AN - REF- 15W_C E1K0 AD APTER
1 5 W 5V Adapte r Re fe re nce Board wi th
IC E2QS03G, IPS65R1K0 C E, BSC 06 7N 0 6L S3 G
& BAS21 - 0 3 W
Application Note
About this document
Scope and purpose
This document is a 15W 5.0V high efficiency USB adapter reference design using Infineon Quasi-Resonant
PWM IC ICE2QS03G with CoolMOS™ IPS65R1K0CE (IPAK) and secondary side synchronous rectification IC
with OptiMOS™ BSC067N06LS3 G (ThinPAK 5x6) in a small form factor, high efficiency and various mode of
protections for a high reliable system.
Intended audience
This document is intended for users who wish to design high efficiency, very small form factor universal 15W
5V AC-DC adapter with Infineon CoolMOS™ CE series, OptiMOS™, Quasi-Resonant PWM IC ICE2QS03G and
synchronous rectification.
1
Revision 1.1, 2014-11-27
15W 5V Adapter Reference Board with ICE2QS03G,
IPS65R1K0CE, BSC067N06LS3 G & BAS21-03W
Abstract
Table of Contents
About this document ................................................................................................................... 1
Table of Contents ........................................................................................................................ 2
1
2
3
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
5.4
5.5
6
6.1
6.2
6.3
6.4
6.5
6.6
7
8
8.1
8.2
9
10
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
Abstract ..................................................................................................................... 4
Reference board ......................................................................................................... 4
Specifications ............................................................................................................. 5
Circuit description....................................................................................................... 6
Mains input rectification and filtering ..................................................................................................... 6
PWM control and switching MOSFET ...................................................................................................... 6
Snubber network....................................................................................................................................... 6
Output stage .............................................................................................................................................. 6
Feedback loop ........................................................................................................................................... 6
Circuit operation ......................................................................................................... 7
Startup operation...................................................................................................................................... 7
Normal mode operation ........................................................................................................................... 7
Primary side peak current control........................................................................................................... 7
Digital frequency reduction ..................................................................................................................... 7
Burst mode operation............................................................................................................................... 7
Protection features ..................................................................................................... 8
V
CC
over voltage and under voltage protection ...................................................................................... 8
Over load/Open loop protection ............................................................................................................. 8
Auto restart for over temperature protection ........................................................................................ 8
Adjustable output overvoltage protection ............................................................................................. 8
Short winding protection ......................................................................................................................... 8
Foldback point protection ....................................................................................................................... 9
Circuit diagram ......................................................................................................... 10
PCB layout ............................................................................................................... 11
Top side ....................................................................................................................................................11
Bottom side..............................................................................................................................................11
Bill of material (BOM) ................................................................................................ 12
Transformer construction .......................................................................................... 13
Test results .............................................................................................................. 14
Efficiency, regulation and output ripple ...............................................................................................14
Standby power ........................................................................................................................................15
Line regulation.........................................................................................................................................16
Load regulation .......................................................................................................................................16
Maximum power......................................................................................................................................17
ESD immunity (EN61000-4-2) .................................................................................................................17
Surge immunity (EN61000-4-5)..............................................................................................................17
Conducted emissions (EN55022 class B) ..............................................................................................18
Thermal measurement ...........................................................................................................................20
2
Revision 1.1, 2014-11-27
Application Note
15W 5V Adapter Reference Board with ICE2QS03G,
IPS65R1K0CE, BSC067N06LS3 G & BAS21-03W
Abstract
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
13
Waveforms and scope plots ........................................................................................ 20
Start up at low/high AC line input voltage with maximum load ........................................................20
Soft start ...................................................................................................................................................21
Drain voltage and current at maximum load .......................................................................................21
Zero crossing point during normal operation ......................................................................................22
Load transient response (Dynamic load from 10% to 100%) .............................................................22
Output ripple voltage at maximum load ..............................................................................................23
Output ripple voltage during burst mode at 1 W load ........................................................................23
Active Burst mode operation .................................................................................................................24
Over load protection (Auto restart mode) ............................................................................................24
Output overvoltage protection (Latched off mode) ............................................................................25
V
CC
under voltage/Short optocoupler protection (Auto restart mode) .............................................25
References ............................................................................................................... 26
Revision History........................................................................................................................ 26
Application Note
3
Revision 1.1, 2014-11-27
15W 5V Adapter Reference Board with ICE2QS03G,
IPS65R1K0CE, 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
15W 5V adapter. The adapter is using
ICE2QS03G,
a second generation current mode control Quasi-
Resonant flyback topology controller,
IPS65R1K0CE,
a CE series of high voltage power CoolMOS™ and
BSC067N06LS3 G,
a third series of medium voltage power OptiMOS™, optimized for 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.
45mm
16mm
31mm
Figure 1
REF-15W_CE1K0 ADAPTER [Dimensions L x W x H: 45mm x 31mm x 16mm]
IPS65R1K0CE
BSC067N06LS3 G
ICE2QS03G
BAS21-03W
BAS21-03W
(Top view)
Figure 2
REF-15W_CE1K0 ADAPTER [Top & Bottom View]
(Bottom view)
Application Note
4
Revision 1.1, 2014-11-27
15W 5V Adapter Reference Board with ICE2QS03G,
IPS65R1K0CE, BSC067N06LS3 G & BAS21-03W
Specifications
3
Table 1
Specifications
Specifications of REF-15W_CE1K0 ADAPTER
85Vac~265Vac
50~60Hz
5V
3A
15W
45kHz
< ±6% of input power
< 40mW
>88% at 115Vac & >87% at 230Vac
Input voltage
Input frequency
Output voltage
Output current
Output power
Minimum switching frequency at full load and minimum
input voltage
Maximum input power for universal mains
No-load power consumption
(EU CoC Version 5, Tier 2 and EPS of DOE USA)
Active mode four point average efficiency (25%,50%,75% &
100%load) (EU CoC Version 5, Tier 2 and EPS of DOE USA)
Active mode at 10% load efficiency
(EU CoC Version 5, Tier 2)
Steady state output ripple
Dynamic load response undershoot & overshoot
Conducted emissions (EN55022 class B)
ESD immunity (EN61000-4-2)
Surge immunity (EN61000-4-5)
Form factor case size (L x W x H)
>86% at 115Vac & >85% at 230Vac
+/-1% of nominal output voltage
(V
ripple_p_p
<100mV)
+/-3% of nominal output voltage
(V
ripple_p_p
<300mV)
Pass with 8 dB margin
level 3 (±6kV) contact discharge
Installation class 3 (2kV: common mode)
(45 x 31 x 16) mm
3
Application Note
5
Revision 1.1, 2014-11-27
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