage output 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 via resistor R9 and capacitor C6 of the ICE2A365 control device. The optocoupler used meets DIN VDE 884 requirements. 5 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 Bill of Material ICE2A365 Charger Adapter 12V/ 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 IC2 26 IC3 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 680nF, 50V 1,2nF, 50V 150µF, 400V 68µF, 35V 1000µF, 35V 2,2nF, 50V * 0,1µF, 275V, X2 1000µF, 35V 2,2nF, 400V 100nF, 50V 1µF, 50V 1000µF, 35V 0,22µF, 275V, X2 470µF, 35V 2,2nF, 250V Y1 2,2nF, 250V Y1 DSS10-01A 1N4148 1N4937 ZPD18 Microfuse 3,15A SFH617A-3X016 TL431CLP ICE2A365 1µH, 3,7A 27mH, 0,9A 18k, 1% 4,7k, 1% 510R 1,5k 44k 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. 05.11.2001 Grid 5mm 5mm 10mm 2,5mm 5mm 5mm 15mm 5mm 7,5mm 5mm 5mm 5mm 15mm 5mm 12,5mm 12,5mm 5mm 10mm 10mm 10mm 5mm Ordering Code Manuf. B43501-A9157-M B41821-A7476-M KZE35VB1000MK25 B37979-G5222-J Epcos Epcos Epcos Epcos (NCC) Alfatec Epcos B81130-C1104-M KZE35VB1000MK25 B32520-C6222-K B37987-F5104-K B37984-M5105-K KZE35VB1000MK25 B81130-C1224-M KZE35VB470MJ20 WKP 2n2 M WKP 2n2 M Epcos (NCC) Alfatec 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 6 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 Transformer Construction Documentation Note: The built-in transformer does not comply with EN60950 safety requirements in respect of electrical isolation. 7 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 Change service Issue status 1.0 2.0 3.0 Changes First issue Page 6, BOM Pos. 4 / 10 / 13 Page 7 Transformerdata Page 6, BOM Pos. 25 and 26 8 of 11 Date 30.08.2001 01.10.2001 05.11.2001 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 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 Revision History Application Note AN-Charger_Adapter Actual Release: 3.0 Date: 2001-11-05 Page of actual Rel. -- 40W-03 Previous Release: V1.0 Page of Subjects changed since last release prev. Rel. -- See change service 9 of 11 Charger_Adapter 40W V3.0 40W Charger Adapter using ICE2A365 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/CoolSET CoolMOS and CoolSET are trademarks of Infineon Technologies AG. Edition 2001-08--30 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. 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