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

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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.

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Technical specifications:

Input Voltage Range 90 ... 264V AC

Input Frequency 50, 60 Hz
Output Voltage 1 5V +-1%
Output Voltage 2 +12V +-8%
Output Voltage 3 -12V +-8%
Output Voltage 4 +30V +-10%
Output Power 1 20W @230V
Output Power 2 15W @230V
Output Power 3 5W @230V
Output Power 4 1W @230V
Line Regulation (85 ...270V) < 1% @ 5V
Load Regulation (10% ... 100%) < 1% @ 5V
Efficiency 80%
Output Ripple Voltage < 100mV
Switching Frequency 21....100 kHz
Temperature Range 0 ... 70°C

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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 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.

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”.

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Schematic:

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Component Legend:

Board Layout:
Component side shown

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Component List:

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Transformer Construction:

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Mesurements:

Efficiency
100
90
80
70
Efficiency [%]

60
50
40
30
20
10
0
0 5 10 15 20 25 30 35 40
Pout [W]

Vin@85V Vin@270V

Frequency Reduction
110
100
90
Frequency [kHz]

80
70
60
50
40
30
20
10
0 5 10 15 20 25 30 35 40
Pout [W]

Vin@85V Vin@270V

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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.

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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.

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