Version 1.0, February 2001 Desing Note DN-SMPS Multistage 40W-1 CoolSET 40W SMPS Multistage 40W using ICE2A365 Author: Harald Zöllinger & 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 SMPS Multistage 40W using ICE2A365 Contents: 40W SMPS Multistage using ICE2A365............................................................................................ 2 Technical specifications:................................................................................................................... 3 Circuit description: ............................................................................................................................ 4 Schematic: .......................................................................................................................................... 5 Component Legend: .......................................................................................................................... 6 Board Layout: ..................................................................................................................................... 6 Component List:................................................................................................................................. 7 Transformer Construction: ............................................................................................................... 8 Mesurements: ................................................................................................................................... 10 1 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 40W SMPS Multistage using 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. Fig: Evaluation board Other output voltages can also be implemented very easily by a simple modification of the transformer and the output circuitry. 2 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Technical specifications: Input Voltage Range Input Frequency Output Voltage 1 Output Voltage 2 Output Voltage 3 Output Voltage 4 Output Power 1 Output Power 2 Output Power 3 Output Power 4 Line Regulation (85 ...270V) Load Regulation (10% ... 100%) Efficiency Output Ripple Voltage Switching Frequency Temperature Range 90 ... 264V AC 50, 60 Hz 5V +-1% +12V +-8% -12V +-8% +30V +-10% 20W @230V 15W @230V 5W @230V 1W @230V < 1% @ 5V < 1% @ 5V 80% < 100mV 21....100 kHz 0 ... 70°C 3 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Circuit description: Introduction The ICE2A365 chip used here was particularly designed for the use in flyback converters. As shown on the circuit diagram (p. 5), only a few additional components are required to create an AC/DC power supply. Input Stage 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. 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 <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 D2 and buffering C4, C19. 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 D7 is applied for voltage limitation. Softstart The Soft-Start function is realised by an internal resistor and the external capacitor C21. 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 R24. When the voltage at R24 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 D1, D4, D5, D6 with low forward voltage. The capacitors C5, C20, C13, C15, C17 provide energy buffering, a filter L3, C9; L8, C14; L7, C16 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. 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”. 4 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Schematic: 5 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Component Legend: Board Layout: Component side shown 6 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Component List: 7 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Transformer Construction: 8 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 9 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 Mesurements: Efficiency [%] Efficiency 100 90 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 30 35 40 Pout [W] Vin@85V Vin@270V Frequency [kHz] Frequency Reduction 110 100 90 80 70 60 50 40 30 20 10 0 5 10 15 20 25 Pout [W] Vin@85V 10 of 13 Vin@270V SMPS Multistage 40W V1.0 SMPS Multistage 40W 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-EVALM-ICE2A365-1 Actual Release: V1.0 Date:15.02.2001 Previous Release: V1.0 Page of Page of Subjects changed since last release actual prev. Rel. Rel. 14 -First Issue 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. 11 of 13 SMPS Multistage 40W V1.0 SMPS Multistage 40W using ICE2A365 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. 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