Version 1.0 , November 2001 Design Note DN-Server Standby-1 CoolSET 20W Server Standby with ICE2A265 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 20W Server Standby with ICE2A265 Table of Contents INTRODUCTION ..................................................................................................................................... 3 LIST OF FEATURES............................................................................................................................... 4 POWER SUPPLY SPECIFICATION ....................................................................................................... 4 SCHEMATIC............................................................................................................................................ 5 DESCRIPTION ........................................................................................................................................ 6 Introduction ....................................................................................................................................... 6 PRIMARY SIDE ........................................................................................................................................ 6 Line Input .......................................................................................................................................... 6 Startup .............................................................................................................................................. 6 Operation Mode ................................................................................................................................ 6 Softstart ............................................................................................................................................ 6 Snubber Network .............................................................................................................................. 6 Limitation of primary current ............................................................................................................. 6 Feedback Network............................................................................................................................ 6 SECONDARY SIDE................................................................................................................................... 7 Output Voltage.................................................................................................................................. 7 Regulation......................................................................................................................................... 7 EMI FILTER ............................................................................................................................................ 7 PCB LAYOUT.......................................................................................................................................... 8 BILL OF MATERIAL EVALS-ICE2A265 ................................................................................................ 9 TRANSFORMER CONSTRUCTION DOCUMENTATION.................................................................... 10 PERFORMANCE DATA........................................................................................................................ 11 EFFICIENCY .......................................................................................................................................... 11 FREQUENCY REDUCTION ...................................................................................................................... 12 NO-LOAD INPUT POWER ........................................................................................................................ 12 REGULATION AND POWER LIMITING ....................................................................................................... 13 OUTPUT VOLTAGE DURING STARTUP ...................................................................................................... 15 STARTUP BEHAVIOR SOFTSTART PHASE................................................................................................ 16 REFERENCES ...................................................................................................................................... 17 2 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Introduction This document is an engineering report that describes a universal input power supply designed in a typical off line flyback converter topology that utilizes the ICE2A265 CoolSETä ä. The application operates in discontinous current mode using the normal 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 a DC standby power supply for PCs. The switch mode power supply ICE2A265 chip used is a current-controlled pulse width modulator with an internal CoolMOS power switch. Figure 1 Server Standby This board was designed to allow testing and demonstrates the basic performance features of 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”. 3 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 List of Features Feature CoolSETä Device ICE2A265 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 the European Commission Table 1 – List of Features Power Supply Specification Description Input Section Input Voltage Line Regulation (120...380V) Input Frequency 3 No Load Input Power (155VAC) 2 No Load Input Power (325VAC) Output Section Output Voltage 3 Output Voltage Ripple (380VAC) Output Current Output Power Total Regulation Load Regulation (10...100%) 4 Efficiency (120VAC) Environmental Conducted EMI Ambient Temperature Symbol Min Typ Max Units VDCIN 120 380 f 47 155/325 <1 50/60 0.23 0.32 VDC % Hz W W VOUT VRipple IOUT POUT 4.75 5.25 4.05 25 η 5.0 0.06 4.00 20 ±2 <1 74 TA 0 25 90 3.95 0 64 VDC VP-P ADC W % % % °C Table 2 – Server Standby Specification 1 VDSBR at Tj = 110°C Burst Mode 3 At nominal load 2 4 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Schematic Figure 2 Server Standby Schematic 5 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Description Introduction The Server Standby is a low cost flyback switching power supply using the ICE2A265 CoolSET integrated circuit from the CoolSETä-F2 family. The circuit shown in Figure 2 details a 5.0V, 20W Server Standby that operates from an input voltage range of 120 to 380 VDC, suitable for applications requiring either an open frame supply or an enclosed surrounding. Primary Side Line Input Just a ceramic capacitor (C8) is needed for the input voltage stage used as radio interference suppressors. Startup During the startup phase, the chip supply capacitor C4 will be charged by resistors R6 and R7. Because of the very low start up current of typically 27µA, high-value resistors 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 no load condition (POUT = 0W) the switching frequency is reduced down to 21kHz in order to reduce the switching losses for a low 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 resistor R17. The very accurate value of the shunt improves the peak power limitation shown in the curve peak power limitation in the rear of this report. Feedback Network Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input via resistor R9 and capacitor C6 of the ICE2A265 control device. The optocoupler used meets DIN VDE 884 requirements. 6 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Secondary Side Output Voltage Power is coupled out on the secondary side via a fast-acting diode D1 with low forward voltage. Capacitors C5, C17 and C20 perform energy buffering, a following filter C9 with one serial choke L3 considerably reduces the output voltage ripple. Storage output capacitors C5, C17 and C20 are designed to exhibit a low internal resistance as possible (ESR) in order to minimize the output voltage ripple caused by the triangular current characteristic. The output voltage is set by the voltage divider R1 and R2. The ceramic capacitor C19 reduces high voltage spikes at the output stage. R20 leads to a safety operation in normal mode during no load condition. 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, R1and 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 and R4. Optocoupler IC1 is used for floating transmission of the control signal to the “Feedback” input via resistor R9 and capacitor C6 of the ICE2A265 control device. The optocoupler used meets DIN VDE 884 requirements. EMI Filter To reduce negative EMI effects, two Y capacitors (C18 & C7) are set in parallel to the transformer. Note: Place the Y capacitor as close as possible to the transformer. 7 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 PCB Layout Figure 3 PCB layout component side shown 8 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Bill of Material Server Standby Pos. Part 1 2 3 4 C1 C2 C4 C5, C17, C20 C6 C7, C18 C8 C9 C12 C13, C19 C14 D1 D2 D3 D4 IC1 IC3 IC2 L3 R1, R2 R3 R4 R5 R6 R7 R8 R9 R10 R17 R18 R20 TR1 TR1 X1, X2 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 Type Ordering Code 1 1 1 3 470nF, 50V 22nF, 50V 22uF, 50V 470uF, 35V B37984-M5474-K B37979-G5223-J B41821-A6226-M KZE 35VB470MK20 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2.2nF, 50V 1nF,250V, Y1 0.1uF, 275V, X2 470uF, 25V 1nF, 400V 100nF, 50V 68nF, 50V MBR745 1N4148 1N4937 ZPD18 SFH617A-3X016 ICE2A265 TL431CLP 1uH, 3,7A 4.7k, 1% 180R 1.2k 2.7k 680k 680k 6.8R 22R 68k, 1W 0.82R, 0.6W, 1%, * 3.3k E20 Coil Former E20/10/6, 0,5 N27 Connector 2pol. B37979-G5222-J 1 1 1 2 B81133-D1104-M KZE 25VB1000MK20 B32520-C6102-K B37987-F5104-K B37987-F5224-K Manuf. Epcos Epcos Epcos (NCC) Alfatec Epcos Epcos (NCC) Alfatec Epcos Epcos Epcos Infineon Infineon 822LY-1R0M Componex see also Transformer Construction * Only for multiple output boards 9 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Transformer Construction Documentation Figure 4 Transformer Construction Data 10 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Performance Data Efficiency Efficiency versus Input Voltage at nominal Load 100 90 80 Efficiency [%] 70 60 50 40 30 20 10 0 115 165 215 265 315 365 20 25 Input Voltage (VDC) Efficiency @ nominal load and Tj=25°C Figure 5 – Efficiency versus Line Input Voltage at Nominal Load Efficiency versus Output Power 80 Efficiency [%] 75 70 65 60 55 50 0 5 10 15 Output Power [W] Efficiency @ Vdcin = 120V Efficiency @ Vdcin = 350V Figure 6 – Efficiency versus Output Power 11 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Frequency Reduction Frequency versus Output Power 120 100 80 60 40 20 0 0 5 10 15 20 Output Power [W] Vdcin = 120V Vdcin = 350V Figure 7 – Frequency versus Output Power No-load input power No Load Input Power versus Line Voltage (Normal Mode) 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0,0 100 150 200 250 300 350 DC Input Voltage [V] Input Power @ No Load (Pout = 0W) Figure 8 – No-load Input Power versus Line Input Voltage in Burst Mode 12 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Regulation and Power Limiting Output Voltage versus Line Input Voltage @ nominal Load 6,00 5,00 4,00 3,00 2,00 1,00 0,00 100 150 200 250 300 350 DC Input Voltage [V] Output Voltage @ nominal load Figure 9 – Output Voltage versus Line Input Voltage @ Nominal Load Load Regulation 6 5 4 3 2 1 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 Output Current [ADC] Output Voltage @ VDcin = 325V Figure 10 – Load Regulation 13 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Peak Power versus Input Voltage 30 25 20 15 10 5 0 100 150 200 250 300 350 DC Input Voltage [V] Peak Power Figure 11 – Peak Power Limitation versus Line Input Voltage Loadjump from 10% up to 100% Load 4,5 4 3,5 3 2,5 2 1,5 1 0 0,0005 0,001 0,0015 0,002 0,0025 0,003 0,0035 0,004 Time [s] Vfb @ 120Vdcin Vfb @ 380Vdcin Figure 12 – Feedbackvoltage during Loadjump from 10% up to 100% Load 14 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Output voltage during startup Vout during Startup @ Vdcin = 120V 6 16 VC4 14 5 12 4 10 3 8 6 2 4 1 2 VOUT 0 0 0 0,005 0,01 0,015 0,02 0,025 0,03 0,035 0,04 Time [s] Vout Vcc Figure 13 – Startup with full Load Condition at VDCIN = 120V, VC4 and VOUT Vout during Startup @ Vdcin = 380V 20 6 18 5 16 VC4 14 4 12 3 10 2 8 6 1 VOUT 4 0 0 0,005 0,01 0,015 0,02 0,025 0,03 -1 0,035 2 0,04 0 Time [s] Vout Vcc Figure 14 – Startup with Full Load Condition at VDCIN = 380V, VC4 and VOUT 15 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 Startup Behavior Softstart Phase Startup @ 120Vdc and nominal Load Condition VFB 7 6 20 18 VC4 16 5 14 4 12 VSS 3 10 Values at the End of the Softstart Phase Vc4 = 15.2V VFB = 6.4V VSS = 4.0V 2 1 0 0,015 0,017 0,019 0,021 0,023 0,025 0,027 0,029 -1 8 6 4 2 0 Time [s] Vfb Vss Vcc Figure 15 Startup Behavior at Nominal Load Condition @ VDCIN = 120V Startup@ Vacin = 380Vdc and nominal Load Condition VFB 7 20 18 6 16 5 VC4 14 4 12 3 Values at the End of the Softstart Phase Vc4 = 15.6V VFB = 4.2V VSS = 4.0V VSS 2 1 0 0,015 0,017 0,019 0,021 0,023 0,025 0,027 -1 0,029 10 8 6 4 2 0 Time [s] Vfb Vss Vcc Figure 16 Startup Behavior at Nominal Load Condition @ VDCIN = 380V 16 of 19 Server Standby V1.0 20W Server Standby with 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 Revision History Application Note AN-Server Standby-1 Previous Release: 1.0 Actual Release: 1.0 Date: 23.11.2001 Page of actual Rel. Date:23.11.2001 Page of Subjects changed since last release prev. Rel. Note: The built-in transformer does not comply with EN60950 safety requirements in respect of electrical isolation. 17 of 19 Server Standby V1.0 20W Server Standby with ICE2A265 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 2001-11--23 Published by Infineon Technologies AG, St.-Martin-Strasse 53, D-81541 München © Infineon Technologies AG 2000. 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