Reference Design

EBC10007

iW1691-03 for 5V 2.1A

Adapter Design

Table of Contents

iW1691-03 For Adapter Design

(AC Input 90 - 264VAC, Output 5V 2.1A)

EBC10007
1.0. Introduction3
2.0. Design Features3
3.0. Power Supply Design Specification4
4.0. Schematic5
5.0. PCB Layout5
6.0. Bill Of Materials6
7.0. Transformer drawing7
8.0. Performance8
8.1. Regulation, Ripple and Efficiency Measurement8
8.2. CV and CC Regulation 8
8.3. Conducted EMI8

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Rev. 1.3
EBC10007

Page 2

5V 2.1A Adapter
with iW1691-03 EBC10007

1.0 Introduction
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.

22mm

EPC17

AC Input

DC Output

Figure 1.1 PCB Top View

Figure 1.3 PCB Side View

43.5mm

22mm
iW1691-03 Digital & Primary VMS Controller
(No Cable - Drop - Compensation)

Figure 1.2 PCB Bottom View

2.0 Design Features

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

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Rev. 1.3
EBC10007

Page 3

5V 2.1A Adapter
with iW1691-03 EBC10007

3.0 Power Supply Design Specification

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

Symbol

Min

Voltage

VIN

90

Frequency

fLINE

47

Typ

Max

Units

264

VAC

63

Hz

150

mW

Comment

Input
50/60

No-load input power (230VAC)

Output
Output voltage

VOUT

4.85

5.25

Output current

IOUT

2.1

100

mVP_P

Output ripple voltage

VRIPPLE

Measured at USB-End

Measured at end of Output DC-Cable

IOUT=2.1A @TA = 25 C
20 MHz Bandwidth

Total Output Power

Continuous output power

POUT

Over-current protection

IOUT_MAX

Active mode protection

10.5

W
2.5

80

Auto-restart

Measured at USB-End,
VIN=115VAC and 230VAC (TAMB = 25 C)

Environmental
Conducted EMI

Meets CISPR22B / EN55022B

Safety
Ambient temperature

Designed to meet IEC950, UL1950 Class II

TAMB

40

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Rev. 1.3
EBC10007

Page 4

5V 2.1A Adapter
with iW1691-03 EBC10007

4.0 Schematic
C12
1 nF / 100V

5V

L1
10 mH

C1
6.8 F

BR1
MB8S

AC Input

C2
10 F

R6
100 k

D8
SBR10U45S

C4
1 nF
250 V

C13
820 F
10 V

R7
220

N
D1
SRGC10MH

Fast latch release circuit

C3
22 nF / 500 V

D3
SRGC10MH

D2
SRGC10MH

R19
10 k
R18
9.1 k

R12
1 k

R14
56 k

R13
100

NC

VSENSE

VIN

ISENSE 6

SD

GND 5

D5

C8
470pF

C16
1 nF

VCC 8

BAV70

C11
R15
33pF 3.9 k

C7
47 pF

820 F
6.3 V

+ R21
1 k

C15
10 F
6.3 V

D4
SRGC10MH
GND

Optional Circuit for OTP and

(or) Double- OVP

R16
18 k

+ C14

R4
3.3 M

R5
3.3 M

D7
1N4148

R20
22

T1
EPC17

L2
330 H

F1
1 A / 250 V

OUTPUT 7

U1
iW1691 - 03

R11
0

R17
1

D6
SRGC10DH

Q1
SPU04N60C3
R9
470

R10
10 k

CY1
330 pF

C6
270 pF

R8
1.24

NTC1
100 k

C9

2.2 F
25 V

C10

2.2 F

Figure 4.1 Design Schematic

5.0 PCB Layout

PCB Top

PCB Bottom
Figure 5.1 PCB Layout 43.5 mm x 22.0 mm

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Rev. 1.3
EBC10007

Page 5

5V 2.1A Adapter
with iW1691-03 EBC10007

6.0 Bill of Materials

Item

Qty.

Ref.

U1

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

C1
C2
C3
C4
C6
C7
C8
C9,C10
C11
C12
C13
C14
C15
C16
CY1
R4, R5
R6
R7
R8
R9
R10, R19
R11
R12
R13
R14
R15
R16
R17
R18
R20
R21
BR1
D1-D4
D5
D6
D7
D8
F1
L1
L2
Q1
NTC1
USB
T1

Description

Manufacturer P/N

iW1691-03, off-line digital PSR & VMS

controller, SOIC-8
6.8F, 400V, E-CAP, (8mm12mm)
10F, 400V, E-CAP, (10mm16mm)
22nF, 500V, X7R, SMD-1206
1nF, 250V, X7R, SMD-0805
270pF, 25V, NPO, SMD-0603
47pF, 25V, NPO, SMD-0603
470pF, 25V, NPO, SMD-0603
2.2F, 25V, X7R, SMD-0805
33pF, 50V, NPO, SMD-0603
1nF, 100V, X7R, SMD-0805
820F, 10V, Solid-CAP, (8mm12mm)
820F, 6.3V, E-CAP, (6.3mm16mm)
10F, 6.3V, X7R, SMD-1206
1nF, 25V, X7R, SMD-0603
330pF, 250V, Y2, radial
3.3M, 1, SMD-1206
100K, 5, SMD-1206
220, 5, SMD-0805
1.24, 1, SMD-1206
470, 1, SMD-0603
10K, 5, SMD-0603
0, 5, SMD-0603
1K, 5, SMD-0603
100, 1, SMD-0603
56K, 1, SMD-0603
3.9K, 1, SMD-0603
18K, 5, SMD-0603
1, 5, SMD-0603
9.1K, 1, SMD-0603
22, 5, SMD-0805
1K, 5, SMD-0805
1A, 800V, bridge rectifier, MB8S
1A, 1000V, fast recovery rectifier, 1206-S
200mA, 70V, ultrafast diode, SOT-23
1A, 200V, fast recovery rectifier, 1206-S
150MA, 75V, rectifier, SOD323F
10A, 45V, Schottky, PowerDI 5
1A, 250V, fuse, axial
10mH, CM inductor, EE8.3, 0.17mm60T
330H, color ring inductor, 0510
4.5A, 650V, N-CH MOSFET, TO-251
100K, 1, SMD-0603
USB connector, vertical
EPC17, transformer, vertical type

Manufacturer

iW1691-03

iWatt, Inc

2GUTWHS6R8M0G12
EKMG401ELL100MJ20S
VJ1206Y223KXEAT5Z
C2012X7R2E102K
C1608C0G1E472J
06033A470KAT4A
06033A471JAT2A
GCM21BR71E225KA73L
C2012X7R2A102K
ULR827M1AF1A
TM8200UE16PB
CGJ5L2X7R0J106K
06033C102KAT7A
DE2B3KY331KA2BM01
9C12063A3304FKHFT
9C12063A1003JLHFT
9C08052A2200JLHFT
RC1206FR-071R24L
ERJ-3EKF4700V
9C06031A1002JLHFT
9C06031A0R00JLHFT
9C06031A1001JLHFT
ERJ-3EKF1000V
ERJ-3EKF5602V
ERJ-3EKF3901V
ERJ-3GEYJ183V
ERJ-3GEYJ1R0V
ERJ-3EKF9101V
ERJ-6GEYJ220V
ERJ-6GEYJ102V
MB8S
SRGC10MH
BAV70
SRGC10DH
1N4148WS
SBR10U45SP5-13
0230001.DRT1P

TOSHIN KOGYO Co.

United Chemi-Con
Vishay Vitramon
TDK Corporation
TDK Corporation
AVX Corporation
AVX Corporation
Murata Electronics
TDK Corporation
TDK Corporation
Man Yue Technology
YIHCON Electronics
TDK Corporation
AVX Corporation
Murata Electronics
Yageo
Yageo
Yageo
Yageo
Panasonic - ECG
Yageo
Yageo
Yageo
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Fairchild Semiconductor
ZOWIE
Fairchild Semiconductor
ZOWIE
Fairchild Semiconductor
Diodes Inc
Littelfuse Inc

8230-80-RC
SPU04N60C3
NTCG164KF104FT1
B0-F44-16064

JW Miller A Bourns
Infineon
TDK Corporation
YuanChuan Electronics

C1608C0G1H330J

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Rev. 1.3
EBC10007

Page 6

5V 2.1A Adapter
with iW1691-03 EBC10007

7.0 Transformer drawing

Schematic:
3

Primary-2 22Ts

9Ts

Primary-1 94Ts

Note:
Dot () denotes electrical
start.

4
1
Bias

Secondary

Electrical start could be

different from
mechanical or winding start.

16Ts

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

Electrical Specifications:
1.
2.
3.

Primary inductance (Lp) = 940H (5%) @10KHz

Primary leakage inductance (Lk) < 2% * Lp
Electrical strength = 3KV, 50/60Hz, 1Min.

Materials:
1.
2.
3.
4.
5.

Core: EPC17 (ferrite material TDK PC40 or equivalent)

Bobbin: EPC17 vertical
Magnet wires (pri): type 2-UEW
Magnet wire (sec): triple insulated wires
Layer insulation tape: 3M1298 or equivalent

Finished:
1.

Varnish the complete assembly

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Rev. 1.3
EBC10007

Page 7

5V 2.1A Adapter
with iW1691-03 EBC10007

8.0 Performance
8.1 Regulation, Ripple and Efficiency Measurement
* Note: Output voltage is measured at USB-End

Vin
(VAC)

90

115

230

264

Pin
(W)

Vout
(V)

Iout
(A)

VRIPPLE
(mVP-P)

0.06
3.31
6.52
9.94
13.57
0.07
3.30
6.48
9.76
13.18
0.09
3.38
6.67
9.81
13.02
0.12
3.41
6.76
9.92
13.14

5.15
5.16
5.17
5.18
5.19
5.15
5.16
5.17
5.18
5.19
5.15
5.15
5.17
5.18
5.19
5.15
5.15
5.17
5.18
5.19

0
0.525
1.050
1.575
2.100
0
0.525
1.050
1.575
2.100
0
0.525
1.050
1.575
2.100
0
0.525
1.050
1.575
2.100

10
18
20
36
60
10
16
20
26
30
10
20
20
22
24
10
24
18
20
24

8.2 CV and CC Regulation

Pout
(W)

(%)

2.71
5.43
8.16
10.90

81.84
83.26
82.08
80.32

2.71
5.43
8.16
10.90

82.09
83.77
83.59
82.69

2.70
5.43
8.16
10.90

79.99
81.39
83.17
83.71

2.70
5.43
8.16
10.90

79.29
80.30
82.24
82.95

OCP
(A)

Average
(%)

2.29

81.9

2.28

83.0

2.28

82.1

2.29

81.2

8.3 Conducted EMI

Vin=230VAC/50Hz, Live

VI Curve (Vin=90VAC/50Hz)
6.0

Amplitude(dBV)

VOUT (V)

5.0
4.0
3.0
2.0
1.0
0.0

500 1000 1500 2000 2500 3000 3500 4000

IOUT (mA)

Frequency(MHz)
Vin=230VAC/50Hz, Neutral

VI Curve (Vin=264VAC/50Hz)
6.0

Amplitude(dBV)

VOUT (V)

5.0
4.0
3.0
2.0
1.0
0.0

500 1000 1500 2000 2500 3000 3500 4000

IOUT (mA)

Frequency(MHz)

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Rev. 1.3
EBC10007

Page 8

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: http://www.iwatt.com
E-mail: info@iwatt.com
Phone: +1 (408) 374-4200
Fax: +1 (408) 341-0455
iWatt Inc.
675 Campbell Technology Parkway, Suite 150
Campbell, CA 95008

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 LIFESUPPORT 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.

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Rev. 1.3
EBC10007

Page 9