1、iW1697-01 for 5V700mA Charger Design,General Design Specification: AC Input Range 90-264Vac DC Output 5.1V, 700950mA(CC) Meet “20mW” No-Load standby Power Consumption Requirement Meet “EPA_2.0” Requirement with 28AWG/1.2m DC-Cable Meet “USB3.0” Dynamic Load Response Requirement Max Ripple 150mVP_P,2
2、,1. Specification,3,2. Schematic Circuit,4,Top side,Bottom side,Digital & Primary VMS Controller iW1697-01 (Cable Drop Compensation 300mV),3. Circuit Board Photograph,PRIMARY,SECONDARY,3DG3020A1, TO-92 Package,680uF/10V, Low ESR E-Cap,EE1614,5,4. Bill of Material,6,5. Transformer Design,SEC,PRI,MATE
3、RIALS: Core : EE1614 (Ferrite Material TDK PC40 or equivalent) Bobbin : EE1614 Horizontal. Magnet Wires (Pri) : Type 2-UEW Magnet Wire (Sec) : Triple Insulated Wires Layer Insulation Tape :3M1298 or equivalent.,SCHEMATIC,10,7,176T,12T,18T,ELECTRICAL SPECIFICATIONS: Primary Inductance (Lp) = 3.2mH10%
4、10KHz Primary Leakage Inductance5% * LP, Short pin7-pin10 Electrical Strength = 3KV, 50/60Hz,1Min,FINISHED : Varnish the complete assembly,1,2,4,Primary,Bias,Secondary,6,Rotating direction of winding machine,Winding Start pin-2 & End pin-1 in “Clockwise” direction looking from Pin 6/10 side of the B
5、obbin.,10,1,5,Instruction for start of first winding,Core is connected to Pin-4,Triple Insulated Wire （Anticlockwise) 0.4mmx1 12T Secondary,2UEW 0.16mmx1 44T Primary (Clockwise),2UEW 0.16mmx1 44T Primary (Clockwise),2UEW 0.16mmx1 44T Primary (Clockwise),4S,1F,7F,2S,10S,5,5S,3F,tube,2 layers of Tape,
6、2UEW 0.23mmx1 17.5T Shield (Anticlockwise),4S,3mm Margin tape, 1T,4F,18T,Forward,3,2UEW 0.16mmx1 44T Primary (Clockwise),3mm,Note: Dot () denote electrical start.Electrical start could be different to Mechanical Winding start.Core is connected to Pin-4(Pri_GND) by wire,2 layers of Tape,2 layers of T
7、ape,2 layers of Tape,7,6. Regulation, Ripple and Efficiency Measurement,6. Regulation, Ripple and Efficiency Measurement,* Note: Output voltage is measured at end of PCB,Meet EPA2.0 with lots of Margin!,8,7. EPA_2.0 Requirement,EPA2.0 (Final) for Low Voltage Model (Pno=3.5W),Meet EPA2.0 with lots of
8、 Margin!,9,8. No Load Standby Power Consumption,No-Load standby power consumption is 18mW at 230Vac!,10,VIN=264Vac/50Hz,VIN=90Vac/50Hz,9. Output VI Characteristics,* Note: Output voltage is monitored at end of output DC-Cable (28AWG1.2m, RCABLE=0.55).,IOUT(150mA/Div),VOUT(1V/Div),2.00V,5.25V,700mA,9
9、00mA,4.75V,IOUT(150mA/Div),VOUT(1V/Div),2.00V,5.25V,700mA,900mA,4.75V,11,10. Turn On Delay Time,90Vac, No Load TST_DELAY=0.89S,90Vac, Full Load TST_DELAY=0.90S,12,90Vac, No Load TRISE=3.628mS,90Vac, Full Load TRISE=7.350mS,264Vac, No Load TRISE=3.532mS,264Vac, Full Load TRISE=7.910mS,11. Output Rise
10、 Time,13,12. AC Startup Voltage Characteristic,No Load, VIN_STARTUP =43.4Vac,Full Load, VIN_STARTUP=69.6Vac,14,13. AC Brownout Voltage Characteristic,No Load, VIN_BROWNOUT =39.9Vac,Full Load, VIN_BROWNOUT=69.6Vac,15,14. VCE Waveform,16,15. VCC supply voltage at static load,iW1697-01,Above test resul
11、t show all voltage measuring points is within normal operating range.,The purpose of this test is to verify operating range of Vcc voltage under various loading conditions.,6-lead SOT-23 package,17,16. VCC supply voltage at startup,VIN=264Vac IOUT=0.7A (Resistive Load),VIN=264Vac IOUT=0A,VIN=90Vac I
12、OUT=0.7A (Resistive Load),VIN=90Vac IOUT=0A,9.76V,8.72V,CH1: Output Current, 0.2A/Div ; CH2: VCC, 2V/Div;,18,17. VCC supply voltage at Load Transition (0mA700mA),Vin=264Vac,Vin=90Vac,7.44V,7.52V,CH1: Output Current, 0.2A/Div ; CH2: VCC, 2V/Div;,19,Test condition : 1). Vin = 90Vac 2). VOUT is measure
13、d at end of cable(28AWG,1.2M) 3). Slew-Rate: 0.1A/us 4). Duty-Cycle: 50%; 5). Freq.: 25Hz. 6). Load: 0mA - 700mA - 0mA From the waveform, the VCC is drop to 7.64V during testing DLR (0mA-700mA-0mA). Min VCC is 7.64V which dont trigger UVLO (3.9V4.3V).,VCC_MIN = 7.64V,18. VCC supply voltage at Dynami
14、c Load,CH1: Output Current, 0.5A/Div,CH2: Output Voltage, 2V/Div,CH3: VCC, 2V/div,20,Test conditions : Load Mode: CR Mode Output Filtering Capacitor (C7): 680uF VOUT is monitored at end of DC-Cable (28AWG/1.2m, RCABLE=0.55) Equipment: E-Load-“Kikusui PLZ 72W”, AC Source-“Kikusui PCR500L”, Digital Os
15、cilloscope-“Tek TDS460A”,19. Load Transition (0mA 600mA, Single Pulse),VOUT_MIN=4.32V,Vin=264Vac,IOUT=600mA,CH1: Output Voltage, 1V/Div; CH2: VSENSE, 2V/Div; CH3: Output Current, 0.2A/Div,Vin=90Vac,VOUT_MIN=4.20V,IOUT=600mA,21,20. Dynamic Load Response,Test Conditions: 1). Load: 0mA-700mA-0A 2). Fre
16、quency: 1Hz 3). Duty-Cycle: 50% 4). Slew-Rate: 0.1A/us 5). VOUT is monitored at end of DC-Cable (28AWG/1.2m, RCABLE=0.55),CH1: Output Voltage, 1V/Div; CH2: Output Current, 0.5A/Div,Vin=264Vac,Vin=90Vac,22,BMAX =IPRI * LPRI / (NP*Ae)=(264*3.48)/(176*18.5)=0.282Tesla,BMAX =IPRI * LPRI / (NP * Ae) =(30
17、4*3.48)/(176*18.5)=0.325Tesla,IPRI is monitored at 90Vac and 700mA load IPRI=264mA,IPRI is monitored at 90Vac and 780mA load (Max Output Power). IPRI=304mA,21. Transformer Flux Density,(Np=176Ts, Lm=4.43mH, Ae=18.5mm2-EE1614 ),CH1: IPRI ,100mA/div,CH1: IPRI ,100mA/div,23,Note: Resistive full-load, o
18、utput (-) is floating.,22. Conducted EMI,Vin=230Vac/50Hz, Neutral,Vin=230Vac/50Hz, Live,24,23. Radiated EMI,Vin=230Vac/50Hz, HORIZONTAL,Vin=230Vac/50Hz, VERTICAL,Note: Resistive full-load, output (-) is floating.,25,24. ESD (IEC 61000-4-2),26,25. RF Immunity,CMU200 (Test mode setup and communicating with Cell phone),iW1697 Demo Board,Samsung Mobile phone (S8300),TDS460A (Output voltage monitoring/ eg, 5V),
