Reference Design EBC iw for 12V 600mA Network Adapter Design

Transcription

1 Reference Design EBC10011 iw for 12V 600mA Network Adapter Design

2 Table of Contents iw For Network Adapter Design (AC Input V AC, Output 12V 600mA) EBC Introduction Design Features Power Supply Design Specification Schematic PCB Layout Bill Of Materials Transformer drawing Performance Regulation, Ripple and Efficiency Measurement CV and CC Regulation Conducted EMI...8 Rev. 1.1 EBC10011 Page 2

3 1.0 Introduction This document provides a reference design for a universal input, 12V 600mA isolated flyback network adapter. For this design the iw 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. EE1614 N L AC Input DC Output Figure 1.1 PCB Top View 50mm 33mm iw (No Cable Drop Compensation) - - Figure 1.2 PCB Bottom View 2.0 Design Features AC input range V AC DC output 12V 600mA Meet 150mW no-load standby power consumption requirement Meet EPA 2.0 requirement at end of output DC-Cable Max ripple < 150mV P_P No Y-Cap design Rev. 1.1 EBC10011 Page 3

4 3.0 Power Supply Design Specification The table below represents the minimum acceptable performance of the design. Description Symbol Min Typ Max Units Comment Input Voltage V IN V AC Frequency f LINE 47 50/60 63 Hz No-load Input Power (230V AC ) 150 mw Output Output voltage V OUT V Measured at the end of DC-Cable Output current I OUT A Output ripple voltage V RIPPLE 150 mv P_P I OUT A = 25 C 20 MHz bandwidth Measured at end of output DC-Cable Total Output Power Continuous output power P OUT 7.2 W Over-current protection I OUT_MAX 0.9 A Auto-restart Active mode protection η 74.6 % Environmental Conducted EMI Meets CISPR22B / EN55022B Safety Designed to meet IEC950, UL1950 Class II Ambient temperature T AMB 0 40 C Measured at the end of DC-Cable, V IN =115V AC and 230V AC (T AMB = 25 C) Rev. 1.1 EBC10011 Page 4

5 4.0 Schematic F1 10Ω L D1 D2 L2 T1 D7 1N4007 1N μh EE16 SR260 AC Input V + N D3 1N4007 D4 1N4007 C1 6.8 μf + R2 4.7 kω C2 6.8 μf L1 5.6 μh + R3 1 MΩ R4 1 MΩ C3 1 nf 1 kv R6 300 Ω R5 220 kω C7 470 µf 16 V + R11 10 kω D5 FR107 R7 3.6 Ω D6 FR102 V - U1 iw R8 24 kω 1 VCC OUTPUT 5 Q1 MJE GND 3 V SENSE I SENSE 4 R kω C6 47pF C4 10μF + C5 0.1μF R Ω Figure 4.1 Design Schematic 5.0 PCB Layout PCB Top PCB Bottom Figure 5.1 PCB Layout 50 mm x 33 mm Rev. 1.1 EBC10011 Page 5

6 6.0 Bill of Materials Item Qty. Ref. Description Manufacturer P/N Manufacturer 1 1 IC1 iw , off-line digital PSR & VMS PWM controller, SOT23-5 iw iwatt, Inc 2 2 C1,C2 6.8μF, 400V, E-CAP, (Φ10mm 12mm) KLH-400V6R8MG125 KOSHIN 3 1 C3 1nF, 1KV, ceramic capacitor CK45-R3AD102K-NR TDK Corporation 4 1 C4 10μF, 50V, low ESR E-CAP, (Ф5mmX11.5mm) KLH-050V100MC100 KOSHIN 5 1 C5 0.1μF, 25V, X7R, SMD-0603 C1608X7R1E104K TDK Corporation 6 1 C6 47pF, 25V, X7R, SMD A470KAT4A AVX Corporation 7 1 C7 470μF, 16V, low ESR E-CAP, (Ф8mmX12mm) EKMG160ELL471MHB5D United Chemi-Con 8 1 R2 4.7KΩ, ±5%, SMD-0805 ERJ-6GEYJ472V Panasonic - ECG 9 2 R3,R4 1MΩ, ±5%, SMD-1206 ERJ-8GEYJ105V Panasonic - ECG 10 1 R5 220KΩ, ±5%, SMD-1206 ERJ-8GEYJ224V Panasonic - ECG 11 1 R6 300Ω, ±5%, SMD-0805 ERJ-6GEYJ301V Panasonic - ECG 12 1 R7 3.6Ω, ±1%, SMD-0805 CRCW08053R60FKEA Vishay Dale 13 1 R8 24KΩ, ±1%, SMD-0805 CRCW080524K0FKEA Vishay Dale 14 1 R9 4.49KΩ, ±1%, SMD R10 2.2Ω, ±1%, SMD-1206 ERJ-8RQF2R2V Panasonic - ECG 16 1 R11 10KΩ, ±5%, SMD-0805 ERJ-6GEYJ103V Panasonic - ECG 17 4 D1,D2,D3,D4 1A, 1000V, rectifier diode, DO-41 1N4007 Taiwan Semiconductor 18 1 D5 1A, 1000V, fast recovery rectifier, DO-41 FR107 Taiwan Semiconductor 19 1 D6 1A, 100V, fast recovery rectifier, DO-41 FR102 Taiwan Semiconductor 20 1 D7 2A, 60V, Schottky diode, DO-15 SR260 Won-Top Electronics 21 1 F1 10Ω, fusible resistor, 1W FRM1WJT-52-10R Yageo 22 1 L1 5.6μH, color ring inductor, RC JW Miller A Bourns 23 1 L2 470μH, color ring inductor, RC JW Miller A Bourns 24 1 Q1 1.5A, 800V,NPN transistor, TO-126 HMJE13003 HSMC CORP 25 1 T1 EE1614, transformer, horizontal type Rev. 1.1 EBC10011 Page 6

7 7.0 Transformer drawing Schematic: 1 10 Primary 128Ts 15Ts Secondary 2 Bias Ts 6 Note: Dot ( ) denotes electrical start. Electrical start could be different from mechanical or winding start. Electrical Specifications: 1. Primary inductance (Lp) = 1.55mH ± 2. Primary leakage inductance (Lk) < 5% * Lp 3. Electrical strength = 3KV, 50/60Hz, 1Min. Materials: 1. Core: EE1614 (ferrite material TDK PC40 or equivalent) 2. Bobbin: EE16 horizontal 3. Magnet wires (pri): type 2-UEW 4. Magnet wire (sec): triple insulated wires 5. Layer insulation tape : 3M1298 or equivalent Finished: 1. Varnish the complete assembly Rev. 1.1 EBC10011 Page 7

8 8.0 Performance 8.1 Regulation, Ripple and Efficiency Measurement * Note: Output voltage is measured at end of PCB Vin (V AC ) Pin (W) Vout (V) Iout (ma) VRIPPLE (mvp-p) Pout (W) η (%) OCP (ma) Average η (%) CV and CC Regulation 8.3 Conducted EMI VI Curve (Vin=90VAC/50Hz) Vin=230VAC/50Hz, Live V OUT (V) V OUT (V) I OUT (ma) VI Curve (Vin=264VAC/50Hz) Amplitude(dBμV) Amplitude(dBμV) Frequency(MHz) Vin=230VAC/50Hz, Neutral I OUT (ma) Frequency(MHz) Rev. 1.1 EBC10011 Page 8

9 Trademark Information 2012 iwatt, Inc. All rights reserved. iwatt, BroadLED, EZ-EMI, Flickerless, Intelligent AC-DC and LED Power, and PrimAccurate are trademarks of iwatt, Inc. All other trademarks and registered trademarks are the property of their respective owners. Contact Information Web: Phone: +1 (408) Fax: +1 (408) iwatt Inc. 675 Campbell Technology Parkway, Suite 150 Campbell, CA Disclaimer iwatt reserves the right to make changes to its products and to discontinue products without notice. The applications information, schematic diagrams, and other reference information included herein is provided as a design aid only and are therefore provided as-is. iwatt makes no warranties with respect to this information and disclaims any implied warranties of merchantability or non-infringement of third-party intellectual property rights. iwatt cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in an iwatt product. No circuit patent licenses are implied. Certain applications using semiconductor products may involve potential risks of death, personal injury, or severe property or environmental damage ( Critical Applications ). IWATT SEMICONDUCTOR PRODUCTS ARE NOT DESIGNED, INTENDED, AUTHORIZED, OR WARRANTED TO BE SUITABLE FOR USE IN LIFE SUPPORT APPLICATIONS, DEVICES OR SYSTEMS, OR OTHER CRITICAL APPLICATIONS. Inclusion of iwatt products in critical applications is understood to be fully at the risk of the customer. Questions concerning potential risk applications should be directed to iwatt, Inc. iwatt semiconductors are typically used in power supplies in which high voltages are present during operation. Highvoltage safety precautions should be observed in design and operation to minimize the chance of injury. Rev. 1.1 EBC10011 Page 9