iW1691-03 for 5V 2.1A Adapter Design

EBC10007

Table of Contents

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Rev. 1.3 EBC10007 Page 2

1.0. Introduction ....................................................................................................................................................................3

2.0. Design Features ............................................................................................................................................................3

3.0. Power Supply Design Specification ...............................................................................................................................4

4.0. Schematic ......................................................................................................................................................................5

5.0. PCB Layout ....................................................................................................................................................................5

6.0. Bill Of Materials ..............................................................................................................................................................6

7.0. Transformer drawing ......................................................................................................................................................7

8.0. Performance ..................................................................................................................................................................8

8.1. Regulation, Ripple and Efficiency Measurement ......................................................................................................8

8.2. CV and CC Regulation ........................................................................................................................................8

8.3. Conducted EMI .................................................................................................................................................8

iW1691-03 For Adapter Design(AC Input 90 - 264VAC, Output 5V 2.1A)EBC10007

5V 2.1A Adapter with iW1691-03 EBC10007

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Rev. 1.3 EBC10007 Page 3

1.0 Introduction

AC input range 90-264VAC DC output 5V 2.1A

Meet 150mW no-load standby power consumption requirement

Meet EPA 2.0 requirement with 26AWG/1.0m DC-Cable

Max ripple < 100mVP_P

2.0 Design Features

AC Input

DC Output

EPC17

22mm

22mm

iW1691-03 Digital & Primary VMS Controller(No Cable Drop Compensation)

43.5mm

- -

This document provides a reference design for a universal input, 5V 2.1A isolated flyback power supply. For this design the iW1691-03 is used. It contains the complete specification of the power supply, a detailed circuit diagram, the entire bill of materials required to build the power supply, drawing of the power transformer, and test data of the most important performance.

Figure 1.1 PCB Top View Figure 1.3 PCB Side View

Figure 1.2 PCB Bottom View

5V 2.1A Adapter with iW1691-03 EBC10007

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Rev. 1.3 EBC10007 Page 4

3.0 Power Supply Design Specification

Description Symbol Min Typ Max Units Comment

Input

Voltage VIN 90 264 VACFrequency fLINE 47 50/60 63 Hz

No-load input power (230VAC) 150 mW

Output

Output voltage VOUT 4.85 5.25 V Measured at USB-End

Output current IOUT 0 2.1 A

Output ripple voltage VRIPPLE 100 mVP_PMeasured at end of Output DC-CableIOUT=2.1A @TA = 25 C20 MHz Bandwidth

Total Output Power

Continuous output power POUT 10.5 W

Over-current protection IOUT_MAX 2.5 A Auto-restart

Active mode protection 80 % Measured at USB-End, VIN=115VAC and 230VAC (TAMB = 25 C)

Environmental

Conducted EMI Meets CISPR22B / EN55022B

Safety Designed to meet IEC950, UL1950 Class II

Ambient temperature TAMB 0 40 C

The table below represents the minimum acceptable performance of the design.

5V 2.1A Adapter with iW1691-03 EBC10007

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Rev. 1.3 EBC10007 Page 5

+

U1iW1691 - 03

Fast latch release circuit

Optional Circuit for OTP and(or) Double- OVP

L2330 H

C16.8 F

C210 F

BR1MB8S

D1SRGC10MH

D3SRGC10MHD2

SRGC10MH

D8SBR10U45S

EPC17

C15R7

220

10 kR19

9.1 kR18

18 kR16

56 kR14

100 R13

1 kR12

1 R17

470 R9

10 k

SPU04N60C3Q1

SRGC10DHD6

1N4148D7

25 V

C102.2 F

C6270 pF

R81.24

10 V

+ +

33pFC8

470pFC161 nF

C747 pF

NTC1100 k

D5BAV70

R153.9 k

+C14

R6 C41 nF250 V

D4SRGC10MH

100 k

R21820 F

C13820 F

6.3 V10 F6.3 V

1 k

AC Input

F11 A / 250 V

10 mH

L

N

L1

NC

VSENSE

VIN

SD

VCC

OUTPUT

ISENSE

GND

1

2

3

8

7

6

4 5

0 R11

C12

T1

1 nF / 100V

R2022

C322 nF / 500 V

R43.3 M

R53.3 M

R10

CY1330 pF

5V

GND

C92.2 F

C11

4.0 Schematic

5.0 PCB Layout

Figure 4.1 Design Schematic

Figure 5.1 PCB Layout 43.5 mm x 22.0 mm

PCB Top PCB Bottom

5V 2.1A Adapter with iW1691-03 EBC10007

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Rev. 1.3 EBC10007 Page 6

6.0 Bill of Materials

Item Qty. Ref. Description Manufacturer P/N Manufacturer

1 1 U1 iW1691-03, off-line digital PSR & VMS controller, SOIC-8 iW1691-03 iWatt, Inc

2 1 C1 6.8F, 400V, E-CAP, (8mm12mm) 2GUTWHS6R8M0G12 TOSHIN KOGYO Co.3 1 C2 10F, 400V, E-CAP, (10mm16mm) EKMG401ELL100MJ20S United Chemi-Con4 1 C3 22nF, 500V, X7R, SMD-1206 VJ1206Y223KXEAT5Z Vishay Vitramon5 1 C4 1nF, 250V, X7R, SMD-0805 C2012X7R2E102K TDK Corporation6 1 C6 270pF, 25V, NPO, SMD-0603 C1608C0G1E472J TDK Corporation7 1 C7 47pF, 25V, NPO, SMD-0603 06033A470KAT4A AVX Corporation8 1 C8 470pF, 25V, NPO, SMD-0603 06033A471JAT2A AVX Corporation9 2 C9,C10 2.2F, 25V, X7R, SMD-0805 GCM21BR71E225KA73L Murata Electronics

10 1 C11 33pF, 50V, NPO, SMD-0603 C1608C0G1H330J TDK Corporation11 1 C12 1nF, 100V, X7R, SMD-0805 C2012X7R2A102K TDK Corporation12 1 C13 820F, 10V, Solid-CAP, (8mm12mm) ULR827M1AF1A Man Yue Technology13 1 C14 820F, 6.3V, E-CAP, (6.3mm16mm) TM8200UE16PB YIHCON Electronics14 1 C15 10F, 6.3V, X7R, SMD-1206 CGJ5L2X7R0J106K TDK Corporation15 1 C16 1nF, 25V, X7R, SMD-0603 06033C102KAT7A AVX Corporation16 1 CY1 330pF, 250V, Y2, radial DE2B3KY331KA2BM01 Murata Electronics17 1 R4, R5 3.3M, 1, SMD-1206 9C12063A3304FKHFT Yageo18 1 R6 100K, 5, SMD-1206 9C12063A1003JLHFT Yageo19 1 R7 220, 5, SMD-0805 9C08052A2200JLHFT Yageo20 1 R8 1.24, 1, SMD-1206 RC1206FR-071R24L Yageo21 1 R9 470, 1, SMD-0603 ERJ-3EKF4700V Panasonic - ECG22 1 R10, R19 10K, 5, SMD-0603 9C06031A1002JLHFT Yageo23 1 R11 0, 5, SMD-0603 9C06031A0R00JLHFT Yageo24 1 R12 1K, 5, SMD-0603 9C06031A1001JLHFT Yageo25 1 R13 100, 1, SMD-0603 ERJ-3EKF1000V Panasonic - ECG26 1 R14 56K, 1, SMD-0603 ERJ-3EKF5602V Panasonic - ECG27 1 R15 3.9K, 1, SMD-0603 ERJ-3EKF3901V Panasonic - ECG28 1 R16 18K, 5, SMD-0603 ERJ-3GEYJ183V Panasonic - ECG29 1 R17 1, 5, SMD-0603 ERJ-3GEYJ1R0V Panasonic - ECG30 1 R18 9.1K, 1, SMD-0603 ERJ-3EKF9101V Panasonic - ECG31 1 R20 22, 5, SMD-0805 ERJ-6GEYJ220V Panasonic - ECG32 1 R21 1K, 5, SMD-0805 ERJ-6GEYJ102V Panasonic - ECG33 1 BR1 1A, 800V, bridge rectifier, MB8S MB8S Fairchild Semiconductor34 1 D1-D4 1A, 1000V, fast recovery rectifier, 1206-S SRGC10MH ZOWIE35 1 D5 200mA, 70V, ultrafast diode, SOT-23 BAV70 Fairchild Semiconductor36 1 D6 1A, 200V, fast recovery rectifier, 1206-S SRGC10DH ZOWIE37 1 D7 150MA, 75V, rectifier, SOD323F 1N4148WS Fairchild Semiconductor38 1 D8 10A, 45V, Schottky, PowerDI 5 SBR10U45SP5-13 Diodes Inc39 1 F1 1A, 250V, fuse, axial 0230001.DRT1P Littelfuse Inc40 1 L1 10mH, CM inductor, EE8.3, 0.17mm60T41 1 L2 330H, color ring inductor, 0510 8230-80-RC JW Miller A Bourns42 1 Q1 4.5A, 650V, N-CH MOSFET, TO-251 SPU04N60C3 Infineon43 1 NTC1 100K, 1, SMD-0603 NTCG164KF104FT1 TDK Corporation44 1 USB USB connector, vertical B0-F44-16064 YuanChuan Electronics45 1 T1 EPC17, transformer, vertical type

5V 2.1A Adapter with iW1691-03 EBC10007

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Rev. 1.3 EBC10007 Page 7

Schematic:

Electrical Specifications:1. Primary inductance (Lp) = 940H (5) @10KHz2. Primary leakage inductance (Lk) < 2 * Lp 3. Electrical strength = 3KV, 50/60Hz, 1Min.

Materials:1. Core: EPC17 (ferrite material TDK PC40 or equivalent)2. Bobbin: EPC17 vertical3. Magnet wires (pri): type 2-UEW4. Magnet wire (sec): triple insulated wires 5. Layer insulation tape: 3M1298 or equivalent

Finished:1. Varnish the complete assembly

7.0 Transformer drawing

A

B94Ts

9Ts

16Ts

2

X

4

1

Bias

Secondary 22TsPrimary-2

Primary-1

3

Note: Dot () denotes electrical

start.

Electrical start could be different from mechanical or winding start.

Ferrite core is to be connected to Pin (3) with copper

5V 2.1A Adapter with iW1691-03 EBC10007

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Rev. 1.3 EBC10007 Page 8

8.0 Performance

8.1 Regulation, Ripple and Efficiency Measurement

* Note: Output voltage is measured at USB-End

Vin(VAC)

Pin(W)

Vout(V)

Iout(A)

VRIPPLE(mVP-P)

Pout(W)

(%)

OCP(A)

Average (%)

90

0.06 5.15 0 10

2.29 81.9 3.31 5.16 0.525 18 2.71 81.84 6.52 5.17 1.050 20 5.43 83.26 9.94 5.18 1.575 36 8.16 82.08 13.57 5.19 2.100 60 10.90 80.32

115

0.07 5.15 0 10

2.28 83.0 3.30 5.16 0.525 16 2.71 82.09 6.48 5.17 1.050 20 5.43 83.77 9.76 5.18 1.575 26 8.16 83.59 13.18 5.19 2.100 30 10.90 82.69

230

0.09 5.15 0 10

2.28 82.1 3.38 5.15 0.525 20 2.70 79.99 6.67 5.17 1.050 20 5.43 81.39 9.81 5.18 1.575 22 8.16 83.17 13.02 5.19 2.100 24 10.90 83.71

264

0.12 5.15 0 10

2.29 81.2 3.41 5.15 0.525 24 2.70 79.29 6.76 5.17 1.050 18 5.43 80.30 9.92 5.18 1.575 20 8.16 82.24 13.14 5.19 2.100 24 10.90 82.95

8.2 CV and CC Regulation 8.3 Conducted EMI

Vin=230VAC/50Hz, Live

Vin=230VAC/50Hz, Neutral

Frequency(MHz)

Frequency(MHz)

Ampl

itude

(dB

V)Am

plitu

de(d

BV)

V OUT

(V)

IOUT (mA)

V OUT

(V)

IOUT (mA)

VI Curve (Vin=264VAC/50Hz)

VI Curve (Vin=90VAC/50Hz)

0 500 1000 1500 2000 2500 3000 3500 4000

6.0

4.0

3.0

2.0

1.0

0.0

5.0

0 500 1000 1500 2000 2500 3000 3500 4000

6.0

4.0

3.0

2.0

1.0

0.0

5.0

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