Power Management & Supply
Version 1.2 , February 2002
Application Note AN-SMPS-ICE2xXXX-1
CoolSET
ICE2xXXX for OFF Line Switch Mode Power Supply (SMPS)
Authors: Harald Zllinger
Rainer Kling
Published by Infineon Technologies AG
http://www.infineon.com
N e v e r s t o p t h i n k i n g
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 2 of 44 Version 1.2
Contents:OPERATING PRINCIPLES ...................................................................................................................................... 3
PROTECTION FUNCTIONS..................................................................................................................................... 9
OVERLOAD AND OPEN-LOOP PROTECTION (FIG. 6)........................................................................................... 11
OVERVOLTAGE PROTECTION DURING SOFT START (FIG. 7).............................................................................. 12
FREQUENCY REDUCTION................................................................................................................................... 13
DESIGN PROCEDURE.......................................................................................................................................... 14
Input Diode Bridge (BR1):........................................................................................................................... 15
Determine Input Capacitor (C3): ................................................................................................................ 15
Transformer Design (TR1): ......................................................................................................................... 17
SENSE RESISTOR ................................................................................................................................................ 18
Winding Design: .......................................................................................................................................... 19
Output Rectifier (D1):.................................................................................................................................. 21
Output Capacitors (C5, C9): ....................................................................................................................... 22
Output Filter (L3, C23): .............................................................................................................................. 23
RC-Filter at Feedback Pin........................................................................................................................... 23
Soft-start capacitor ...................................................................................................................................... 24
VCC Capacitor: ........................................................................................................................................... 25
Start-up Resistor (R6, R7): .......................................................................................................................... 25
CLAMPING NETWORK:....................................................................................................................................... 26
CALCULATION OF LOSSES: ................................................................................................................................ 27
Switching losses:.......................................................................................................................................... 28
Conduction losses: ....................................................................................................................................... 28
REGULATION LOOP: .......................................................................................................................................... 29
Regulation Loop Elements:.......................................................................................................................... 30
Zeros and Poles of transfer characteristics: ............................................................................................... 31
Calculation of transient impedance ZPWM of ICE2AXXX............................................................................. 32
Transfer characteristics:.............................................................................................................................. 33
CONTINUOUS CONDUCTION MODE (CCM) ....................................................................................................... 36
TRANSFORMER CALCULATION:.......................................................................................................................... 36
SLOPE COMPENSATION...................................................................................................................................... 37
TRANSFORMER CONSTRUCTION ........................................................................................................................ 38
LAYOUT RECOMMENDATION:............................................................................................................................ 39
OUTPUT POWER TABLE ..................................................................................................................................... 40
SUMMARY OF USED NOMENCLATURE................................................................................................................ 41
REFERENCES...................................................................................................................................................... 42
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Operating Principles
The ICE2AXXX is designed for a current-mode flyback configuration in discontinous (DCM) orcontinous conduction (CCM) mode.
The control circuit has a fixed frequency. The duty cycle (D) of the integrated CoolMOS Transistor is
controlled to maintain a constant output voltage (VOUT).
Fig. 1 shows the input voltage (VDC IN), the primary current(ILPK), and the secondary (ISEC) transformer
currentof the flyback converter depicted on p. 3
When the CoolMOS Transistor is swiched on, the initial state of all windings on the transformer is at
positive potential.
The rectifier diode (D1) on the secondary side is reverse biased and therefore does not conduct.
Consequently no current flows in the secondary winding. During this phase, energy is stored in the
inductance of the primary winding and the transformer can be treated as a simple series inductor.
Fig. 1 shows that there is a linear increase of the primary current (IPRI) while the CoolMOS Transistor
is on.
When the CoolMOS Transistor is swiched off, the voltage reverses on all transformer windings
(flyback action) until it is clamped by rectifier diode on the secondary side. Now the secondary rectifier
diode (D1) is conducting, and the magnetizing energy stored in the transformer core is transferred to
the secondary side during the reset interval.
In the discontinous conduction mode DCM the secondary current (ISEC) decreases from its peakvalue to zero (Fig. 1). During this period the whole energy stored in the primary inductance is
transferred to the secondary side (neglecting losses and energy stored in the primary leakage
inductance), then the next storage cycle starts. Taking into account the transformer turns ratio, the
secondary voltage (VSEC) is reflected back (VR) to the primary winding and adds to the input voltage
(VDC IN + VR). An additional transient voltage may appear on the primary winding due to energy stored
in the uncoupled leakage inductance in the primary winding. This voltage is not clamped by the
secondary side winding. If the flyback current (ILPK and ISEC) does not reach zero before the next on
cycle the converter is operating in continous conduction mode (Fig. 2).Note:
When the system shifts to continous conduction operation, its transfer function is changed to a two
pole system with low output impedance. In this case additional design rules have to be taken intoaccount including different loop compensation and slope compensation on the primary side.
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Voltage and current waveforms in discontinous conduction mode (DCM)operation:
VDC IN min + VR
VDC IN min
0 T
IPEAK ILPK
VIN + VR
VDC IN
0
IPEAK ILPK
ISECIPEAK
ISECIPEAK
Light load
tOFF tON tOFF T tON
Full load
Duty Cycle: D = 0,5 Duty Cycle: D < 0,5
Voltage
Current
Fig. 1
Duty Cycle:
TtD ON=
VDC IN > VDC IN minVDC IN = VDC IN min
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Comparison of continous conduction (CCM) and discontinous conduction (DCM)mode.
VDC IN + VR
VDC IN
0 T
IPEAKILPK
VDC IN + VR
VDC IN
0
IPEAKILPK
ISEC
IPEAK
ISECIPEAK
tOFF tON tOFF T tON
CCM DCM
IPri0
ISec0
Fig. 2
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Input stageAs shown in Fig. 3 the AC input power is rectified and filtered by the bridge rectifier (BR1) and the bulk
capacitor C3. This create a DC high voltage bus which is connected to the primary winding of the
transformer (TR1). The transformer is driven by the CoolSET integrated high voltage, avalanche
rugged CoolMOS transistor, with an external sense resistor (R17) for precision current mesurement.
Output stageThe secondary winding power is rectified and filtered by a diode (D1), capacitors (C5, C9 and C20).
The output LC-filter (L3, C23) reduces the output voltage ripple.
Other output voltagesOther output voltages can be realized by adjusting the transformer turn ratio and the output stage.
Chip supplyThe current in the bias winding is rectified and filtered by a diode (D2) and a resistor (R8) in order to
charge the the supply capacitor (C4). This creates a bias voltage that powers the CoolSET ICE
2AXXX. The resistors R6 and R7 charge the VCC Cap and supply the chip during startup. The Zener
diode (D4) clamps the chip supply voltage (Vcc) in order to protect the chip in case of an over-voltage
condition. Capacitor C13 filters high frequency ripples on the chip supply voltage (Vcc).
Soft-StartA soft-start function is activated during start-up, and can be adjusted by capacitor C14. In addition to
start-up, soft-start is activated at each restart attempt during auto-restart and when restarting after one
of the several protection functions are activated. This effectively minimizes current and voltage
stresses on the CoolMOS MOSFET, the snubber network, and the output rectifier during start-up.
The soft-start feature further helps to minimize output overshoot and prevents saturation of the
transformer during start-up.
Clamping networkThe clamping network which consists of a diode (D3), a resistor (R10) and a capacitor (C12) clamps
the voltage spike caused by the transformer leakage inductance to a safe value this limits the
avalanche losses of the CoolMOS transistor.
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Control LoopThe resistors R1 and R2 represent the voltage divider for the reference diode TL431CLP (IC2). R4
supplies the TL431CLP reference diode with a minimum current and R3 the LED of the optocoupler.
The network which consists of capacitors C1 and C2 determines the corner frequencies fg1 and fg2.
R5 sets the gain of the control loop.
Slope CompensationThe current mode controller becomes unstable whenever the steady state duty cycle D is larger than
0.5. In order to realize a design with a duty cycle greater 0.5, the slope of the current needs to be
compensated. The slope compensation is realized by the network consisting of capacitor C17, C18
and the resistor R19.
Ripple ReductionInductor L5 and capacitor C23 attenuate the differential mode emission currents caused by the
fundamental and harmonic frequencies of the primary current waveform.
SMPS Calculation Software FLYCALFLYCAL is an EXCEL spread sheet with all Equations needed for the easy calculaton of your SMPS.
FLYCAL corresponds with the calculaton example in this application note. You only have to enter the
main parameters of your application in FLYCAL and to follow step by step the principle outlined in the
calculation example. FLYCAL contains all equations used in the example with the same consecutive
numbering.
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Circuit Diagram:
Fig. 3
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Protection FunctionsThe block diagram displayed in Fig. 4 shows the interal functions of the protection unit. The
comparators C1, C2, C3 and C4 compare the soft-start and feedback-pin voltages. Logic gates
connected to the comparator outputs ensure the combination of the signals and enables the setting of
the Error-Latch.
Fig. 4
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Fig. 5 shows the relation between the voltages at the soft start (Vss) and the feedback pins (VFB) of
ICE2AXXX, as a function of the supply voltage (Vcc) during an overvoltage condition at CoolSET softstart.
Depending on the voltage levels at the inputs, the overvoltage and (Vcc PIN 7) and overload (VFB
PIN 2) protection functions are activated.
Fig. 5
FeedbackVoltage
6.5V
5.3V
4.0V
0.8V4.8V6.5V
Overload &open loopDetection
Soft startVoltage
Overvoltageshutdownwhen Vccexceeds
16,5V
NormalOperation
Soft-start
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Overload and Open-Loop Protection Feedback voltage (VFB) exceeds 4.8V and soft start voltage (VSS) is above 5.3V (soft start is completed) (t1)
After a 5s delay the CoolMOS is switched off (t2)
Voltage at Vcc Pin (VCC) decreases to 8.5V (t2)
Control logic is switched off (t3)
Start-up resistor charges Vcc capacitor (t3)
Operation starts again with soft start after Vcc voltage has exceeded 13.5V (t4)
Fig. 6
Fig. 7
Fig. 8
t1 t2 t3 t4
VCC
VFB
VSS
t1, t2
t1, t2
t3t4
VCC
VFB
VSS
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Overvoltage Protection During Soft Start Feedback voltage (VFB) exceeds 4.8V and soft-start voltage (VSS) is below 4.0V (soft start phase) (t1)
Voltage at Vcc pin (VCC) exceeds 16.5V (t2)
CoolMOS transistor is immediately switched off (t2)
Voltage at VCC pin decreases to 8.5V (t3)
Control logic is switched off (t3)
Start-up resistor charges VCC capacitor (t4)
Operation starts again with soft start after VCC
voltage has exceeded 13.5V (t5)
Fig. 9
Fig. 10
Fig. 11
t1 t2 t3 t4 t5
t2
t3VCC
VFB
VSS
VCC
VFB
VSS
t1, t2
t3
t4t5
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Frequency ReductionThe frequency of the oscillator depends on the voltage at pin FB.
Below a voltage of typ. 1.75V the frequency decreases down to 21.5 kHz.
Due to this frequency reduction the power losses in low load condition can be reduced very effectively.
This dependency is shown in Fig. 12
Fig. 12
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Design Procedurefor fixed frequency Flyback Converter with ICE2AXXX operating in discontinuous current mode.
Procedure Example
Define input Parameters:
Minimal AC input voltage: VAC minMaximal AC input voltage: VAC maxLine frequency: fACMax. output power: POUT maxNom. output power: POUT nomMin. output power: POUT minOutput voltage: VOUTOutput ripple voltage: VOUT RippleReflection voltage: VRmaxEstimated efficiency: DC ripple voltage: VDC IN RippleAuxiliary voltage: VAuxOptocoupler gain: GCUsed CoolSET
90V
264V
50Hz
50W
40W
0,5W
16V
0,05V
120V
0,85
30V
12V
1
ICE2A365
There are no special requirements imposed on
the input rectifier and storage capacitor in the
flyback converter. The components will be
selected to meet the power rating and hold-up
requirements.
Maximum input power:
max
max OUT
INPP = (Eq 1) WWPIN 5985,0
50max ==
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Input Diode Bridge (BR1):
cosmin
=
AC
MAXINACRMS V
PI (Eq 2)
Maximum DC IN voltage
2maxmax = ACPKDC VV (Eq 3)
Determine Input Capacitor (C3):
Minimum peak input voltage at no load condition
2minmin = ACPKDC VV (Eq 4)
RipplePKDCDC VVV = minmin (Eq 5)
Calculation of discharging time at each half-line
cycle:
+=90
arcsin15 min
min
PKDC
DC
DV
V
msT (Eq 6)
Required energy at discharging time of C3:
DININ TPW = max (Eq 7)
Calculation of input capacitor value CIN:
2min
2min
2
DCPKDC
ININVV
WC
= (Eq 8)
AV
WI ACRMS 09,16,09059
=
=
VVV PKDC 3732264max ==
VVV PKDC 127290min ==
we choose a ripple voltage of 30V
VVVVDC 9730127min ==
msVV
msTD 7,79012797arcsin
15 =
+=
WsmsWWIN 46,07,759 ==
FVV
WsCIN 9,136940916129
46,0222=
=
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Alternatively a rule of thumb for choosing CIN can
be applied:
Input voltage CIN115V 2F/W
230V 1F/W
85V ...270V 2 ...3F/W....................
Recalculation of input Capacitor:
Select a capacitor from the Epcos Databook
of Aluminium Electrolytic Capacitors.
The following types are preferred:
For 85C Applications:
Series B43303-........ 2000h life time
B43501-........ 10000h life time
For 105C Applications:
Series B43504-........ 3000h life time B43505-........ 5000h life time
IN
INPKDCDC C
WVV
=
22minmin (Eq 9)
Note that special requirements for hold uptime, including cycle skip/dropout, or otherfactors which affect the resulting minimum DCinput voltage and capacitor time should beconsidered at this point also.
FWFW 177359 =
We choose 150F 400V (based on Eq 8)
VFWsVVDC 100150
46,0216129 2min =
=
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Transformer Design (TR1):
Calculation of peak current of primary inductance:
minmax
maxmax
DCR
R
VVVD+
= (Eq 10a)
maxmin
2DV
PI
DC
MAXINLPK
= (Eq 10b)
3maxDII LPKLRMS = (Eq 11)
Calculation of primary inductance within the limit
of maximum Duty-Cycle :
fIVD
LLPK
DCP
=minmax (Eq 12)
Select core type and inductance factor (AL) from EpcosFerrite Databook or CD-ROMPassive Components.Fix maximum flux density:
Bmax 0,2T ...0,3T for ferrite cores depending on core material.
We choose 0,2T for material N27
The number of primary turns can be calculated as:
L
PP A
LN = (Eq 13)
The number of secondary turns can be calculated
as:
( )maxR
FDIODEOUTP
VVVN
Ns+
= (Eq 14)
The number of auxiliary turns can be calculated
as:
( )maxR
FDIODEAuxAux V
VVNsN
+= (Eq 15)
55,0100120
120max =
+=
VVVD
AV
WI LPK 16,255,0100592
=
=
AAI LRMS 92,0355,016,2 ==
HHzA
VLP 25310*10016,2
10055,03
=
=
Selected core: E 25/13/7Material = N27
AL = 111 nH
s = 0,75 mmAe = 52 mm2
AN = 61 mm2
lN = 57,5 mm
7,47111253
==
nHHN P turns
we choose Np = 46 turns
( ) 46,6120
8,01646=
+=
VVVNs
we choose NS = 7 turns
( ) 6,5120
7,01246=
+=
VVVNs
we choose NAux = 5 turns
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Verification of primary inductance, primary peakcurrent, max. duty cycle, flux density and gap:
lPP ANL =2 (Eq 16)
fLpP
I INLPK
=
5,0max (Eq 17)
NsNVV
V PFDIODEOUTR+
=
)( (Eq 18)
minmax
DC
LPKP
VfIL
D
= (Eq 19)
R
LPKP
VfIL
D
=max' (Eq 20)
eP
LPKP
ANIL
B
=max (Eq 21)
P
eP
LAN
s
=
27104 (Eq 22)
Sense resistorThe sense resistance RSense can be used to
individually define the maximum peak current and
thus the maximum power transmitted.
Caution:When calculating the maximum peak current,
short term peaks in output-power must also be
taken into consideration.
LPK
csthSense I
VR = (Eq23)
HnHLP 235111462 ==
AHzH
WI LPK 24,210*1002355,0
593
=
=
VVVVR 110746)8,016(
=
+=
53,0100
10024,2235max =
=
VkHzAHD
47,0110
10024,2235'max =
=
VkHzAHD
mTmm
AHB 2105246
24,22352max
=
=
mmH
mms 588,0235
5246104 227=
=
Vcsth = 1.0V typ. (taken from data sheet)
== 45,024,20,1
AVRSense
we select 0,43 ILPK = 2,33A
POUTmax = 54W
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Winding Design:
see also page 38Transformer Construction
The primary winding of 46 turns has to be divided
into 23+23 turns in order to get the best coupling
between primary and secondary winding.
The effective bobbin width and winding cross
section can be calculated as:
MBWBWe = 2 (Eq 24)
BWBWA
A eNNe
= (Eq 25)
Calculate copper section for primary andsecondary winding:
The winding cross section AN has to be
subdivided according to the number of windings.
Primary winding 0,5Secondary winding 0,45Auxiliary winding 0,05
Copper space factor fCu :0,2 ....0,4
BWNBWfA
AP
eCuNP
=
5,0 (Eq 26)
( )( )( )dAWG log28277,197,9 = (Eq 27)
From bobbin datasheet E25/13/7: BW = 15,6mm
Margin determined: M = 0mm
we use triple insulated wire for secondarywinding
mmBWe 6,15=
261mmANe =
We calculate the available area for each winding:Used for calculation: fCu =0,3
22
2,046
3,0615,0 mmmmAP =
=
diameter dp 0,5mm 25 AWG
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BWNBWfA
As
eCuNs
=
45,0 (Eq 28)
BWNBWfA
Aaux
eCuNaux
=
05,0 (Eq 29)
With the effective bobbin width we check the
number of turns per layer:
PP d
BWeN = (Eq 30)
22
18,17
3,06145,0 mmmmAs =
=
diameter ds 2 x 0,8mm 2 x 20 AWG
22
18,05
3,06105,0 mmmmAaux =
=
diameter da 0,5mm 25 AWG
Primary:
3146,06,15
==
mmmmN P turns per layer
2 layer needed
Secondary:
621,126,15
=
=
mmmmN S turns per layer
2 layer needed
Auxiliary: 1 layer !
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Output Rectifier (D1):
The output rectifier diodes in flyback converters
are subjected to a large PEAK and RMS current
stress. The values depend on the load and
operating mode. The voltage requirements
depend on the output voltage and the transformer
winding ratio.
Calculation of the maximum reverse voltage:
+=
P
SPKDCOUTRDiode N
NVVV max (Eq 31)
Calculation of the maximum current on secondary
side:
S
PLPKSPK N
NII = (Eq 32)
max'31 DII SPKSRMS = (Eq 33)
VVVVRDiode 8,7246737316 =
+=
AAI SPK 3,1574633,2 ==
AAI SRMS 9,547,0313,15 ==
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Output Capacitors (C5, C9):
Output capacitors are highly stressed in flyback
converters. Normally the capacitor will be selected
for 3 major parameters: capacitance value, lowESR and ripple current rating.
Max. voltage overshoot: VOUT
Number of clock periods: nCP
fVI
COUT
OUTOUT
=CPmax n (Eq 34)
OUT
OUTOUT V
PI max= (Eq 34a)
22OUTSRMSRipple III = (Eq 34b)
Select a capacitor out of Epcos Databookfor Aluminium Electrolytic Capacitors.
The following types are preferred:
For 105C Applications low impedance:
Series B41856-........ 4000h life time
For 105C Applications lowest impedance:
Series B41859-........ 4000h life time
To calculate the output capacitor, it is necessary
to set the maximum voltage overshoot in case of
switching off @ maximum load condition.
After switching off the load, the control loop
needs about 10...20 internal clock periods to
reduce the duty cycle.
VVOUT 5,0=
nCP = 20
FHzV
ACOUT 125010*1005,0201,3
3=
=
AVWIOUT 1,316
50==
AAAI Ripple 0,51,39,522==
We select 1000F 35V (based on Eq 34):
B41859-F7108-M
ESR Zmax = 0,034 @ 100kHz
IacR = 1,94A
we need 2 capacitors in parallel
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Output Filter (L3, C23):
The output filter consists of one capacitor (C23)
and one inductor (L3) in a L-C filter topology.
Zero frequency of output capacitor (C5,C9, C20)
and associated ESR:
OUTESRZCOUT CR
f
=
21 (Eq 35)
Calculation of the inductance (L3) needed for the
substitution of the zero caused by the output
capacitors:
( )LC
ESROUTOUT C
RCL
2
= (Eq 36)
RC-Filter at Feedback Pin
(C6, R9)
The RC Filter at the Feedback pin is designed to
supress any noise which may be coupled in on
this track.
Typical values:
C6 : 1...4,7nF
R9 : 22 Ohm
Note that the value of C6 interacts with theinternal pullup (3,7k typical) to create a filter.
kHzF
f ZCOUT 7,41000034,021
=
=
We use CLC (C23) 470uF
uHuF
uFLOUT 5,2470)034,01000( 2
=
=
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Soft-start capacitor
(C14)
The voltage at the soft-start pin together with
feedback voltage controls the overvoltage, open
loop and overcurrent protection functions.
The softstart capacitor must be calculated in such
a way that the output voltage and thus the
feedback voltage is within the working range (VFB< 4.8V) before the over-current threshold (typ.
5.3V) is reached.
OUTnomOUT
outSstart PP
CVot
=
max
2 (Eq37)
)1ln(
11
REF
StartSoftStartSoft
SstartSS
VV
RtC
= (Eq38)
Rsoft start = 50k typ (from datasheet).
msWW
uFVtSstart 454054247016 2 =
=
nF
VVk
msC SS 586)
5,61,51ln(50
145 =
=
choose 560nF
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VCC Capacitor:
(C4, C13)
The VCC capacitor needs to ensure the power
supply of the IC until the power can be provided
by the auxiliary winding.
In parallel with the VCC Capacitor it is
recommended to use a 100nF ceramic capacitor
very close between pin 7 & 8. Alternatively, an HF
type electrolytic with low ESR and ESL may be
used.
32*3
CCHY
softstartVCCVCC V
tIC
= (Eq 39)
Start-up Resistor (R6, R7):
IVCC1 = max. quiescent current (Control IC)
ILoadC = VCC-Capacitor load-current (C4)
CVCC = Value of VCC-capacitor (C4)
LoadCVCC
DCStart II
VR+
=
1
min (Eq 40)
Start up Time tStart:
LoadC
CConVCCStart I
VCt = (Eq 41)
uFV
msmACVCC 4932*
5452,8
=
=
we choose 47uF
ICCLmax = 55A
ILoadC = 70A
=+
= kA
VRStart 801)7055(100
R6 = R7 =1/2 RStart = 400k
Choose 2 with value: 390k
sA
VFtStart 7,8735,1347
=
=
Note:Before the IC can be plugged into the applicationboard, the VCC capacitor must be alwaysdischarged!
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Clamping Network:(R10/C12/D3)
RDCDSSBRClamp VVVV = max)( (Eq 42)
For calculating the clamping network it is
necessary to know the leakage inductance. The
most common way is to have the value of the
leakage inductance (LLK) given in percentage of
the primary inductance (Lp). If it is known that the
transformer construction is very consistent,
measuring the primary leakage inductance by
shorting the secondary windings will give an exact
number (assuming the availability of a good LCR
analyser).
%xLpLLK =
( ) ClampClampRLKLPK
Clamp VVVLI
C+
=
2
(Eq 43)
( )fIL
VVVR
LPKLK
RRClampClamp
+=
2
22
5,0 (Eq 44)
VVVVVClamp 166110373650 ==
In our example we choose 5% of the primary
inductance for leakage inductance.
HHLLK 8,11%5235 ==
( ) nFVVVHACClamp 2,1166166110
8,11)24,2( 2=
+
=
we choose 1,5nF
( ) =
+= k
HzAHVVVRClamp 9,2310*100)24,2(8,115,0
11011016632
22
we choose 22k
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 27 of 44 Version 1.2
Calculation of Losses:
Input diode bridge (BR1):
2= FACRMSDIN VIP (Eq 45)
Calculation of copper resistance RCu:
P
PNPCu A
pNlR 100
= (Eq 46)
Calculation of copper losses (TR1):
PCuMAXLPKPCu RDIP = 312 (Eq 47)
SCuMAXSPKSCu RDIP = 31'2
Output rectifier diode (D1):
FDIODESPKDDIODE VD
IP =3'max (Eq 48)
WVAPDIN 2,2211,1 ==
Copper resistivity p100 @ 100C = 0,0172mm2/m
== mmm
mmmmmRPCu 1,27746,0
/2,17460644,02
2
== mmm
mmmmmRSCu 6,610,2/2,1770644,0
2
2
mWmAPPCu 7,2251,2773153,0)33,2( 2 ==
mWmAPSCu 4,22701,23147,0)3,15( 2 ==
=+= mWmWmWPCu 1,4534,2277,225
WVAPDDIODE 58,0347,03,15 ==
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 28 of 44 Version 1.2
COOLMOS TRANSISTOR:ICE2A365 Co(er) = 30pFCalculated @ VDCmin = 100V
CO 80pF (CO = CO(er) + CExtern)
RDSON = 1,1 (@ 125C)
Switching losses:
fVCP DCOSON =2
min21 (Eq 49)
Conduction losses:
max2
31 DIRP LPKDSOND = (Eq 50)
Summary of Losses:
DSONLosses PPP += (Eq 51)
Thermal Calculation:
Table of typical thermal Resistance [WK
]:
Heatsink DIP8 DIP7 TO220No 90 96 74
3 cm 64 726 cm 56 65
thLosses RPdT *= (Eq 52)
TadTTj += (Eq 53)
(see also ICE2AXXX Data Sheet)
mWHzVpFPSON 4010*1001008021 32 ==
WAPD 95,053,0)33,2(131 2 ==
WmWmWPLosses 99,095040 =+=
KWKWdT 4,5556*99,0 ==
CCKTj =+= 4,115504,55
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 29 of 44 Version 1.2
Regulation Loop:Reference: TL431 (IC2)
VREF =2,5V
IKAmin=1mA
Optocoupler: SFH617-3 (IC1)
Gc = 1 ...2 CTR 100% ...200%
VFD = 1,2V
IFmax =20mA (maximum current limit)
Primary side:Feedback voltage:
Values from ICE2AXXX datasheetVRef int = 6,5V typ.
VFBmax = 4,5V
Av = 3,65
RFB = 3,7k typ.
FB
fFB R
VI intRemax = (Eq 54)
FB
FBfFB R
VVI maxintRemin
= (Eq 55)
Secondary side:
= 121
REF
OUT
VV
RR (Eq 56)
the value of R2 can be fixed at 4,3k
( )max
3)(
F
REFFDOUT
IVVV
R+
(Eq 57)
min
min3
4KA
FBFD
IGc
IRV
R
+
(Eq 58)
Fig. 13
Fig. 14
mAkVI FB 76,17,3
5,6max =
=
mAk
VVI FB 5,07,36,45,6
min =
=
kVVkR 22,231
5,2163,41 =
=
( ) kmA
VVVR 74,020
)5,22,1(163 =
+ 0,75k
kmA
mAkVR 58,1
11
5,075,02,1
4 =
+
1,5k
FB3,76,5
VFB
R3 R1R4
R5
R2
C2C1
TL431
Vout
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 30 of 44 Version 1.2
Regulation Loop Elements:
Fig. 15
Transfer Characteristics of Regulation Loop Elements:
3
73R
kGK CFB
= (Eq 59) Feedback
OUT
REFVD V
VRR
RK =+
=
212 (Eq 60) VoltageDivider
( )
++
+
=
5
5
21
12
1)(CR
Rp
CRpfLRZ
pF
ESRL
ESRPL
PWMPWR
(Eq 61) Powerstage
ZPWM = Transimpedance VFB/ID
9
29
9
11
)(CLpCRp
CRppF
ESR
ESRLC
++
+= (Eq 62) Output filter
( ))251(1
2121
2151)(
CRpCRRRRp
CCRppFr+
+
++= (Eq 63) Regulator
+
KFB KVD
FPWR(p) FLC(p)
Fr(p)
Vo
Vref
VIN
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 31 of 44 Version 1.2
Zeros and Poles of transfer characteristics:
Poles of powerstage @ min. and max. load:
=== 9,45416 2
max
2
WV
PV
ROUT
OUTLH (Eq 64) === 5125,0
16 2
min
2
WV
PV
ROUT
OUTLL (Eq 65)
5
1CR
fLH
OH
=
Hz
FfOH 1,3120009,4
1=
=
(Eq 66)
5
1CR
fLL
OL
=
Hz
FfOL 31,02000512
1=
=
(Eq 67)
We use the gain (Gc) of the optocoupler stage KFB and the voltage divider KVD as a constant.
373
RkG
K CFB
= KFB = 4,9 GFB = 13,9db
OUT
REFVD V
VRR
RK =+
=
212 KVD = 0,15 GVD = -16,4db
With adjustment of the transfer characteristics of the regulator we want to reach equal gain within theoperating range and to compensate the pole fo of the powerstage FPWR().
Because of the compensation of the output capacitors zero (see page 22 Eq35, Eq36) we neglect itas well as the LC-Filter pole.
Consequently the transfer characteristic of the power stage is reduced to a single-pole response.
In order to calculate the gain of the open loop we have to select the cross-over frequency.
We calculate the gain of the Power-Stage with max. output power at the selected cross-overfrequencyfg = 3kHz:
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 32 of 44 Version 1.2
Calculation of transient impedance ZPWM of ICE2AXXX
The transient impedance defines the direct relationship between the level of the peak current and the
feedback pin voltage. It is required for the calculation of the power stage amplification.
PWM-Op gain -Av = 3,65 (according to datasheet)
csth
sensev
pk
FBPWM V
RAIVZ =
= (Eq 68)
AV
VIV
Zpk
FBPWM 57,100,1
43,065,3 ==
=
Gain @ crossover frequency:
+
=
2
1
12
1)(
fofg
fLRZ
fgF pLPWM
PWR
(Eq 69)
05,0
1,3130001
12
8,01002351,57,1
1)3(2
=
+
=
kHzHRkHzFPWR
GPWR(3kHz) = -26,2db
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 33 of 44 Version 1.2
Transfer characteristics:
Fig. 16
At the crossover frequency (fg) we calculate the open loop gain:
Gol() = Gs () + Gr () = 0.
With the equations for the transfer characteristics we calculate the gain of the regulation loop @ fg.
For the gain of the regulation loop we calculate:
Gs = GFB + GPWR + GVD = 13,9db 26,2db 16,4db
Gs = -28,7db
We calculate the separate components of the regulator:
Gs () + Gr () = 0 Gr = 0 (-28,7db) = 28,7db
KFB
KVD
GLC()
GPWR()
Full-load1 10 100 1 103 1 104 1 105
50
0
50
Gr()
GPWR()
Low-load
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 34 of 44 Version 1.2
( ))251(1
2121
)2151)(CRpC
RRRRp
CCRppFr+
+
++=
( )21
215log20RR
RRRGr
+=
2121105 20
RRRRR
Gr
+
=
kkR 15,9965,3105 202,32
== 100k (Eq 70)
252
1CR
fp
=
fgRC
=
5212
pFkHzk
C 53031002
12 =
=
560pF (Eq 71)
In order to have enough phase margin @ low load condition we select the zero frequency of the
compensation network to be at the middle between the min. and max. load poles of the power stage.
oh
ol
ff
ohom fflog5,0
10
= HzHzf om 2,3101,31 1,3115,0log5,0==
( )21521
CCRfz
+=
2
5211 C
fomRC
=
nFpFHzk
C 4925602,31002
11 =
=
470nF (Eq 72)
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 35 of 44 Version 1.2
Open Loop Gain
Fig. 17
Open Loop Phase
Fig. 18
1 10 100 1 103 1 104 1 10550
37
24
11
2
15
28
41
54
67
80
1 10 100 1 103 1 104 1 105180
142
104
66
28
10
Low-load
Full-load
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 36 of 44 Version 1.2
Continuous Conduction Mode (CCM)
Fig. 19
Transformer calculation:The transformer is calculated in such a way that
DCM operation is just barely reached (A=0) at
minimum output power POmin.
Pomin = 2W
Pomax = 10W
Dmax = 0,6
min
max
PoPo
p =
+
=
minmax
maxmin
dcVDPoPo
Ipk
( )pfIpk
DpPoLp
+= 2
max2
max *1
52
10==
WWp
AV
WWIpk 25,08,01006,0
102=
+=
( ) mHkHz
WLp 91,6510025,06,0*1510
2
2=
+=
Ipk
A*IpkIprim Isec
tON tOFF
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 37 of 44 Version 1.2
Slope CompensationSlope compensation is necessary for stable regulator operation in Continuous Conduction Mode(CCM), up to and beyond a duty cycle of 0.5 (see also [4]).An simple method of slope compensation using the components R19, C17 and C18 is illustrated in the
circuit diagram on page 3 .
Fig. 20
VonVR =s
p
nn
n =
p
R
p LV
LVonm ==2
p
Rkorr L
Vmm
==
222
For duty cycle = 0,5 applies:
usV
m FBkorrkorr 5= PWM
p
RFBkorr ZL
usVV
=
25
CComp (C17) is selected at 10nF.
C18 is selected at 100nF.
RComp (R19):
CompFBkorr
Comp
CVCC
VtR
=
1ln
Tton
-VFBkorrVFB
Ipk
IsecIprim
mkorr = m2/2
m2=n*Vo/Lpm1=Vi/Lp
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 38 of 44 Version 1.2
Transformer ConstructionThe winding topology has a considerable influence on the performance and reliability of the transformer.
In order to reduce leakage inductance and proximity to acceptable limits, the use of a sandwich construction is recommended.
In order to meet international safety requirements a transformer for Off - Line power supply must have adequate insulation
between primary and secondary windings.
This can be achieved by using a margin-wound construction or by using triple insulated wire for the secondary winding.
The creepage distance for the universal input voltage range is typically 8mm. This results in a minimum margin width (as a half
of the creepage distance) of 4mm. Additionally the neccesary insulation between primary and secondary winding is provided
using three layers of basic insulation tape.
Example of winding topology for margin wound transformers:
Fig. 21
Example of winding topology with triple insulated wire for secondary winding:
Fig. 22BW* : value from bobbin datasheet
Primary second
half
Auxiliary
Secondary
margin margin
Triple insulation
Creepage
distance
BW*
BWe
Primary first
half
Primary second
half
BW*
Primary first
half
Auxiliary
SecondaryTriple Insulated
Wire
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 39 of 44 Version 1.2
Layout Recommendation:
Fig. 23
In order to avoid crosstalk on the board between power and signal path we have to use care regarding
the track layout when designing the PCB.
The power path (see Fig. 23) has to be as short as possible and needs to be separated from the VCC
Path and the feedback path. All GND paths have to be connected together at pin 8 (star ground) of
ICE2AXX.
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 40 of 44 Version 1.2
CoolSET TableDevICE Package Current
ARdson
Pout @190Vacin
Ta=75C / Tj = 125C
Pout @85Vacin
Ta=75C / Tj = 125C
Heatsink FrequencyKHz
VDS=650V
ICE2A0565 DIP8 0.5 6.0 23 13 6 cm 100
ICE2A0565Z DIP7 0.5 6.0 21 12 6 cm 100
ICE2A165 DIP8 1.0 3.0 31 18 6 cm 100
ICE2B165 DIP8 1.0 3.0 31 18 6 cm 67
ICE2A265 DIP8 2.0 0.9 52 32 6 cm 100
ICE2B265 DIP8 2.0 0.9 52 32 6 cm 67
ICE2A365 DIP8 3.0 0.45 67 45 6 cm 100
ICE2B365 DIP8 3.0 0.45 73 45 6 cm 67
ICE2A765P TO220 7.0 0.5 240 130 2.7 k/W 100
ICE2B765P TO220 7.0 0.5 240 130 2.7 k/W 67
VDS=800V
ICE2A180 DIP8 1.0 3.0 31 18 6 cm 100
ICE2A180Z DIP7 1.0 3.0 29 17 6 cm 100
ICE2A280 DIP8 2.0 0.8 54 34 6 cm 100
ICE2A280Z DIP7 2.0 0.8 50 31 6 cm 100
Output Power Notes:
The output power was created using the equations of this application note (see Calculation of Losses
on page 27). It shows the maximum practical continuous power @ Ta = 75 C and
Tj = 125 C with the recommended heatsink as a copper area on PCB for DIP7 / 8 and PDSO14
packages.
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 41 of 44 Version 1.2
Summary of used NomenclatureBmax Magnetic InductanceBW Bobbin WidthBWe Effective Bobbin WidthCIN Capacitance of Bulk CapacitorCOUT Output CapacitanceCOSS Output Capacitance of CoolMOSCExtern Output Capacitance of external ComponentsCClamp Capacitance of Clamping CapacitorCVCC Capacitance of VCC CapacitorD Duty CycleDmax Maximum Duty Cyclef Operating Frequency of CoolSET (f = 100kHz)fAC Line Frequency (Germany FAC = 50Hz)fg Crossover FrequencyfCu Copper Space Factor (0,2 ... 0,4)fOH Frequency Open Loop (High)fOm Frequency Open Loop (middle)fOL Frequency Open Loop (Low)fZCOUT Zero Frequency of output CapacitorGC Optocoupler GainIFBmax Maximum Feedback CurrentIFBmin Minimum Feedback CurrentIFmax Maximum Current (Optocoupler)IKAmin Minimum Current (TL431)ILoadC VCC Capacitor Load CurrentILPK Peak Current through the primary InductanceIACRMS Root Mean Square Current through the primaryInductanceIACRMS Root Mean Square Current through the BridgeRectifierIPRI Primary Current @ time tISEC Secondary Current @ time tISPK Peak Current through the secondary diodeISRMS RMS Current through the secondary diodeIVCC1 Maximum quiescent Current of CoolSET (ControlIC)LOUT Inductance output FilterLP Primary InductanceLLK Leakage InductanceM Margin (of Transformer)nCP Number of Clock PeriodsnpCOUT Number of parallel output CapacitorsNP Number of primary TurnsNS Number of secondary TurnsNAux Number of auxiliary TurnsPCu Power losses of Copper ResistorPD Conduction lossesPDIN Power losses input DiodePDDIODE Power losses rectifier Diode (secondary side)PIN MAX Maximum Input PowerPOUT max Maximum Output PowerPOUT min Minimum Output PowerPPCu Power losses of Copper Resistor (primaryInductance)PSCu Power losses of Copper Resistor (secondaryInductance)PSOFF Switching losses of CoolMOS Transistor (Off Operation)
PSON Switching losses of CoolMOS Transistor (On Operation)
RCu Copper Resistor (Transformer)RDSON Resistance of switching CoolMOS Transistor (On Operation)RL Load ResistanceRLH Maximum LoadRLL Minimum Load (defined by Designer)RFB Internal Feedback Resistor (CoolSET )RPCu Copper Resistor of primary InductanceRSCu Copper Resistor of secondary InductanceRClamp Clamping ResistorRStart Start up ResistorT Time of one PeriodTD Discharging Time of Input Capacitor C3tON On Time (CoolMOS )tOFF Off Time (CoolMOS )tr Rising Time (Voltage)tStart Start up TimeVAC min Minimal AC Input VoltageVAC max Maximal AC Input VoltageVAux Auxiliary VoltageV(BR)DSS Drain Source Breakdown VoltageVCCon Turn On Threshold for CoolSET @ Vcc - PinVDC IN DC Input VoltageVDC IN max Maximum DC Input VoltageVDC IN min Minimum DC Input VoltageVDC max PK Maximum DC Input Voltage PeakVDC min PK Minimum DC Input Voltage PeakVDC min Minimum DC Input Voltage @ maximum loadVDDIODE Reverse Voltage rectifier Diode (secondary side)VFBmax Maximum Feedback Voltage (CoolSET )VFDIODE Output Diode Forward VoltageVFD Forward Diode Voltage (Optocoupler)VOUT Output Voltage (secondary Side)VOUT Ripple Output Ripple Voltage (secondary Side)VR Reflected Voltage (from secondary side to primaryside)VRDiode Reverse Voltage DiodeVRefint Internal Reference Voltage (CoolSET )VREF Reference Voltage TL431VRipple DC Ripple Voltage (on primary Side)VSEC Voltage on Sekondary InductorVClamp Maximum Voltage overshoot @ clamping networkWIN Discharging Energie Input CapacitorZPWM Transimpedanz
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 42 of 44 Version 1.2
References
[1] Keith Billings,Switch Mode Power Supply Handbook
[2] Ralph E. Tarter,Solid-State Power Conversion Handbook
[3] R. D. Middlebrook and Slobodan Cuk,Advances in Switched-Mode Power Conversion
[4] Herfurth Michael,Ansteuerschaltungen fr getaktete Stromversorgungen mit Erstellung eines linearisierten
Signalfluplans zur Dimensionierung der Regelung
[5] Herfurth Michael,Topologie, bertragungsverhalten und Dimensionierung hufig eingesetzter
Regelverstrker
[6] Infineon Technologies, Datasheet, CoolSET-II
Off Line SMPS Current Mode Controller with 650V/800V CoolMOS on Board,
[7] Robert W. Erickson,Fundamentals of Power Electronics
ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 43 of 44 Version 1.2
Revision History
Application Note AN-SMPS-ICE2xXXX-1Actual Release: V1.2 Date:05.02.2002 Previous Release: V1.0
Page of
actual
Rel.
Page of
prev. Rel.
Subjects changed since last release
44 ---------- Second Issue
40 ------------- CoolSET Table Update
For questions on technology, delivery and prices please contact the Infineon Technologies Offices inGermany or the Infineon Technologies Companies and Representatives worldwide: see the addresslist on the last page or our webpage athttp://www.infineon.com
CoolMOS and CoolSET are trademarks of Infineon Technologies AG.
Edition 2001-03-01Published by Infineon Technologies AG,St.-Martin-Strasse 53,D-81541 Mnchen
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 chartsstated herein.Infineon Technologies is an approved CECC manufacturer.
InformationFor further information on technology, delivery terms and conditions and prices please contact your nearest Infineon Technologies Office inGermany or our Infineon Technologies Representatives worldwide (see address list).
WarningsDue to technical requirements components may contain dangerous substances. For information on the types in question please contact yournearest Infineon Technologies Office.Infineon Technologies Components may only be used in life-support devices or systems with the express written approval of InfineonTechnologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system, or to affect thesafety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body, or to supportand/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 beendangered.
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ICE2xXXX for OFF Line Switch Mode Power Supplies
AN-SMPS-ICE2xXXX-1 Page 44 of 44 Version 1.2
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RCInfineon TechnologiesAsia Pacific Pte.Ltd.Taiwan Branch10F,No.136 Nan King East RoadSection 23,TaipeiT (+8 86)2-27 73 66 06Fax (+8 86)2-27 71 20 76SGPInfineon Technologies AsiaPacific,Pte.Ltd.168 Kallang WaySingapore 349 253T (+65)8 40 06 10Fax (+65)7 42 62 39USAInfineon Technologies Corporation1730 North First StreetSan Jose,CA 95112T (+1)4 08-5 01 60 00Fax (+1)4 08-5 01 24 24Siemens Components,Inc.Optoelectronics Division19000 Homestead RoadCupertino,CA 95014T (+1)4 08-2 57 79 10Fax (+1)4 08-7 25 34 39Siemens Components,Inc.Special Products Division186 Wood Avenue SouthIselin,NJ 08830-2770T (+1)7 32-9 06 43 00Fax (+1)7 32-6 32 28 30VRCInfineon TechnologiesHong Kong Ltd.Beijing OfficeRoom 2106,Building AVantone New World PlazaNo.2 Fu Cheng Men Wai Da JieJie100037 BeijingT (+86)10 -68 57 90 -06,-07Fax (+86)10 -68 57 90 08Infineon TechnologiesHong Kong Ltd.Chengdu OfficeRoom14J1,Jinyang Mansion58 Tidu StreetChengdu,Sichuan Province 610 016T (+86)28-6 61 54 46 /79 51Fax (+86)28 -6 61 01 59Infineon TechnologiesHong Kong Ltd.Shanghai OfficeRoom1101,Lucky Target SquareNo.500 Chengdu Road NorthShanghai 200003T (+86)21-63 6126 18 /19Fax (+86)21-63 61 11 67Infineon TechnologiesHong Kong Ltd.Shenzhen OfficeRoom 1502,Block ATian An International BuildingRenim South RoadShenzhen 518 005T (+86)7 55 -2 28 91 04Fax (+86)7 55-2 28 02 17ZASiemens Ltd.Components DivisionP.O.B.3438Halfway House 1685T (+27)11-6 52 -27 02Fax (+27)11-6 52 20 42