AN-EVAL-ICE2A365-1 Application Note Datasheet by Infineon Technologies

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Version 1.2 , August 2001
Application Note
AN-EVAL-ICE2A365-1
CoolSET
40W Evaluation Board with ICE2A365
Author: Harald Zöllinger
Published by Infineon Technologies AG
http://www.infineon.com
Never stop thinking
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Contents:
40W Evaluation Board with ICE2A365..................................................3
Technical specifications:.......................................................................4
Circuit description: ................................................................................4
Schematic:............................................................................................6
Component Legend: .............................................................................7
Board Layout: .......................................................................................7
Component List:....................................................................................8
Transformer Construction .....................................................................9
Measurements:...................................................................................10
References: ........................................................................................10
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40W Evaluation Board with 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.
Evaluation board
Other output voltages can also be implemented very easily by a simple modification of the transformer
and the output circuitry.
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Technical specifications:
Input Voltage Range 85 ... 270V AC
Input Frequency 50, 60 Hz
Output Voltage 16V +-5%
Peak Output Power 54W
Line Regulation (85 ...270V) < 1%
Load Regulation (10% ... 100%) < 1%
Efficiency > 80 %
Output Ripple Voltage < 200mV
Switching Frequency 21...100 kHz
Stby Power with Burst Mode @ noload <400mW
EMI EN55022B
Temperature Range 0 ... 50°C
Circuit description:
Introduction
The ICE2A365 chip used here was particularly designed for the use in flyback converters. As shown
on the circuit diagram (p. 3), 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 L5 and X2-
capacitors 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.
ICE2A365 Power Supply
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 <85 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, C13. 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 D4 is
applied for voltage limitation.
Softstart
The Soft-Start function is realised by an internal resistor and the external capacitor C14.
Primary Current – CoolMOS
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 R17. When the voltage at R17
exceeds the internal current-limit threshold, the gate driver is shut off immediately.
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Output Stage
Output Voltage
On the secondary side the power is coupled out via a fast-acting diode D1 with low forward voltage.
The capacitors C5, C9, C20 provide energy buffering, a filter L3, C23 reduces the output voltage ripple
considerably.
Storage capacitors C5, C9,and C20 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”.
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Schematic:
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Component Legend:
Board Layout:
Component side shown
Infineon ‘eUmn‘cgmx Pas. Parl TvDe Grid Orderina Code Manu'. 1 BR1 3500 C1500 2 C1 1330”}: SUV 5mm Epcos 3 C2 1nF 50V 5mm Epcos 4 CS 150uF 400V 10mm B435017A91577M Epcos 5 C4 68LJF 35V 2 5mm B418217A74767M Epcos 6 CS 1000uF 35V 5mm KZESSVB1OOUMK25 (NCO) Allatec 7 06 2 2nF 50V 5mm 13379794352220 Epcos 8 C7 ' 9 C8 U1UF 275V X2 15mm BB11307C11047M Epcos 1U 09 ' 11 C12 2,2nF‘ 400V 7,5mm BS25207C62227K Epcos 12 C13 100nF, 50V 5mm BS79877F51047K Epcos 13 C14 1uF, 50V 5mm BS7984M51057K Epcos 14 C20 1000M, 35V 5mm KZESSVB1OOUMK25 (NCC) Allatec 15 C22 0 22uF 275V X2 15mm BB11307C12247M EDCDS 16 C23 47UuF 35V 5mm KZESSVB47OMJ20 (NCC) Allalec 17 C24 2 2nF 250V Y1 12 5mm WKF’ 2H2 M mea 18 C25 2 2nF 250V Y1 12 5mm WKF’ 2H2 M mea 19 D1 DSS1OVO1A 5mm IXYS 20 D2 1N4148 10mm 21 D3 1N4937 10mm 22 D4 ZPD1B 10mm 23 F1 Micvcfuse 3 15A 5mm 24 \C1 SFH617A73X016 25 \C3 ICEZASBS Inlineon 26 \C2 TL431CLF’ 27 L3 1uH 3 7A 5mm 822LV71R0M COmDonex 28 L5 27mH, 0,9A BB27327R29017330 Epcos 29 R1 24k, 1% 10mm 30 R2 4,3k, 1% 10mm 31 R3 680R 10mm 32 R4 1 2k 10mm 33 R5 150k 10mm 34 R6 430k 10mm 35 R7 430k 10mm 36 R8 4 7R 10mm 37 R9 flR 10mm 38 R10 39k 2W 10mm 39 R16 ' 40 R17 O43R 0 SW 1% 10mm 41 R18 ’ 42 R20 wwre 10mm 43 TR1 E25 Cowl Formev 44 TR1 E25/13/7 0 75 N27 599 also Translormer Consmlcficn 45 D1 Heatsink 18W FK224 Fischer 46 x1 Connector 2pcl. 47 x2 Connector 2pcl.
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Component List:
Part List
ICE2A365 Evaluation Board 16V/ 40W 19.09.2001
Pos. Part Type Grid Ordering Code Manuf.
1 BR1 B500 C1500
2 C1 330nF, 50V 5mm Epcos
3 C2 1nF, 50V 5mm Epcos
4 C3 150uF, 400V 10mm B43501-A9157-M Epcos
5 C4 68uF, 35V 2,5mm B41821-A7476-M Epcos
6 C5 1000uF, 35V 5mm KZE35VB1000MK25 (NCC) Alfatec
7 C6 2,2nF, 50V 5mm B37979-G5222-J Epcos
8C7*
9 C8 0,1uF, 275V, X2 15mm B81130-C1104-M Epcos
10 C9 *
11 C12 2,2nF, 400V 7,5mm B32520-C6222-K Epcos
12 C13 100nF, 50V 5mm B37987-F5104-K Epcos
13 C14 1uF, 50V 5mm B37984-M5105-K Epcos
14 C20 1000uf, 35V 5mm KZE35VB1000MK25 (NCC) Alfatec
15 C22 0,22uF, 275V, X2 15mm B81130-C1224-M Epcos
16 C23 470uF, 35V 5mm KZE35VB470MJ20 (NCC) Alfatec
17 C24 2,2nF, 250V Y1 12,5mm WKP 2n2 M Wima
18 C25 2,2nF, 250V Y1 12,5mm WKP 2n2 M Wima
19 D1 DSS10-01A 5mm IXYS
20 D2 1N4148 10mm
21 D3 1N4937 10mm
22 D4 ZPD18 10mm
23 F1 Microfuse 3,15A 5mm
24 IC1 SFH617A-3X016
25 IC3 ICE2A365 Infineon
26 IC2 TL431CLP
27 L3 1uH, 3,7A 5mm 822LY-1R0M Componex
28 L5 27mH, 0,9A B82732-R2901-B30 Epcos
29 R1 24k, 1% 10mm
30 R2 4,3k, 1% 10mm
31 R3 680R 10mm
32 R4 1,2k 10mm
33 R5 150k 10mm
34 R6 430k 10mm
35 R7 430k 10mm
36 R8 4,7R 10mm
37 R9 22R 10mm
38 R10 39k, 2W 10mm
39 R16 *
40 R17 0,43R, 0,6W, 1%, 10mm
41 R18 *
42 R20 wire 10mm
43 TR1 E25 Coil Former
44 TR1 E25/13/7, 0,75 N27 see also Transformer Construction
45 D1 Heatsink, 18K/W FK224 Fischer
46 X1 Connector 2pol.
47 X2 Connector 2pol.
* = not assembled
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Transformer Construction
Note:
The built-in transformer does not comply with EN60950 safety requirements
in respect of electrical isolation.
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Measurements:
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
Efficiency
0
10
20
30
40
50
60
70
80
90
100
0 5 10 15 20 25 30 35 40
Pout [W]
Efficiency [%]
Vin@85V Vin@270V
Frequency Reduction
10
20
30
40
50
60
70
80
90
100
110
0 5 10 15 20 25 30 35 40
Pout [W]
Vin@85V Vin@270V
Output Power Limitation vs Input Voltage
0
10
20
30
40
50
60
85 100 150 200 250 265
Vacin [V]
Pout [W]
No-load Input Power
0
50
100
150
200
250
300
350
400
0 50 100 150 200 250 300
Vacin [V]
Pin [mW]
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Revision History
Application Note AN-EVAL-ICE2A365-1
Actual Release: V1.2 Date:16.08.2001 Previous Release: V1.1
Page of
actual
Rel.
Page of
prev. Rel. Subjects changed since last release
12 14 First Issue
12 12 Part List
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.
Edition 2000--05--09
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.
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Your feedback will help us to continously improve the quality of this dokument.
Please send your proposal (including a reference to this dokument) to:
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