Reference Design

EBC10004

iW1677-00 for 5V 1A
Ultra-Thin Charger Design

Table of Contents

iW1677-00 for Untra-Thin Charger Design

(AC Input 90264VAC, DC Output 5V 1A)
EBC10004

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

www.iwatt.com
Rev. 1.1
EBC10004
Apr, 2012

Page 2

5V 1A Ultra-Thin Charger
with iW1677-00 EBC10004

1.0 Introduction
This document provides a reference design for a universal input, 5V 1A isolated flyback power supply. For this design the
iW1677-00 is used. This document contains the complete specification of the power supply, a detailed circuit diagram,
an entire bill of materials required to build the power supply, a drawing of the power transformer, and test data of the
most important performance.

DC Output

AC Input

10mm

EPC13

Figure 1.1 PCB Top View

Figure 1.3 PCB Side View

22mm

40mm

iW1677-00
(No Cable-Drop-Compensation)

Figure 1.2 PCB Bottom View

2.0 Design Features

AC input range 90-264VAC
DC output 5V 1.001.10A (CC)
Meet 30mW no-load standby power consumption requirement
Meet EPA 2.0 requirement with 26AWG/1.2m DC-Cable
Meet USB 3.0 dynamic load response requirement
Meet MoU requirement

www.iwatt.com
Rev. 1.1
EBC10004
Apr, 2012

Page 3

5V 1A Ultra-Thin Charger
with iW1677-00 EBC10004

3.0 Power Supply Design Specification

The information in 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

30

mW

5.25

Comment

Input

50/60

No-load input power (230VAC)

Output
Constant
voltage
Constant
current

Output voltage

VOUT_CV

4.75

Output current

IOUT_CV

Output voltage

VOUT_CC

> 2.5

Output current

IOUT_CC

Output ripple voltage

5.00

Depending on battery
voltage

VRIPPLE

1.10

80

mVP_P

Measured at PCB end

Min VOUT is dependent on VCC supply

voltage

Measured at end of output DC - Cable

IOUT=1A @TA=25C
20MHz bandwidth

Total Output Power

Continuous output power

POUT

Over-current protection

IOUT_MAX

Active mode efficiency

W
1.10

68.2

Auto-restart

Measured at end of output DC-Cable,

VIN=115VAC and 230VAC (TAMB=25C)

Environmental
Conducted EMI

Meets CISPR22B/EN55022B

Safety
Ambient temperature

Designed to meet IEC950, UL1950 Class II

TAMB

40

www.iwatt.com
Rev. 1.1
EBC10004
Apr, 2012

Page 4

5V 1A Ultra-Thin Charger
with iW1677-00 EBC10004

4.0 Schematic
F1
10

D9
SCD34
5V

C1
4.7 F

T1
EPC13

L1
330 H

BD1
ABS8

AC Input

C10
4.7 F

FB1
4.7 H

R2
3 M

R8
3 M

C2
470 pF
C8
270 F

R10
300

U1
DMZ6005

C4
270 F

+ C7

100 F

+ R14

3.9 k

D5
SRGC10MH
GND
R4
1

IC1
iW1677 - 00

R7
15.4 k

R9
4.3 k

C3
39pF

D6
SRGC10DH

C9
4.7F

OUTPUT 6

VCC

VSENSE

ASU

C6
100nF

U2
UTC5302DL

GND 5
ISENSE 4
R3
2.7

Figure 4.1 Design Schematic

5.0 PCB Layout

PCB Top

PCB Bottom
Figure 5.1 PCB Layout 40.0 mm x 22.0 mm

www.iwatt.com
Rev. 1.1
EBC10004
Apr, 2012

Page 5

5V 1A Ultra-Thin Charger
with iW1677-00 EBC10004

6.0 Bill of Materials

Item

Qty.

Ref.

Description

Manufacturer P/N

IC1

iW1677-00 (no CDC), off-line digital PSR &

PWM & VMS controller, SOT23-6

2
3
4
5

2
1
1
2

C1, C10
C2
C3
C4, C8

4.7F, 400V, E-Cap, (6.3mm14mm)

470pF, 250V, X7R, SMD-0805
39pF, 25V, NPO, SMD-0805
270F, 6.3V, solid capacitors, (5mm7mm)

PKRM-400V4R7ME140 KOSHIN
0805VC471KAT2A
AVX Corporation
08053A390KAT2A
AVX Corporation

6
7
8
9
10
11
12
13
14
15
16
17

1
1
1
1
1
1
1
1
1
1
1
1

C6
C7
C9
R2
R3
R4
R7
R8
R9
R10
R14
BD1

100nF, 25V, X7R, SMD-0805

100F, 6.3V, E-Cap, (4mm7mm)
4.7uF, 25V, X5R, SMD-0805
3M 5%, SMD-1206
2.7 1%, SMD-0805
1 5%, SMD-0805
15.4K 1%, SMD-0805
1M 5%, SMD-1206
4.3K 1%, SMD-0805
300, 5%, SMD-0805
3K 5%, SMD-0805
1A, 800V, rectifier bridge, ABS

08053C104KAT2A
KR26R3V101MB070
C2012X5R1E475K
ERJ-8GEYJ305V
ERJ-6RQF2R7V
ERJ-6GEYJ1R0V
ERJ-6ENF15R4V
ERJ-8GEYJ105V
ERJ-6ENF4301V
ERJ-6GEYJ301V
ERJ-6GEYJ302V
ABS8

Man Yue Technology

AVX Corporation
KOSHIN
TDK Corporation
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Panasonic - ECG
Taiwan Semiconductor

18

D6

SRGC10DH

ZOWIE

19

D5

SRGC10MH

ZOWIE

20
21
22
23
24
25
26

1
1
1
1
1
1
1

D9
F1
L1
FB1
U1
U2
T1

SCD34H
FRM1WJT-52-10R

ZOWIE
Yageo

LQM21FN4R7M80L
DMZ6005
UTC5302DL

Murata Electronics
ARK Microelectronics
United Technologies

1A, 200V, fast recovery rectifier (Trr=150ns),

SMD-1206S
1A, 1000V, fast recovery rectifier (Trr=500ns),
SMD-1206S
3A, 40V, Schottky diode, SMD-2010
10, fusible resistor, 1W
330uH, I type inductor, 4mmx6mm
4.7uH, chip inductor, SMD-0805
12mA600V, depletion mode MOSFET, SOT23
2A, 800V, NPN transistor, TO-251
EPC13, horizontal type

iW1677-00

ULR277M0JD07RRX0CR

Manufacturer
iWatt, Inc

www.iwatt.com
Rev. 1.1
EBC10004
Apr, 2012

Page 6

5V 1A Ultra-Thin Charger
with iW1677-00 EBC10004

7.0 Transformer drawing

Schematic:
Core is connected to Pin-1

1
Primary

A
160Ts

10Ts Secondary

5
B

3
Bias

14Ts

Notes:
Dot () denotes electrical
start.
Electrical start could be
different from
Mechanical/Winding start.

Electrical Specifications:
1.
2.
3.

Primary inductance (Lp) = 1.55mH (7%) @10KHz

Primary leakage inductance < 5% * LP, short pin 2,3,4,A,B
Electrical strength = 3KV, 50/60Hz, 1Min.

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

Core: EPC13 (ferrite material TDK PC40 or equivalent)

Bobbin: EPC13 horizontal
Magnet wires (pri): type 2-UEW
Magnet wire (sec): triple insulated wires
Layer insulation tape: 3M1298 or equivalent

Finished:
1.

Varnish the complete assembly

www.iwatt.com
Rev. 1.1
EBC10004
Apr, 2012

Page 7

5V 1A Ultra-Thin Charger
with iW1677-00 EBC10004

8.0 Performance
8.1 Regulation, Ripple and Efficiency Measurement
* Note: Output voltage is measured at end of PCB

Vin
(VAC)

90

115

230

264

Pin
(W)

Vout
(V)

Iout
(mA)

VRIPPLE
(mVP_P)

0.015
1.60
3.22
4.92
6.66
0.016
1.59
3.17
4.80
6.46
0.021
1.63
3.22
4.78
6.38
0.025
1.65
3.25
4.83
6.43

4.95
4.94
4.95
4.97
4.99
4.95
4.93
4.95
4.97
4.99
4.95
4.93
4.95
4.96
4.99
4.95
4.93
4.95
4.96
4.99

0
250
500
750
1000
0
250
500
750
1000
0
250
500
750
1000
0
250
500
750
1000

4.8
31.2
37.2
47.2
74.4
4.4
30.4
33.6
48.4
68.0
7.6
46.8
48.8
49.6
62.4
5.6
34.4
39.2
50.4
68.8

8.2 CV and CC Regulation

Pout
(W)

(%)

1.23
2.47
3.73
4.99

77.17
76.85
75.79
74.89

1.23
2.48
3.73
4.99

77.53
78.05
77.67
77.13

1.23
2.48
3.72
4.99

75.67
76.98
77.87
78.11

1.23
2.48
3.72
4.99

74.79
76.15
76.99
77.59

OCP
(A)

Average
(%)

1.07

76.18

1.08

77.60

1.07

77.16

1.07

76.38

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

200

400

600

800 1000

1200

1400

1600

IOUT (mA)

Frequency(MHz)

VI Curve (Vin=264VAC/50Hz)

Vin=230VAC/50Hz, Neutral

6.0

Amplitude(dBV)

VOUT (V)

5.0
4.0
3.0
2.0
1.0
0.0

200

400

600

800 1000

IOUT (mA)

1200

1400

1600

Frequency(MHz)

www.iwatt.com

Rev. 1.1
EBC10004
Apr, 2012

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.

www.iwatt.com

Rev. 1.1
EBC10004
Apr, 2012

Page 9