AN - REF- 15W_C 61K5 - THIN PAK AD APTER 1 5 W 5 V Adapte r Re fe re nce Board wi th IC E2QS03G, IPL65R1 K5 C 6 S, BSC 0 6 7 N 06 L S3 G & BAS21 - 0 3 W Application Note About this document Scope and purpose This document is an engineering report that describes 15 W 5 V USB adapter reference design board using Infineon Quasi-Resonant PWM IC ICE2QS03G with CoolMOS™ IPL65R1K5C6S (ThinPAK 5x6) and secondary side synchronous rectification IC with OptiMOS™ BSC067N06LS3 G (ThinPAK 5x6). The reference USB adapter board is specially designed in a very small form factor, high efficiency, low standby power, various modes of protections for a high reliable system and it pass conductive EMI, ESD and Lightning surge test. This board can be used for production by customers after final verification with minor changes. Intended audience This document is intended for users who wish to design 15 W 5 V AC-DC adapter in short period of time, high efficiency, high reliability and very small form factor with Infineon CoolMOS™ C6 series, OptiMOS™, QuasiResonant PWM IC ICE2QS03G and synchronous rectification. Table of Contents About this document ................................................................................................................... 1 Table of Contents ........................................................................................................................ 1 1 Abstract ..................................................................................................................... 3 2 Reference board ......................................................................................................... 3 3 Specification .............................................................................................................. 4 4 4.1 4.2 4.3 4.4 4.5 Circuit description....................................................................................................... 5 Mains input rectification and filtering ..................................................................................................... 5 PWM control and switching MOSFET ...................................................................................................... 5 Snubber network....................................................................................................................................... 5 Output stage .............................................................................................................................................. 5 Feedback loop ........................................................................................................................................... 5 5 Circuit operation ......................................................................................................... 6 1 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Abstract 5.1 5.2 5.3 5.4 5.5 Startup operation...................................................................................................................................... 6 Normal mode operation ........................................................................................................................... 6 Primary side peak current control........................................................................................................... 6 Digital frequency reduction ..................................................................................................................... 6 Burst mode operation............................................................................................................................... 6 6 6.1 6.2 6.3 6.4 6.5 6.6 Protection features ..................................................................................................... 7 VCC over voltage and under voltage protection ...................................................................................... 7 Over load/Open loop protection ............................................................................................................. 7 Auto restart for over temperature protection ........................................................................................ 7 Adjustable output overvoltage protection ............................................................................................. 7 Short winding protection ......................................................................................................................... 7 Foldback point protection ....................................................................................................................... 8 7 Circuit diagram ........................................................................................................... 9 8 8.1 8.2 PCB layout ............................................................................................................... 10 Top side ....................................................................................................................................................10 Bottom side..............................................................................................................................................10 9 Component list ......................................................................................................... 11 10 Transformer construction .......................................................................................... 12 11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 Test results .............................................................................................................. 13 Efficiency, regulations and output ripple .............................................................................................13 Standby power ........................................................................................................................................14 Line regulation.........................................................................................................................................15 Load regulation .......................................................................................................................................15 Maximum power......................................................................................................................................16 ESD immunity (EN61000-4-2) .................................................................................................................16 Surge immunity (EN61000-4-5)..............................................................................................................16 Conducted emissions (EN55022 class B) ..............................................................................................17 Thermal measurement ...........................................................................................................................19 12 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 Waveforms and scope plots ........................................................................................ 20 Start up at low/high AC line input voltage with maximum load ........................................................20 Soft start ...................................................................................................................................................20 Start up delay time & output voltage rise time ....................................................................................21 Hold up time ............................................................................................................................................21 Drain & current sense voltage at maximum load.................................................................................22 Zero crossing point during normal operation ......................................................................................22 Load transient response (Dynamic load from 1.67% to 100%) ..........................................................23 Output ripple voltage at maximum load ..............................................................................................23 Output ripple voltage during burst mode at 1 W load ........................................................................24 Active Burst mode operation .................................................................................................................24 Over load protection (Auto restart mode) ............................................................................................25 Output overvoltage protection (Latched off mode) ............................................................................25 VCC under voltage/Short optocoupler protection (Auto restart mode) .............................................26 13 References ............................................................................................................... 26 Revision History........................................................................................................................ 26 Application Note 2 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Abstract 1 Abstract This application note is an engineering report of a very small form factor reference design for universal input 15 W 5 V adapter. The adapter is using ICE2QS03G, a second generation current mode control QuasiResonant flyback topology controller, IPL65R1K5C6S, a C6 series of high voltage power CoolMOS™ and BSC067N06LS3 G, a third series of medium voltage power logic level OptiMOS™ , optimized for logic level driver of Synchronous Rectification. The distinguishing features of this reference design are very small form factor, best-in-class low standby power, very high efficiency, good EMI performance and various modes of protection for high reliable system. 2 Reference board This document contains the list of features, the power supply specification, schematic, bill of material and the transformer construction documentation. Typical operating characteristics such as performance curve and scope waveforms are showed at the rear of the report. Figure 1 REF-15W_C61K5-THINPAK ADAPTER [Dimensions L x W x H: 47mm x 31mm x 16mm] ICE2QS03G BSC067N06LS3 G BAS21-03W IPL65R1K5C6S (Top view) Figure 2 (Bottom view) REF-15W_C61K5-THINPAK ADAPTER [Top & Bottom View] Application Note 3 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Specification 3 Table 1 Specification Specification of REF-15W_C61K5-THINPAK ADAPTER Input voltage 85 VAC ~265 VAC Input frequency 47~63 Hz Output voltage, current & power 5 V/3 A/15 W Output voltage rise time <30 ms Start up delay time (VAC 115 V, 60 Hz, Full Load) <250 ms Hold up time (VAC 115 V, 60 Hz, Full Load) >5 ms Mains ON/OFF Overshoot (85 VAC ~ 265 VAC) +/-3% of nominal output voltage (Vripple_p_p <300 mV) Dynamic load response +/-3% of nominal output voltage (50mA to full load, slew rate at 1.5 A/µs, 100 Hz) (Vripple_p_p <300 mV) Output ripple voltage +/-1% of nominal output voltage (full load, 85 VAC ~265 VAC) (Vripple_p_p<100 mV) Active mode four point average efficiency (25%,50%,75%,100%load) (EU CoC Version 5, Tier 2 and EPS of DOE USA) >88% at 115 VAC & >87% at 230 VAC 10% load efficiency >87% at 115 VAC & >85% at 230 VAC (EU CoC Version 5, Tier 2) Conducted emissions (EN55022 class B) Pass with 8 dB margin Safety <50 µA @ VAC = 265 V Leakage Current (50 µA @ VAC = 265 V,L to FG & N to FG) ESD immunity (EN61000-4-2) Level 4 (±8 kV) contact discharge Surge immunity (EN61000-4-5) Installation class 3 (2 kV: common mode) Form factor case size (L x W x H) (47 x 31 x 16) mm3 Application Note 4 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Circuit description 4 Circuit description 4.1 Mains input rectification and filtering The AC line input side comprises the input fuse F1 as over-current protection. A rectified DC voltage (120 V ~ 374 V) is obtained through a bridge rectifier BR1 and a pi filter C13, FB21 and C22. The pi filer also attenuates the differential mode conducted EMI. 4.2 PWM control and switching MOSFET The PWM pulse is generated by the Quasi Resonant PWM current-mode Controller ICE2QS03G and this PWM pulse drives the high voltage power CoolMOS™, IPL65R1K5C6S (C6) which designed according to the revolutionary Superjunction (SJ) principle. The CoolMOS™ C6 provides all benefits of a fast switching SJ MOSFET while not sacrificing ease of use. It achieves extremely low conduction and switching losses and can make switching applications more efficient, more compact, lighter and cooler. The PWM switch-on is determined by the zero-crossing input signal and the value of the up/down counter. The PWM switch-off is determined by the feedback signal VFB and the current sensing signal VCS. ICE2QS03G also performs all necessary protection functions in flyback converters. Details about the information mentioned above are illustrated in the product datasheet. 4.3 Snubber network A snubber network DZD11 dissipates the energy of the leakage inductance and suppress ringing on the SMPS transformer. 4.4 Output stage On the secondary side, 5 V output, the PWM pulse is generated by synchronous rectification controller UCC24610. The synchronous rectification pulse drives the logic level medium voltage power OptiMOS™, BSC067N06LS3 G which is optimized for synchronous rectification such as the lowest RDS(on), the perfect switching behavior of fast switching, the smallest footprint and highest power density. The capacitors C22 provides energy buffering following with the LC filter FB21 and C24 to reduce the output ripple and prevent interference between SMPS switching frequency and line frequency considerably. Storage capacitor C22 is designed to have an internal resistance (ESR) as small as possible. This is to minimize the output voltage ripple caused by the triangular current. 4.5 Feedback loop For feedback, the output is sensed by the voltage divider of R26 and R25 and compared to TL431 internal reference voltage. C25, C26 and R24 comprise the compensation network. The output voltage of TL431 is converted to the current signal via optocoupler IC12 and two resistors R22 and R23 for regulation control. Application Note 5 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Circuit operation 5 Circuit operation 5.1 Startup operation Since there is a built-in startup cell in the ICE2QS03G, there is no need for external start up resistor, which can improve standby performance significantly. When VCC reaches the turn on voltage threshold 18V, the IC begins with a soft start. The soft-start implemented in ICE2QS03G is a digital time-based function. The preset soft-start time is 12 ms with 4 steps. If not limited by other functions, the peak voltage on CS pin will increase step by step from 0.32 V to 1 V finally. After IC turns on, the VCC voltage is supplied by auxiliary windings of the transformer. 5.2 Normal mode operation The secondary output voltage is built up after startup. The secondary regulation control is adopted with TL431 and optocoupler. The compensation network C25, C26 and R24 constitutes the external circuitry of the error amplifier of TL431. This circuitry allows the feedback to be precisely controlled with respect to dynamically varying load conditions, therefore providing stable control. 5.3 Primary side peak current control The MOSFET drain source current is sensed via external resistor R14 and R14A. Since ICE2QS03G is a current mode controller, it would have a cycle-by-cycle primary current and feedback voltage control which can make sure the maximum power of the converter is controlled in every switching cycle. 5.4 Digital frequency reduction During normal operation, the switching frequency for ICE2QS03G is digitally reduced with decreasing load. At light load, the CoolMOS™ IPL65R1K5C6S will be turned on not at the first minimum drain-source voltage time, but on the nth. The counter is in range of 1 to 7, which depends on feedback voltage in a time-base. The feedback voltage decreases when the output power requirement decreases, and vice versa. Therefore, the counter is set by monitoring voltage VFB. The counter will be increased with low VFB and decreased with high VFB. The thresholds are preset inside the IC. 5.5 Burst mode operation At light load condition, the SMPS enters into Active Burst Mode. At this stage, the controller is always active but the VCC must be kept above the switch off threshold. During active burst mode, the efficiency increase significantly and at the same time it supports low ripple on Vout and fast response on load jump. For determination of entering Active Burst Mode operation, three conditions apply: 1. The feedback voltage is lower than the threshold of V FBEB(1.25 V). ACCordingly, the peak current sense voltage across the shunt resistor is 0.1667; 2. The up/down counter is 7; 3. And a certain blanking time (tBEB=24 ms). Once all of these conditions are fulfilled, the Active Burst Mode flip-flop is set and the controller enters Active Burst Mode operation. This multi-condition determination for entering Active Burst Mode operation prevents mis-triggering of entering Active Burst Mode operation, so that the controller enters Active Burst Mode operation only when the output power is really low during the preset blanking time. Application Note 6 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Protection features During active burst mode, the maximum current sense voltage is reduced from 1 V to 0.34 V so as to reduce the conduction loss and the audible noise. At the burst mode, the FB voltage is changing like a sawtooth between 3.0 and 3.6 V. The feedback voltage immediately increases if there is a high load jump. This is observed by one comparator. As the current limit is 34% during Active Burst Mode a certain load is needed so that feedback voltage can exceed VFBLB (4.5 V). After leaving active burst mode, maximum current can now be provided to stabilize Vout. In addition, the up/down counter will be set to 1 immediately after leaving Active Burst Mode. This is helpful to decrease the output voltage undershoot. 6 Protection features 6.1 VCC over voltage and under voltage protection During normal operation, the VCC voltage is continuously monitored. When the VCC voltage increases up to VCC,OVP or VCC voltage falls below the under voltage lock out level V CC,off, the IC will enter into autorestart mode. 6.2 Over load/Open loop protection In case of open control loop, feedback voltage is pulled up with internally block. After a fixed blanking time, the IC enters into auto restart mode. In case of secondary short-circuit or overload, regulation voltage VFB will also be pulled up, same protection is applied and IC will auto restart. 6.3 Auto restart for over temperature protection The IC has a built-in over temperature protection function. When the controller’s temperature reaches 140°C, the IC will shut down switch and enters into auto restart. This can protect power MOSFET from overheated. 6.4 Adjustable output overvoltage protection During off-time of the power switch, the voltage at the zero-crossing pin ZC is monitored for output overvoltage detection. If the voltage is higher than the preset threshold 3.7 V for a preset period 100 μs, the IC is latched off. 6.5 Short winding protection The source current of the MOSFET is sensed via external resistor R14 and R14A. If the voltage at the current sensing pin is higher than the preset threshold V CSSW of 1.68 V during the on-time of the power switch, the IC is latched off. This constitutes a short winding protection. To avoid an accidental latch off, a spike blanking time of 190 ns is integrated in the output of internal comparator. Application Note 7 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Protection features 6.6 Foldback point protection For a quasi-resonant flyback converter, the maximum possible output power is increased when a constant current limit value is used for all the mains input voltage range. This is usually not desired as this will increase additional cost on transformer and output diode in case of output over power conditions. The internal foldback protection is implemented to adjust the V CS voltage limit according to the bus voltage. Here, the input line voltage is sensed using the current flowing out of ZC pin, during the MOSFET on-time. As the result, the maximum current limit will be lower at high input voltage and the maximum output power can be well limited versus the input voltage. Application Note 8 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Circuit diagram 7 Circuit diagram Figure 3 Schematic of REF-15W_C61K5-THINPAK ADAPTER Application Note 9 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W PCB layout 8 PCB layout 8.1 Top side Figure 4 Top side copper and component legend 8.2 Bottom side Figure 5 Bottom side copper and component legend Application Note 10 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Component list 9 Component list Table 2 Bill of materials(V0.7) No. Designator Description Footprint Part Number Manufacturer Quantity 1 BR1 (800V/1A) SOP-4 D1UBA80 SHINDENGEN 1 2 C12 470pF/250V MKT3/13/10_0M8 DE1B3KL471KC4BNA1S MURATA 1 3 C13, C13A 15uF/400V RB10H(10x16) 400AX15M10X16 RUBYCON 2 4 C16 22uF/35V 1206 C3216X5R1V226M TDK 1 5 C17 100nF/50V 0402 GRM155R71H104KE14D MURATA 1 6 C18, C26 1nF/50V 0402 GRM155R71H102KA01D MURATA 2 7 C19 47pF/50V 0402 GRM1555C1H470JA01D MURATA 1 8 C21 560pF/100V 0603 GRM1885C2A561JA01D MURATA 1 9 C22 820uF/6.3V RB6.3 MP6RL820MC8 MATSUKI POLYMER 1 10 C24 450uF/6.3V RB5 MP6RL450MB8 MATSUKI POLYMER 1 11 C25 220nF/25V 0402 GRM155C81E224KE01D MURATA 1 12 C27 1uF/25V 0402 GRM155R61E105KA12D MURATA 1 13 D12,D13 200V/0.25A SOD323 BAS21-03W INFINEON 2 14 D21 50V/8A DO-221BC(SMPA) V8PAN50-M3/I 15 DZD11 140V 2F ST02D-140F2 16 F1 250V/1A AXIAL0.4_V 3mm 0263001.HAT1L 1 17 FB21 FAIR RITE AXIAL0.4_V 3mm 2743002112 1 18 FB22,FB23 @ C12 lead B64290P0035X038 EPCOS 2 19 IC11 ICE2QS03G SO-8 ICE2QS03G INFINEON 1 20 IC12 TCMT1103 half pitch mini flat TCMT1103 1 21 IC21 TL431 SOT-23 TL431BFDT 1 22 IC22 UCC24610 SO-8 UCC24610 1 23 L11 100µH/0.8A CH6 7447462101 WURTH ELECTRONICS 1 24 Q11 650V/1.5Ω ThinPAK(5x6) IPL65R1K5C6S INFINEON 1 25 Q21 60V/6.7mΩ PG-TDSON-8 BSC067N06LS3 G INFINEON 1 26 R12, R15 10R 0402 2 0R 0402 4 27 R12A, R13, R14B, R15A 28 R12B 43k/1% 0402 1 29 R12C 12k/1% 0402 30 R14, R14A 2R/0.33W/1% 1206 31 R18 10k 0402 32 R21 47R/0.5W 0805 33 R22 130R 0402 1 34 R23 1.2k 0402 1 35 R24 12k 0402 1 36 R25, R26 20k 0402 2 37 R27 2R 0402 1 38 R28 68k 0402 1 39 R29 220k 0402 1 40 R30 43.2k 0402 1 41 R31, R33 51.1k 0402 1 42 R32 75k 0402 1 43 TR1 718µH(66:5:15) TR_RM6_THT8Pin 1 44 USB Port USBPORT USB2 Short JL-CAF-001 1 45 ZD11 22V Zener SOD323 UDZS22B 1 Application Note 1 SHINDENGEN 1 1 ERJ8BQF2R0V 2 1 ERJP6WF47R0V 11 1 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Transformer construction 10 Transformer construction Core and material: RM6 TP4A Bobbin: RM6 with 4 pin Primary Inductance, Lp=718 μH ( ±10%), measured between pin 2 and pin 1 Figure 6 Start 2 Stop X No. of turns 33 Wire size 1XAWG#34 7 S2 Flying wire 15mm 7 floating F2 Flying wire 15mm floating 30 5 30 1XAWG#34 1XLitz TIW(7 X AWG#29) 1XAWG#34 X 8 1 7 33 15 1XAWG#34 1XAWG#34 Layer /2 Primary Shield Secondary Shield 1 1 /2 Primary Auxiliary Transformer structure Application Note 12 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results 11 Test results 11.1 Efficiency, regulations and output ripple Table 3 Efficiency, regulation & output ripple Vin Pin Vout Iout (VAC) (W) (VDC) (A) Vout_ripple_pk_pk (mV) 0.0307 5.01 0.00 58.90 1.7000 5.01 0.30 68.20 1.50 88.41 4.2000 5.01 0.75 24.12 3.76 89.46 8.4300 5.01 1.50 31.50 7.52 89.15 12.6800 5.01 2.25 35.80 11.27 88.90 17.2600 5.01 3.00 49.50 15.03 87.08 0.0310 5.01 0.00 62.50 1.7100 5.01 0.30 72.00 1.50 87.89 4.2000 5.01 0.75 23.60 3.76 89.46 8.3700 5.01 1.50 32.00 7.52 89.78 12.5500 5.01 2.25 31.90 11.27 89.82 16.8400 5.01 3.00 40.80 15.03 89.25 0.0334 5.01 0.00 67.90 1.7500 5.01 0.30 70.80 1.50 85.89 4.3700 5.01 0.75 22.00 3.76 85.98 8.4900 5.01 1.50 32.00 7.52 88.52 12.6500 5.01 2.25 31.80 11.27 89.11 17.0700 5.01 3.00 37.70 15.03 88.05 0.0353 5.01 0.00 72.00 1.7700 5.01 0.30 79.30 1.50 84.92 4.4600 5.01 0.75 22.90 3.76 84.25 8.5600 5.01 1.50 31.70 7.52 87.79 12.7400 5.01 2.25 34.50 11.27 88.48 17.2500 5.01 3.00 42.10 15.03 87.13 85 115 230 265 Figure 7 Pout Efficiency(η) (%) (W) Average η (%) OLP Pin (W) OLP Iout (A) 20.60 3.52 20.37 3.60 21.01 3.73 21.39 3.76 88.65 89.58 87.91 86.91 Efficiency vs AC line input voltage Application Note 13 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results Figure 8 Efficiency vs output power @ 115 VAC and 230 VAC line 11.2 Standby power Figure 9 Standby power @ no load vs AC line input voltage (measured by Yokogawa WT210 power meter - integration mode) Application Note 14 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results 11.3 Line regulation Figure 10 Line regulation Vout @ full load vs AC line input voltage 11.4 Load regulation Figure 11 Load regulation Vout vs output power Application Note 15 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results 11.5 Maximum power Figure 12 Maximum input power (before over-load protection) vs AC line input voltage 11.6 ESD immunity (EN61000-4-2) Pass EN61000-4-2 level 3 (±8 kV) contact discharge. 11.7 Surge immunity (EN61000-4-5) Pass EN61000-4-5 Installation class 3 (2 kV: common mode). Application Note 16 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results 11.8 Conducted emissions (EN55022 class B) The conducted EMI was measured by Schaffner (SMR25503) and followed the test standard of EN55022 (CISPR 22) class B. The demo board was set up at maximum load (15 W) with input voltage of 115 VAC and 230 VAC. Figure 13 Conducted emissions(Line) at 115 VAC and maximum Load Figure 14 Conducted emissions(Neutral) at 115 VAC and maximum Load Application Note 17 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results Figure 15 Conducted emissions(line) at 230 VAC and maximum Load Figure 16 Conducted emissions(Neutral) at 230 VAC and maximum Load Pass conducted EMI EN55022 (CISPR 22) class B with > 8 dB margin for QP. Application Note 18 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Test results 11.9 Thermal measurement The reference adapter’s open frame thermal test was done by thermal infrared camera (TVS-500EX) at the ambient temperature 25 ⁰C. The thermal measures were taken after two hours running with full load and the highest temperature of Q11 (CoolMOS™ C6 ThinPAK 5x6) is 75.6 ⁰C for low line and 90.3 ⁰C for high line. Table 4 Hottest temperature of reference board No. Major component 85 VAC (°C) 1 Q11 (IPL65R1K5C6S) 75.6 90.3 2 Q21 (BSC067N06LS3 G) 55.3 68.8 3 IC22 (SR IC) 49.1 57.7 4 TR1 (Transformer) 59.2 63.7 5 IC11 (ICE2QS03G) 63.8 63.8 6 BR1 (bridge diode) 62.5 48.2 7 DZD11(Snubber zenor diode) 78.8 86.1 8 C13A (Bulk Cap) 52.5 48.6 9 L11 (Differnetial Choke) 54.3 46.7 10 Ambient 25 (PCB bottom side, 85 VAC & full load) 265 VAC (°C) 25 (PCB bottom side, 265 VAC & full load) (PCB top side, 85 VAC & full load) (PCB top side, 265 VAC & full load) Figure 17 Infrared thermal image of REF-15W_C61K5-THINPAK ADAPTER Application Note 19 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Waveforms and scope plots 12 Waveforms and scope plots All waveforms and scope plots were recorded with a LeCroy 6050 oscilloscope 12.1 Start up at low/high AC line input voltage with maximum load 192 ms 192 ms Channel 1; C1 : Drain voltage (VDrain) Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Supply voltage (VCC) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Zero crossing voltage (VZC) Channel 4; C4 : Zero crossing voltage (VZC) Start up time @ 85 VAC & full load= 192 ms Start up time @ 265 VAC & full load = 192 ms Figure 18 Start up 12.2 Soft start 12ms Channel 1; C1 : Current sense voltage (VCS) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Zero crossing voltage (VZC) Soft start time @ 85 VAC & full load = 12 ms Figure 19 Soft start Application Note 20 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Waveforms and scope plots 12.3 Start up delay time & output voltage rise time 196 ms 196 ms 20 ms 20 ms Channel 1; C1 : Mains AC voltage (VAC) Channel 1; C1 : Mains AC voltage (VAC) Channel 4; C4 : Output voltage (Vout) Channel 4; C4 : Output voltage (Vout) 85 VA 265 VAC ~Startup delay time = 196 ms ~Output voltage rise time=20 ms Figure 20 Start up delay time 12.4 Hold up time ~Startup delay time = 196 ms ~Output voltage rise time=20 ms 8 ms 112 ms Channel 1; C1 : Mains AC voltage (VAC) Channel 1; C1 : Mains AC voltage (VAC) Channel 4; C4 : Output voltage (Vout) Channel 4; C4 : Output voltage (Vout) Hold up time @ 85 VAC = 8 ms Hold up time @ 265 VAC = 112 ms Figure 21 Hold up time Application Note 21 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Waveforms and scope plots 12.5 Drain & current sense voltage at maximum load Channel 1; C1 : Drain-source voltage (VDS) Channel 2; C2 : Current sense voltage (VCS) VDrain_peak @ 85 VAC = 339 V Figure 22 Drain & current sense voltage 12.6 Channel 1; C1 : Drain-source voltage (VDS) Channel 2; C2 : Current sense voltage (VCS) VDrain_peak @ 265 VAC = 591 V Zero crossing point during normal operation Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Current sense voltage (VCS) @ 85 VAC , 2nd zero crossing Figure 23 Zero crossing Application Note Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Current sense voltage (VCS) @ 85 VAC , 7th zero crossing 22 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Waveforms and scope plots 12.7 Load transient response (Dynamic load from 1.67% to 100%) Channel 1; C1 : Output ripple voltage (Vout) Channel 1; C1 : Output ripple voltage (Vout) Channel 2; C2 : Output current (Iout) Channel 2; C2 : Output current (Iout) Vripple_pk_pk @ 85 VAC =248 mV Vripple_pk_pk @ 265 VAC =261 mV (Load change from 50 mA to 3 A,100 Hz,1.5 A/μS slew rate) (Load change from 50mA to 3 A,100 Hz,1.5 A/μS slew rate) Probe terminal end with decoupling capacitor of 0.1 μF(ceramic) & 1 μF(Electrolytic), 20 MHz filter Probe terminal end with decoupling capacitor of 0.1 μF(ceramic) & 1 μF(Electrolytic), 20 MHz filter Figure 24 Load transient response 12.8 Output ripple voltage at maximum load Channel 1; C1 : Output ripple voltage (Vout) Channel 1; C1 : Output ripple voltage (Vout) Channel 2; C2 : Output current (Iout) Channel 2; C2 : Output current (Iout) Vripple_pk_pk @ 85 VAC = 49.5 mV Vripple_pk_pk @ 265 VAC = 42.1 mV Probe terminal end with decoupling capacitor of 0.1 μF(ceramic) & 1 μF(Electrolytic), 20 MHz filter Probe terminal end with decoupling capacitor of 0.1 μF(ceramic) & 1 μF(Electrolytic), 20 MHz filter Figure 25 AC output ripple voltage at maximum load Application Note 23 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Waveforms and scope plots 12.9 Output ripple voltage during burst mode at 1 W load Channel 1; C1 : Output ripple voltage (Vout) Channel 1; C1 : Output ripple voltage (Vout) Channel 2; C2 : Output current (Iout) Channel 2; C2 : Output current (Iout) Vripple_pk_pk @ 85 VAC = 64.6 mV Vripple_pk_pk @ 265 VAC = 74.8 mV Probe terminal end with decoupling capacitor of 0.1 μF(ceramic) & 1 μF(Electrolytic), 20 MHz filter Probe terminal end with decoupling capacitor of 0.1 μF(ceramic) & 1 μF(Electrolytic), 20 MHz filter Figure 26 AC output ripple voltage at 1 W load(Burst Mode) 12.10 Active Burst mode operation 6th 7th Channel 1; C1 : Drain voltage (VDrain) Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Supply voltage (VCC) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Zero crossing voltage (VZC) Condition: VFB<1.2 V, NZC=7 and tblanking =24 ms Channel 4; C4 : Zero crossing voltage (VZC) Condition: VFB>4.5 V (load change form full load to 1 W load) Figure 27 Active burst mode at 85 VAC Application Note (load change from 1 W to full load) 24 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W Waveforms and scope plots 12.11 Over load protection (Auto restart mode) built-in 30ms blanking Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Zero crossing voltage (VZC) Condition: VFB>4.5 V & last for 30 ms blanking time (@ 85 VAC, output load change from full load to short load) Figure 28 Over load protection 12.12 Output overvoltage protection (Latched off mode) Channel 1; C1 : Output voltage (Vout) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Zero crossing voltage (VZC) Condition: VO >5.5 V (VZC>3.7 V) (@ 85 VAC, short R26 during while system operation at no load) Figure 29 Output overvoltage protection Application Note 25 Revision 1.0, 2015-03-12 15 W 5 V Adapter Reference Board with ICE2QS03G, IPL65R1K5C6S, BSC067N06LS3 G & BAS21-03W References 12.13 VCC under voltage/Short optocoupler protection (Auto restart mode) Exit autorestart Enter autorestart Channel 1; C1 : Drain voltage (VDrain) Channel 2; C2 : Supply voltage (VCC) Channel 3; C3 : Feedback voltage (VFB) Channel 4; C4 : Zero crossing voltage (VZC) Condition: VCC <10.5 V (@ 85 VAC , short the transistor of optocoupler during system operating @ full load & release) Figure 30 VCC under voltage/short optocoupler protection 13 References [1] ICE2QS03G data sheet, Infineon Technologies AG [2] IPL65R1K5C6S data sheet, 650V CoolMOS™ CE Power Transistor, Infineon Technologies AG [3] BSC067N06LS3 G data sheet, 60V OptiMOS™ 3 Power Transistor, Infineon Technologies AG [4] BAS21-03W data sheet, Infineon Technologies AG [5] ICE2QS03G design guide. [ANPS0027] [6] ThinPAK Product Brief Revision History Major changes since the last revisiono Page or Reference -- Application Note Description of change First Release 26 Revision 1.0, 2015-03-12 Trademarks of Infineon Technologies AG AURIX™, C166™, CanPAK™, CIPOS™, CIPURSE™, CoolMOS™, CoolSET™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, EasyPIM™, EconoBRIDGE™, EconoDUAL™, EconoPIM™, EconoPACK™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, I²RF™, ISOFACE™, IsoPACK™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™, PrimeSTACK™, PRO-SIL™, PROFET™, RASIC™, ReverSave™, SatRIC™, SIEGET™, SINDRION™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, TEMPFET™, thinQ!™, TRENCHSTOP™, TriCore™. Other Trademarks Advance Design System™ (ADS) of Agilent Technologies, AMBA™, ARM™, MULTI-ICE™, KEIL™, PRIMECELL™, REALVIEW™, THUMB™, µVision™ of ARM Limited, UK. AUTOSAR™ is licensed by AUTOSAR development partnership. Bluetooth™ of Bluetooth SIG Inc. CAT-iq™ of DECT Forum. COLOSSUS™, FirstGPS™ of Trimble Navigation Ltd. EMV™ of EMVCo, LLC (Visa Holdings Inc.). EPCOS™ of Epcos AG. FLEXGO™ of Microsoft Corporation. FlexRay™ is licensed by FlexRay Consortium. HYPERTERMINAL™ of Hilgraeve Incorporated. IEC™ of Commission Electrotechnique Internationale. IrDA™ of Infrared Data Association Corporation. ISO™ of INTERNATIONAL ORGANIZATION FOR STANDARDIZATION. MATLAB™ of MathWorks, Inc. MAXIM™ of Ma xim Integrated Products, Inc. MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS Technologies, I nc., USA. muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of Applied Wave Research Inc., OmniVision™ of OmniVision Technologies, Inc. Openwave™ Openwave Systems Inc. RED HAT™ Red Hat, Inc. RFMD™ RF Micro Devices, Inc. SIRIUS™ of Sirius Satellite Radio Inc. SOLARIS™ of Sun Microsystems, Inc. SPANSION™ of Spansion LLC Ltd. Symbian™ of Symbian Software Limited. TAIYO YUDEN™ of Taiyo Yuden Co. TEAKLITE™ of CEVA, Inc. TEKTRONIX™ of Tektronix Inc. TOKO™ of TOKO KABUSHIKI KAISHA TA. UNIX™ of X/Open Company Limited. VERILOG™, PALLADIUM™ of Cade nce Design Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™ of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited. Last Trademarks Update 2011-11-11 www.infineon.com Edition 2015-03-12 Published by Infineon Technologies AG 81726 Munich, Germany © 2015 Infineon Technologies AG. All Rights Reserved. Do you have a question about any aspect of this document? Email: [email protected] Document reference AN_201409_PL21_014 Legal Disclaimer THE INFORMATION GIVEN IN THIS APPLICATION NOTE (INCLUDING BUT NOT LIMITED TO CONTENTS OF REFERENCED WEBSITES) IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY, CONDITION OR QUALITY OF THE INFINEON TECHNOLOGIES COMPONENT. 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