Reference Design EBC10011 iw1706-00 for 12V 600mA Network Adapter Design
Table of Contents iw1706-00 For Network Adapter Design (AC Input 90 264V AC, Output 12V 600mA) EBC10011 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 Rev. 1.1 EBC10011 Page 2
1.0 Introduction This document provides a reference design for a universal input, 12V 600mA isolated flyback network adapter. For this design the iw1706-00 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 iw1706-00- (No Cable Drop Compensation) - - Figure 1.2 PCB Bottom View 2.0 Design Features AC input range 90-264V 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
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 90 264 V AC Frequency f LINE 47 50/60 63 Hz No-load Input Power (230V AC ) 150 mw Output Output voltage V OUT 11.4 12.0 12.6 V Measured at the end of DC-Cable Output current I OUT 0 0.6 A Output ripple voltage V RIPPLE 150 mv P_P I OUT =0.6A @T 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
4.0 Schematic F1 10Ω L D1 D2 L2 T1 D7 1N4007 1N4007 470 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 iw1706-00 R8 24 kω 1 VCC OUTPUT 5 Q1 MJE13003 2 GND 3 V SENSE I SENSE 4 R9 4.49 kω C6 47pF C4 10μF + C5 0.1μF R10 2.2 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
6.0 Bill of Materials Item Qty. Ref. Description Manufacturer P/N Manufacturer 1 1 IC1 iw1706-00, off-line digital PSR & VMS PWM controller, SOT23-5 iw1706-00 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-0603 06033A470KAT4A 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-0805 15 1 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, 0510 8230-38-RC JW Miller A Bourns 23 1 L2 470μH, color ring inductor, 0510 8230-84-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
7.0 Transformer drawing Schematic: 1 10 Primary 128Ts 15Ts Secondary 2 Bias 5 3 12Ts 6 Note: Dot ( ) denotes electrical start. Electrical start could be different from mechanical or winding start. Electrical Specifications: 1. Primary inductance (Lp) = 1.55mH ± (7%) @10KHz 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
8.0 Performance 8.1 Regulation, Ripple and Efficiency Measurement * Note: Output voltage is measured at end of PCB Vin (V AC ) 90 115 230 264 Pin (W) Vout (V) Iout (ma) VRIPPLE (mvp-p) Pout (W) η (%) 0.062 11.90 0 10 2.286 11.99 150 46 1.80 78.67 4.560 11.98 300 76 3.59 78.82 6.980 12.01 450 68 5.40 77.43 9.506 12.03 600 110 7.22 75.93 0.070 11.91 0 8 2.272 11.98 150 46 1.80 79.09 4.469 11.98 300 62 3.59 80.42 6.740 12.01 450 66 5.40 80.19 9.100 12.03 600 82 7.22 79.32 0.120 11.90 0 8 2.381 11.98 150 56 1.80 75.47 4.557 11.99 300 58 3.60 78.93 6.726 11.99 450 68 5.40 80.22 8.921 12.03 600 76 7.22 80.91 0.167 11.90 0 10 2.433 11.98 150 42 1.80 73.86 4.631 11.99 300 64 3.60 77.67 6.803 11.99 450 74 5.40 79.31 8.993 12.03 600 72 7.22 80.26 OCP (ma) Average η (%) 701 77.71 700 79.75 713 78.88 706 77.78 8.2 CV and CC Regulation 8.3 Conducted EMI 18.0 15.0 VI Curve (Vin=90VAC/50Hz) Vin=230VAC/50Hz, Live V OUT (V) V OUT (V) 12.0 9.0 6.0 3.0 0.0 0 100 200 300 400 500 600 700 800 I OUT (ma) VI Curve (Vin=264VAC/50Hz) 18.0 15.0 12.0 9.0 6.0 3.0 Amplitude(dBμV) Amplitude(dBμV) Frequency(MHz) Vin=230VAC/50Hz, Neutral 0.0 0 100 200 300 400 500 600 700 800 I OUT (ma) Frequency(MHz) Rev. 1.1 EBC10011 Page 8
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