Version 1.0 , Nov. 2001 Design Note DN-EVALMF2ICE2A265-1 CoolSET 35W DVD Power Supply with ICE2A265 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 35W DVD Power Supply ICE2A265 Contents: 35W Multi Output Evaluation Board for DVD Supply with ICE2A265 ........................................... 3 Technical specifications: .................................................................................................................. 4 Circuit description: ............................................................................................................................ 4 Schematic: .......................................................................................................................................... 6 Board Layout; Component Legend: ................................................................................................ 7 Component List: ................................................................................................................................ 8 Transformer Construction: ............................................................................................................... 9 Mesurements:................................................................................................................................... 10 2 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 35W Multi Output Evaluation Board for DVD Supply with ICE2A265 The board described here was designed as a typical power supply in flyback converter topology with six output voltages and secondary control. This type of switch mode power supply is particularly suitable as an AC/DC power supply for DVD supply, video games, satellite decoders, etc. The switch mode power supply ICE2A265 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 auto restart mode. Fig: Evaluation board Note: Other output voltages can also be implemented very easily by a simple modification of the transformer and the output circuitry. 3 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Technical specifications: Input Voltage Range Input Frequency Output Voltage 1 Output Voltage 2 Output Voltage 3 Output Voltage 4 Output Voltage 5 Output Voltage 6 (isolated) Line Regulation (190 ...270V) Load Regulation (10% ... 100%) Efficiency Switching Frequency Temperature Range 190 ... 264V AC 50, 60 Hz +5V +-3%; 1,5A peak +16V +-8%; 1,5A peak +12V +-8%; 70mA -12V +-8%; 70mA -22V +-8%; 50mA +5V +-5%; 40mA < 1% @ 5V < 1% @ 5V >80% 21....100 kHz 0 ... 50°C Circuit description: Introduction The ICE2A265 chip used here was particularly designed for the use in flyback converters. As shown on the circuit diagram (p. 6), 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 L1 and X2capacitors C13 and C18 as radio interference suppressors. After the bridge rectifier D12...D15 and the input capacitor C1, a voltage of 200 to 380 VDC depending on input voltage is available. ICE2A265 Power Supply Startup From the DC input voltage, the chip's starting current supply is derived using the resistors R6 and diode D11. 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 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 D10 and buffering C2, C21. The Resistor R8 is used for current limiting during the charging of C2. In order to not exceed the maximum voltage at the VCC pin, an external zenerdiode D9 is applied for voltage limitation. Softstart The Soft-Start function is realised by an internal resistor and the external capacitor C14. 4 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Primary Current – CoolMOS Clamping Network R12, C19 and D1 dissipate the energy of the leakage inductance. Limitation of primary current The CoolMOS source current is sensed by an external shunt resistor R7. When the voltage at R7 exceeds the internal current-limit threshold, the gate driver is shut off immediately. Output Stage On the secondary side the power is coupled out via a fast-acting diodes D2, D3, D4, D5, D7, D8 with low forward voltage. The capacitors C3, C4, C5, C9, C11, C26 provide energy buffering, a filter L2, C6; L3, C7; L4, C8; L5, C10; L6, C12 reduces the output voltage ripple considerably. All storage capacitors 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 for the +5V output. Regulation The output voltage is controlled using a type TL431 IC2 reference diode. This device incorporates the voltage reference the error amplifier, and a driver stage. The compensation network C15, C16, 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 U1 is used for floating transmission of the control signal to the “Feedback” input of the ICE2A265 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”. 5 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Schematic: 6 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Board Layout; Component Legend: Component side shown 7 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Component List: Part List 35W DVD Supply Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part C1 C2 C3, C4, C6, C7 C5, C9, C26 C8, C10, C27 C11 C12 C13, C18 C14, C15 C16, C20 C17 C19 C21, C22, C23, C24, C25, C30, C31 C28, C29, C34, C35 C33 D1 D2 D8 D3, D4, D5, D7 D9 D10 Pcs. Type 1 47uF, 400V 1 47uF, 35V Grid 10mm 2,5mm Ordering Code B43501B41821- Manuf. EPCOS EPCOS 4 1000uF, 25V 5mm KZE25VB1000MK20 NCC 3 3 1 1 2 2 2 5mm 5mm 5mm 5mm 15mm 5mm 5mm KZE25VB220MH11 KZE25VB100MF11 KZE35VB220MH15 KZE35VB150MH11 B81130B37984B37979- NCC NCC NCC NCC EPCOS EPCOS EPCOS 1 220uF, 25V 100uF, 25V 220uF, 35V 150uF, 35V 0,1uF, 275V, X2 470nF, 50V 2,2nF, 50V * 2,2nF, 400V 7,5mm B32520- EPCOS 7 100nF, 50V 5mm B37987- EPCOS 5mm B37984- EPCOS 4 1uF, 50V 1 1 2 1 1nF, 250V, Y1 1N4937 MUR420 MBR540 12,5mm 10mm 15mm 15mm 4 MUR120 12,5mm 1 1 BZX 79/B18 1N4148 22 D11, D12, D13, D14, D15 5 1N4007 23 24 25 26 27 28 29 D16, D18 D17 D19 F1 IC2 IC3 U1 2 1 1 1 1 1 1 * * * Fuse 3,15A TL431CLP ICE2A265 SFH617A-3X016 30 K1, K2, K3, K4, K5, K6, K7 7 Connector 2 3 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 wire 27mH, 0,9A 1uH, 3,7A 2,2uH, 0,6A 4k92, 1% 4k7, 1% 750R 1,2k 47k 330k 0,68R 1% 4,7R 22R 47k SMT1 coil former ED29/ 0,98mm gap 31 Br1, Br2, Br3 32 L1 33 L2, L3, L4 34 L5, L6 35 R1 36 R2 37 R3 38 R4 39 R5 40 R6 41 R7 42 R8, R11 43 R9 44 R12 45 TR1 46 TR1 * = not assembled 08.06.2003 WKP 1n M Wima 10mm 10mm 12,5mm 10mm 10mm 10mm SOT-54 DIP8 2,5mm Infineon 10mm 5mm 10mm 10mm 10mm 10mm 10mm 10mm 10mm 12,5mm 10mm 10mm 12,5mm 4mm 8 of 12 B82732822LY-1R0M B82141- see also Winding Instruction EPCOS Componex EPCOS Orega Orega DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Transformer Construction: 9 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Mesurements: 10 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 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 11 of 12 DN-EVALMF2ICE2A265 V1.0 35W DVD Power Supply ICE2A265 Revision History Design Note DN-EVALM-ICE2A265-1 Actual Release: V1.0 Date: 11.04.2002 Previous Release: V1.0 Page of Page of Subjects changed since last release prev. actual Rel. Rel. 12 -New 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--15 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. 12 of 12 DN-EVALMF2ICE2A265 V1.0