Infineon ApplicationNote - Demoboard - ICE5QR0680AG AN v01 - 00 EN
Infineon ApplicationNote - Demoboard - ICE5QR0680AG AN v01 - 00 EN
Infineon ApplicationNote - Demoboard - ICE5QR0680AG AN v01 - 00 EN
Intended audience
This document is intended for power-supply design/application engineers, students, etc., who wish to design
low-cost and highly reliable systems of off-line SMPS, such as auxiliary power supplies for white goods, PCs,
servers and TVs, or enclosed adapters for blu-ray players, set-top boxes, games consoles, etc.
Table of contents
About this document....................................................................................................................... 1
Table of contents ............................................................................................................................ 1
1 Abstract ........................................................................................................................ 3
2 Demo board .................................................................................................................. 4
3 Specifications of the demo board .................................................................................... 5
4 Circuit description ......................................................................................................... 6
4.1 Line input ................................................................................................................................................. 6
4.2 Start-up .................................................................................................................................................... 6
4.3 Integrated MOSFET and PWM control .................................................................................................... 6
4.4 Clamper circuit ........................................................................................................................................ 6
4.5 Output stage ............................................................................................................................................ 6
4.6 Feedback loop ......................................................................................................................................... 6
4.7 Primary side peak-current control ......................................................................................................... 6
4.8 Digital frequency reduction .................................................................................................................... 7
4.9 Active Burst Mode (ABM) ......................................................................................................................... 7
5 Protection features ........................................................................................................ 8
6 Circuit diagram.............................................................................................................. 9
7 PCB layout ................................................................................................................... 11
7.1 Top side ................................................................................................................................................. 11
7.2 Bottom side ........................................................................................................................................... 11
8 Bill of materials ............................................................................................................ 12
9 Transformer construction .............................................................................................. 14
10 Test results .................................................................................................................. 16
Application Note Please read the Important Notice and Warnings at the end of this document Revision 1.0
www.infineon.com 2017-05-19
42 W 12 V 5 V SMPS demo board with ICE5QR0680AG
Abstract
1 Abstract
This AN is an engineering report for a 42 W 12 V and 5 V demo board designed in a QR flyback converter
topology using the 5th generation QR CoolSET™ ICE5QR0680AG. The target applications of ICE5QR0680AG are
either auxiliary power supplies for white goods, PCs, servers or TVs, or enclosed adapters for Blu-ray players,
set-top boxes, games consoles, etc. With the CoolMOS™ integrated into this IC, it greatly simplifies the design
and layout of the PCB. The new improved digital frequency reduction with proprietary QR operation offers
lower EMI and higher efficiency for a wide AC range by reducing the switching frequency difference between
low- and high-line. The enhanced Active Burst Mode (ABM) power enables flexibility in standby power
operation range selection, and QR operation during ABM. As a result, the system efficiency over the entire load
range is significantly improved compared to a conventional free-running QR converter implemented with only
maximum switching frequency limitation at light loads. In addition, numerous adjustable protection functions
have been implemented in ICE5QR0680AG to protect the system and customize the IC for the chosen
application. In case of failure modes such as brownout or line over-voltage, V CC over-/under-voltage, open
control-loop or over-load, output over-voltage, over-temperature, V CC short-to-ground and Current Sense (CS)
short-to-ground, the device enters protection mode. By means of the cycle-by-cycle Peak Current Limitation
(PCL), the dimensions of the transformer and the current rating of the secondary diode can both be optimized.
Thus, a cost-effective solution can easily be achieved.
2 Demo board
This document contains the list of features, the power-supply specifications, schematics, bill of materials and
the transformer construction documentation. Typical operating characteristics such as performance curve and
scope waveforms are shown at the end of the report.
ICE5QR0680AG
Figure 1 DEMO_5QR0680AG_42W1
Note: The demo board is designed for dual output with cross-regulated loop feedback. It may not regulate
properly if loading is applied only to single output. If the user wants to evaluate for single-output (12 V
only) conditions, the following changes are necessary on the board.
2. Change R26 to 10 kΩ and R25 to 38 kΩ (to disable 5 V feedback and enable 100% weighted factor
on 12 V output)
Since the board (especially the transformer) is designed for dual output with optimized cross-
regulation, single-output efficiency might not be optimized. It is only for IC functional evaluation
under single-output conditions.
4 Circuit description
4.1 Line input
The AC-line input side comprises the input fuse F1 as over-current protection. The choke L11, X-capacitors C11
and C14 and Y-capacitors C12, C12A and C12B act as EMI suppressors. Optional spark-gap devices SA1, SA2 and
varistor VAR can absorb HV stress during a lightning surge test. A rectified DC voltage (120~424 V DC) is
obtained through the bridge rectifier BR1 together with the bulk capacitor C13.
4.2 Start-up
To achieve fast and safe start-up, ICE5QR0680AG is implemented with a start-up resistor and V CC short-to-GND
protection. When VVCC reaches the turn-on voltage threshold 16 V, the IC begins with a soft-start. The soft-start
implemented in ICE5QR0680AG is a digital time-based function. The preset soft-start time is 12 ms with four
steps. If not limited by other functions, the peak voltage on the CS pin will increase in increments from 0.3 V to
1 V. After IC turn-on, the V CC voltage is supplied by auxiliary windings of the transformer. V CC short-to-GND
protection is implemented during the start-up time.
For a QR flyback converter, the maximum possible output power is increased when a constant current limit
value is used for the whole-line input voltage range. This is usually not desirable, as this will increase the cost of
the transformer and output diode in case of output over-power conditions.
Internal current limitation with a line-dependent VCS curve and the new proprietary QR switching, which
reduces switching frequency difference between the minimum and maximum line, are implemented in the
ICE5QR0680AG. As a result, the maximum output power can be limited against the input voltage.
5 Protection features
Protection is one of the major factors in determining whether the system is safe and robust – therefore
sufficient protection is necessary. ICE5QR0680AG provides comprehensive protection to ensure the system is
operating safely. This includes line over-voltage, brownout, V CC over-voltage and under-voltage, over-load,
output over-voltage, over-temperature (controller junction), CS short-to-GND and V CC short-to-GND. When
those faults are found, the system will go into protection mode. Once the fault is removed, the system resumes
normal operation. A list of protections and failure conditions are shown in the table below.
6 Circuit diagram
1. Star ground at bulk capacitor C13: all primary grounds should be connected to the ground of bulk
capacitor C13 separately in one point. This effectively reduces the switching noise going into the sensitive
pins of the CoolSET™ device. The primary star ground can be split into four groups, as follows:
i. Combine signal (all small signal grounds connecting to the CoolSET™ GND pin, such as filter
capacitor grounds C17, C18, C19, C111, C112 and optocoupler ground) and power grounds (CS
resistors R14 and R14A)
ii. V CC ground includes the V CC capacitor ground C16 and the auxiliary winding ground, pin 5 of
the power transformer
iii. EMI return ground includes Y capacitor C12
iv. DC ground from bridge rectifier BR1
2. Filter capacitor close to the controller ground: filter capacitors C17, C18, C19, C111 and C112 should be
placed as close to the controller ground and the controller pin as possible to reduce the switching noise
coupled into the controller.
3. HV traces clearance: HV traces should retain enough spacing from the nearby traces. Otherwise, arcing
could occur.
i. 400 V traces (positive rail of bulk capacitor C13) to nearby trace: greater than 2.0 mm
ii. 600 V traces (drain voltage of CoolSET™ IC11) to nearby trace: greater than 2.5 mm
4. Recommended minimum 232 mm2 copper area at drain pin to add on PCB for better thermal performance.
5. Power-loop area (bulk capacitor C13, primary winding of the transformer TR1 (pins 1 and 3), IC11 drain
pin, IC11 CS pin and CS resistor R14/R14A) should be as small as possible to minimize the switching
emissions.
7 PCB layout
7.1 Top side
8 Bill of materials
Table 3 Bill of materials (R0.7)
No. Designator Description Part number Manufacturer Quantity
1 BR1 600 V/2 A D2SB60A Shindengen 1
2 C11 0.33 µF/305 V B32922C3334M*** Epcos 1
3 C12 2.2 nF/500 V DE1E3RA222MA4BQ Murata 1
4 C13 120 µF/450 V ESMQ451VSN121MP30S 1
5 C15 2.2 nF/1000 V RDE7U3A222J3K1H03 Murata 1
6 C16 33 µF/50 V 50PX33MEFC5X11 Rubycon 1
7 C17 100 nF/50 V GRM188R71H104KA93D Murata 1
8 C18, C26 1 nF/50 V GRM1885C1H102GA01D Murata 2
9 C19 68 pF/50 V GRM1885C1H680GA01D Murata 1
10 C111 22 nF/50 V GCM188R71H223KA37D Murata 1
11 C22, C22A 1000 uF/16 V 16ZLH1000MEFC10X16 Rubycon 2
12 C24 470 uF/16 V 16ZLH470MEFC8X11.5 Rubycon 1
13 C25 220 nF/50 V GRM188R71H224KAC4D Murata 1
14 C28, C210 330 uF/10 V 10ZLH330MEFC6.3X11 Rubycon 2
15 D11 1 A/800 V UF4006 1
16 D12 0.2 A/200 V BAV20WS 1
17 D13 0.2 A/150 V/50 ns FDH400 1
18 D21 30 A/100 V VF30100SG 1
19 D22 1 A/50 V SB150 1
20 F1 2 A/300 V 36912000000 1
21 HS21 Heatsink 513002B02500G 1
22 IC11 ICE5QR0680AG ICE5QR0680AG Infineon 1
23 IC12 Optocoupler SFH617A-3 1
24 IC21 Shunt regulator TL431BVLPG 1
25 JP1, JP2, JP3, JP4, JP5, JP6 Jumper 7
26 L11 33 mH/1.4 A CL4003301 MEC 1
27 L21 2.2 uH/6 A 744772022 Wurth Electronics 1
28 L22 4.7 uH/4.2 A 744 746 204 7 Wurth Electronics 1
29 R11 33 kR/2 W/350 V ERG-2SJ333A Panasonic 1
30 R12 27 Ω (0603) 1
31 R12A 0 Ω (0603) 1
32 R13 27 Ω (0603) 1
33 R14 0.81 R/0.5 W/±1% RCWE1206R820FKEA 1
9 Transformer construction
Core and materials: EE30/15/7 (EF30), TP4A (TDG)
Bobbin: 070-5313 (12-pin, THT, horizontal version)
Primary inductance: Lp = 315 μH (±10%), measured between pin 1 and pin 3
Manufacturer and part number: Wurth Electronics Midcom (750343506)
10 Test results
10.1 Efficiency, regulation and output ripple
Table 4 Efficiency, regulation and output ripple
OLP Iout12V
V5 Efficie
Input Pin I5 V5RPP V12 I12 V12RPP Pout Average η OLP Pin (fixed 5 V at
(V ncy η
(V AC/Hz) (W) (A) (mV) (V DC) (A) (mV) (W) (%) (W) 0.2 A)
DC) (%)
(A)
0.04 4.99 0.000 37 12.15 0.000 107
0.09 4.61 0.006 71 13.03 0.000 47 0.03 32.28
14.72 5.06 0.060 17 11.90 1.000 44 12.20 82.88
85 V AC/60 Hz 12.53 5.06 0.050 16 11.89 0.853 39 10.39 82.93 59.30 3.93
25.00 5.07 0.100 21 11.87 1.705 60 20.74 82.98
82.33
37.82 5.08 0.150 26 11.85 2.559 78 31.08 82.17
50.98 5.08 0.200 30 11.84 3.412 93 41.41 81.23
0.05 4.96 0.000 37 12.15 0.000 58
0.09 4.60 0.006 80 13.06 0.000 53 0.03 30.52
14.60 5.05 0.060 17 11.91 1.000 41 12.21 83.65
115 V AC/60
12.45 5.06 0.050 16 11.90 0.853 38 10.40 83.53 66.70 4.59
Hz
24.58 5.06 0.100 20 11.89 1.705 58 20.77 84.50
84.02
37.06 5.07 0.150 25 11.85 2.559 73 31.09 83.89
49.27 5.07 0.200 26 11.86 3.412 41.46 84.15
0.08 4.95 0.000 37 12.17 0.000 63
0.13 4.52 0.006 81 13.25 0.000 53 0.03 21.30
14.66 5.04 0.060 16 11.94 1.000 41 12.24 83.49
230 V AC/50
12.54 5.05 0.050 16 11.93 0.853 39 10.42 83.09 75.00 5.29
Hz
24.36 5.05 0.100 19 11.91 1.705 58 20.81 85.41
85.02
36.49 5.06 0.150 21 11.88 2.559 71 31.15 85.37
48.20 5.06 0.200 22 11.88 3.412 71 41.54 86.19
0.09 4.95 0.000 40 12.16 0.000 66
0.14 4.51 0.006 83 13.26 0.000 56 0.03 19.37
14.77 5.04 0.060 17 11.94 1.000 41 12.24 82.89
265 V AC/50
12.62 5.05 0.050 16 11.93 0.853 39 10.42 82.57 76.70 5.49
Hz
24.42 5.05 0.100 21 11.91 1.705 61 20.81 85.24
84.84
36.50 5.06 0.150 21 11.89 2.559 71 31.17 85.40
48.25 5.06 0.200 21 11.89 3.412 68 41.56 86.14
0.11 4.95 0.000 42 12.17 0.000 68
0.16 4.50 0.006 90 13.28 0.000 57 0.03 16.87
14.87 5.04 0.060 16 11.94 1.000 41 12.24 82.33
300 V AC/50
12.73 5.04 0.050 16 11.93 0.853 38 10.42 81.87 78.90 5.67
Hz
24.53 5.05 0.100 20 11.92 1.705 58 20.82 84.89
84.52
36.58 5.06 0.150 27 11.89 2.559 70 31.19 85.25
48.32 5.06 0.200 22 11.89 3.412 66 41.58 86.05
Figure 7 Standby power at no-load and 30 mW load vs AC-line input voltage (measured by
Yokogawa WT210 power meter – integration mode)
Figure 10 Maximum input power (before over-load protection) vs AC-line input voltage
1
PCB spark-gap distance needs to reduce to 0.5 mm.
Application Note 20 Revision 1.0
2017-05-19
42 W 12 V 5 V SMPS demo board with ICE5QR0680AG
Test results
Pass conducted emissions EN 55022 (CISPR 22) class B with 6 dB margin for quasi peak measurement at low-
line (115 V AC).
Application Note 21 Revision 1.0
2017-05-19
42 W 12 V 5 V SMPS demo board with ICE5QR0680AG
Test results
Pass conducted emissions EN 55022 (CISPR 22) class B with 6 dB margin for quasi peak measurement at high-
line (230 V AC).
Application Note 22 Revision 1.0
2017-05-19
42 W 12 V 5 V SMPS demo board with ICE5QR0680AG
Test results
11.2 Soft-start
C2 (purple) : 5 V output ripple voltage (VOut5) C2 (purple) : 5 V output ripple voltage (VOut5)
C3 (blue) : 12 V output ripple voltage (VOut12) C3 (blue) : 12 V output ripple voltage (VOut12)
5 Vripple_pk_pk at 85 V AC ≈ 214 mV 5 Vripple_pk_pk at 300 V AC ≈ 226 mV
12 Vripple_pk_pk at 85 V AC ≈ 478 mV 12 Vripple_pk_pk at 85 V AC ≈ 505 mV
(85 V AC, 12 V load change from 10% to 100% and 5 V at (300 V AC, 12 V load change from 10% to 100% and 5 V
200 mA load, 100 Hz, 0.4 A/µs slew rate) at 200 mA load, 100 Hz, 0.4 A/µs slew rate)
Probe terminal end with decoupling capacitor of 0.1 Probe terminal end with decoupling capacitor of 0.1
μF (ceramic) and 1 µF (electrolytic), 20 MHz BW μF (ceramic) and 1 µF (electrolytic), 20 MHz BW
Figure 20 Load transient response
C2 (purple) : 5 V output ripple voltage (VOut5) C2 (purple) : 5 V output ripple voltage (VOut5)
C3 (blue) : 12 V output ripple voltage (VOut12) C3 (blue) : 12 V output ripple voltage (VOut12)
5 Vripple_pk_pk at 85 V AC ≈ 20 mV 5 Vripple_pk_pk at 300 V AC ≈ 17 mV
12 Vripple_pk_pk at 85 V AC ≈ 146 mV 12 Vripple_pk_pk at 300 V AC ≈ 138 mV
Probe terminal end with decoupling capacitor of 0.1 Probe terminal end with decoupling capacitor of 0.1
μF (ceramic) and 1 μF (electrolytic), 20 MHz BW μF (ceramic) and 1 μF (electrolytic), 20 MHz BW
Figure 21 Output ripple voltage at maximum load
C2 (purple) : 5 V output ripple voltage (VOut5) C2 (purple) : 5 V output ripple voltage (VOut5)
C3 (blue) : 12 V output ripple voltage (VOut12) C3 (blue) : 12 V output ripple voltage (VOut12)
5 Vripple_pk_pk at 85 V AC ≈ 24 mV 5 Vripple_pk_pk at 300 V AC ≈ 31 mV
12 Vripple_pk_pk at 85 V AC ≈ 121 mV 12 Vripple_pk_pk at 300 V AC ≈ 141 mV
Load: 5 V at 6 mA and 12 V at 80 mA Load: 5 V at 6 mA and 12 V at 80 mA
Probe terminal end with decoupling capacitor of 0.1 μF Probe terminal end with decoupling capacitor of 0.1 μF
(ceramic) and 1 μF (electrolytic), 20 MHz BW (ceramic) and 1 μF (electrolytic), 20 MHz BW
Figure 22 Output ripple voltage at ABM 1 W load
(85 V AC, load change from 10.5 W to 1 W) (300 V AC, load change from 10.5 W to 1 W)
(5 V x 50 mA + 12 V x 0.853 A) to (5 V x 50 mA + 12 V x (5 V x 50 mA + 12 V x 0.853 A) to (5 V x 50 mA + 12 V x
0.0.062 A) 0.0.062 A)
Figure 23 Entering ABM
85 V AC, load change from 1 W to 41.25 W 300 V AC, load change from 1 W to 41.25 W
(5 V x 50 mA + 12 V x 0.0.062 A) to (5 V x 50 mA + 12 V x (5 V x 50 mA + 12 V x 0.0.062 A) to (5 V x 50 mA + 12 V x
3.41 A) 3.41 A)
Figure 25 Leaving ABM
12 References
[1] ICE5QRxxxxAx datasheet, Infineon Technologies AG
[2] AN-201609_PL83_026-Fifth-Generation QR Design Guide
[3] Calculation Tool QRt CoolSET™ Generation 5
Revision history
Major changes since the last revision
Page or reference Description of change
-- First release