iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply 1 Description The iW1830-EVAL1 evaluation board implements a 15W power supply based on Dialog Semiconductor’s iW1830 AccuSwitch™ digital offline power supply controller IC. The evaluation board supplies a 5V, 3A regulated output voltage using a primary-side controlled quasi-resonant flyback converter that meets the U.S. Department of Energy’s most recent level VI efficiency standard and the EU’s Code of Conduct, Version 5, Tier 2 standard for both active mode and no-load standby power consumption. The iW1830 controller integrates a 700V power MOSFET to lower the power supply BOM cost and uses Dialog’s advanced PrimAccurate™ digital control technology to eliminate the need for external secondary-side feedback components, further reducing component count and cost, while improving reliability. It operates in quasi-resonant mode to improve efficiency and help meet EMI standards. This quasi-resonant operation and Dialog’s EZ-EMI® technology enable EMI compliance with minimal external filtering. Proprietary control technology allows high efficiency across a broad range of loads, which enables the iW1830 to meet stringent international standards for power supply efficiency. 2 Features ●● Wide input voltage range: 90VAC to 264VAC ●● Output voltage: 5V ●● Output current: 3A ●● Total output power: 15W max. ●● Integrated 700V MOSFET ●● EZ-EMI® technology: excellent EMI performance with a minimum of EMI filtering components ●● Quasi-resonant operation ●● Low component count and small PCB footprint ●● iW1830 IC protections: xx Output short-circuit, over-current, over-voltage ●● Active mode efficiency > 82% ●● Supports high capacitance loads up to 6,000mF xx Input voltage protection: brown-out, brown-in, unplug ●● Low no-load power: < 50mW (at 230 VAC) xx Over-temperature protection - internal sensor 3 Applications ●● Power Supplies for: xx White Goods xx Home Appliances xx Industrial Control xx Network Devices Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 1 of 7 18-May-2016 © 2016 Dialog Semiconductor iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply WARNING Disclaimer for High Voltage (Mains Powered) Evaluation Boards Warning This evaluation board is powered by AC mains voltage. When powered, this evaluation board generates non-insulated high voltages which may produce electrical shock, burn, and/or fire hazards, resulting in risk of property damage, personal injury, and/or death. When the evaluation board is powered, never touch the board or its electrical circuits since they may be operating at high voltages that can cause an electrical shock hazard. TO BE USED FOR EVALUATION PURPOSES ONLY This board is intended for evaluation purposes only and not intended for commercial use in an end product. Any other use is strictly prohibited by Dialog Semiconductor. WORK AREA AND PERSONAL SAFETY This board should be used in a test area/laboratory specifically designed and designated for working with, and evaluating high-voltage electrical devices. Only trained and qualified professional personnel with experience, knowledge and training in the use of high-voltage electrical circuits should use this evaluation board. Trained personnel must use required personal protective equipment and required laboratory equipment when working with the evaluation board. The professional personnel operating this evaluation board and the test area/laboratory in which it is operated must be qualified according to the local regulations, guidelines and labor laws applicable to working with non-isolated mains voltages and high voltage circuits. An isolated housing is highly recommended when using this evaluation board. Use this evaluation board at your own risk. NOT AGENCY APPROVED This evaluation board has not been agency tested or approved for safety, technical performance, and/or regulatory requirements, such as electromagnetic interference or other technical regulatory or safety requirements. Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 2 of 7 18-May-2016 © 2016 Dialog Semiconductor iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply 4 Evaluation Board Specifications The table below shows the electrical specifications of the evalution board specified at TA = 25ºC, unless otherwise noted. Symbol Min Voltage VIN 90 Frequency fLINE 47 Description Typ Max Units 264 VAC 63 Hz 50 mW 5.25 V 3 A 200 mVP_P Comment Input 50/60 No-load input power (230VAC) 2 wire Output Output voltage VOUT 4.75 Output current IOUT 0 Output ripple voltage 5.00 VRIPPLE Measured at the end of PCB Connected with 10mF E-cap and 100nF C-cap; IOUT = 3A@TA = 25ºC 20MHz Bandwidth Total Output Power Continuous output power POUT Over current protection OCP Active mode efficiency η 15 W 3.6 82.2 A Auto-restart % Average of efficiency measured at 25%/50%/75%/100% VIN = 115VAC Environmental Safety (Note 1) (Note 2) Ambient temperature Designed to Meet UL1310 (up to 120VAC) Designed to Meet EN60335-1:2012 TAMB 0 40 ºC Free convection, sea level Note 1: The iW1830-EVAL1 has been designed to meet UL1310 (up to 120VAC) with the exception of the common mode choke L4 (see Note 2) and EN60335-1:2012, however individual boards have not been tested or verified to these standards. Note 2: The iW1830-EVAL1 uses a common mode choke which is intended for 5V/3A designs that are used as part of circuits in white goods. Alternative UL-1310 compliant parts should be used if this design is used for a standalone 5V/3A power unit. Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 3 of 7 18-May-2016 © 2016 Dialog Semiconductor iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply 5 Schematic The schematic shown in Figure 5.1 is the complete schematic for the evalution board. The specific part numbers can be found in the Bill-of-Materials in section 6. CY1 CY2 680pF 680pF L1 470uH L4 4 AC F1 3.15A/250V 3 + 1 AC - E1 R2 1K BR1 SDB157 2 + C1 22uF R13 750R + R19 2M C2 22uF T1 6 R12 2M D5 FS1D-L R7 100R R5 NC D1 SBR30A60CT C11 NC R6 10K L2 10uH CON1 C3 10nF/500V E2 Z1 160V 12 R15 27R 4 8 5V3A CON2 C10 1nF + C4 + C5 + C6 1000uF 1000uF 1000uF R3 3.6K D6 FS1M-L C8 220pF U1 iW1830 8 D D 7 5 S VCC 1 4 R1 1.8R R18 1.3R ISENSE 3 GND VSENSE 2 R9 2.2R R4 18R D7 FS1D-L 1 R10 18K 3 R11 1K GND R14 56K R8 3K C7 100nF C9 10uF/50V Figure 5.1 : Complete Evalution Board Schematic for the iW1830-EVAL1 Board. Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 4 of 7 18-May-2016 © 2016 Dialog Semiconductor iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply 6 Bill of Materials Table 1: Bill-of-Materials List for EVB iW1830-EVAL1 Item Qty. Ref. Description Footprint Mfg. Part Number Manufacturer 1 1 U1 iW1830, Off-line digital PWM Controller with 4A/700V MOS co-packed, DIP 7 DIP-7 iW1830-00 Dialog Semiconductor 2 1 BR1 SDB157,1000V,1.5A,Bridge rectifier SDB-1 SDB157-TP 3 4 5 7 8 9 10 11 12 13 2 1 3 1 1 1 1 1 2 1 C1, C2 C3 C4,C5,C6 C7 C8 C9 C10 C11 CY1,CY2 D1 22uF,400V, Φ12.5X20,E-CAP 10nF,500V,X7R,SMD-1206 1000uF,10V,Φ8X20,E-CAP 100nF,50V,X7R,SMD-0805 220pF,100V,X7R,SMD-0805 10uF,50V,X5R,SMD-1206 1nF,100V,X7R,SMD-0805 NA 680pF,250V , X1,Y1-cap SBR30A60CT,30A,60V FS1D-L, 1A200V,Fast Recovery Rectifier (Trr=150ns) FS1M-L, 1A1000V,Fast Recovery Rectifier (Trr=500ns) CE12.5x20 CS1206 CE8X20 CS0805 CS0806 CS1206 CS0805 Z1 CMZ5954B,160V,1.5W,ZENER Diode,SMA SMA 1 1 1 F1 L1 L2 Axial-3.6x10 Axial-04x10 LS0805 20 1 L4 LD4.5X10 744 841 330 Würth Elektronik 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12,R19 R13 R14 R15 R18 RS1206 RS0805 RS0805 RS0805 RC1206FR-071R8L RC0805JR-071KL RC0805JR-073K6L RC0805JR-0718RL YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation RS1206 RS1206 RS0603 RS0603 RS0603 RS0603 RS1206 RS0805 RS0603 RS1206 RS1206 RC1206JR-0710KL RC1206JR-07100RL RC0603FR-073KL RC0603JR-072R2L RC0603FR-0718KL RC0603JR-071KL RC1206JR-072ML RC0805JR-07750RL RC0603FR-0756KL RC1206JR-0727RL RC1206FR-071R3L YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation YAGEO Corporation 37 1 CON1 691 216 910 002 Würth Elektronik 38 1 CON2 3.15A,250V, Fuse, Φ3.6X10mm 470uH,126mA,Color Ring Inductor, 0410 10uH,Chip Inductor(Chip Coil) CM Inductor,WE-CMB NiZn Common Mode Power Line Choke (Note 1) 1.8Ω±1%,SMD-1206 1K±5%,SMD-0805 3.6KΩ±5%,SMD-0805 18Ω±5%,SMD-0805 NA 10KΩ±5%,SMD-1206 100Ω±5%,SMD-1206 3KΩ±1%,SMD-0603 2.2Ω±5%,SMD-0603 18KΩ±1%,SMD-0603 1KΩ±5%,SMD-0603 2MΩ±5%,SMD-1206 750Ω±5%,SMD-0805 56KΩ±1%,SMD-0603 27Ω±5%,SMD-1206 1.3Ω±1%,SMD-1206 Serie 2169 - 7.50mm Horizontal Entry Modular with Rising Cage Clamp - 3.5mm² Wires WRTBL WR-TBL Terminal block-serie 101, 5.00mm Modular-blue-Horizontal entry with pressure clamp - 12.6mm DE1B3KX681KN4AN01F Murata Electronics SBR30A60CT Diodes Incorporated Micro Commercial FS1D-LTP Components Corp. Micro Commercial FS1M-LTP Components Corp. Central Semiconductor CMZ5954B Corp. 08743.15MXEP Littelfuse Inc. 77F471J-RC Bourns Inc. LQM21FN100M80L Murata Electronics 14 2 D5,D7 15 1 D6 16 1 17 18 19 691 101 710 002 Würth Elektronik 39 1 T1 750 343 109 Würth Elektronik 40 4 Supporter EE20/10/6 (EF20),14-Pin EXT, THT, Horizontal for 5V3A Self-Retaining Spacer WA-SNSR ,Nylon 66, natural 702 917 000 Würth Elektronik 41 1 HeatSink HeatSink for D1, Thermal resistance 36K/W V5629W32 ASSMANN WSW COMPONENTS Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 5 of 7 Radial, Disc TO-220AB DO-214AC DO-214AC Micro Commercial Components Corp. EKXG401ELL220MK20S Nippon Chemi-Con CC1206KKX7RBBB103 YAGEO Corporation UPA1A102MPD1TD Nichicon CC0805KRX7R9BB104 YAGEO Corporation CC0805KRX7R0BB221 YAGEO Corporation GRM32ER71H106KA12L Murata Electronics CC0805KRX7R0BB102 YAGEO Corporation 18-May-2016 © 2016 Dialog Semiconductor iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply Item Qty. Ref. 42 1 Themical Grease 43 1 44 45 Note 1: Description Footprint Mfg. Part Number Manufacturer CW7270 Chemtronics Screw set HEAT SINK GREASE SILICONE FREE for Heatsink and D1 Machine screw pan phillips M3 for heatsink and D1 MPMS 003 0008 PH B&F Fastener Supply 1 Screw set Washer flat M3 steel for heatsink and D1 MFWZ 003 B&F Fastener Supply 1 Screw set Washer split lock M3 steel for heatsink and D1 MLWZ 003 B&F Fastener Supply The iW1830-EVAL1 evaluation board uses a common mode choke which is intended for 5V/3A designs that are used as part of circuits in white goods. Alternative UL-1310 compliant parts should be used if this design is used for a standalone 5V/3A power unit. Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 6 of 7 18-May-2016 © 2016 Dialog Semiconductor iW1830-EVAL1 Evaluation Board for 15W Single-Output Switch-Mode Power Supply Disclaimer This evaluation board is provided for evaluation purposes only and is not intended for commercial use in any end product. Dialog Semiconductor expressly disclaims all warranties, express, implied or statutory, including (but not limited to) the implied warranties of non-infringement, suitability for a specific application(s) or end product(s), product quality or reliability. All risks and liability regarding quality, use or performance of this evaluation board are those of the customer/user. The user, and/or user’s employer, if user is using this evaluation board for employer-related purposes, assumes all responsibility and liability for proper and safe handling of the evaluation boards and indemnify Dialog Semiconductor from any and all claims arising from use of the evaluation board. The user, and/or user’s employer, if user is using this evaluation board for employer-related purposes, understands that this evaluation board has not been agency tested or approved for safety, technical performance, and/or regulatory requirements, by any agency. This includes electromagnetic interference or other technical regulatory or safety testing and certifications. The user, and/or user’s employer, if user is using this evaluation board for employer-related purposes, assumes all responsibility for using this evaluation board in a test area or laboratory which is qualified and/or certified according to the local regulations, guidelines and labor laws applicable to working with non-isolated mains voltages and high voltage circuits. Information in this document is believed to be accurate and reliable. However, Dialog Semiconductor does not give any representations or warranties, expressed or implied, as to the accuracy or completeness of such information. Dialog Semiconductor furthermore takes no responsibility whatsoever for the content in this document if provided by any information source outside of Dialog Semiconductor. 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Phone: +31 73 640 88 22 Taiwan Dialog Semiconductor Taiwan Phone: +886 281 786 222 Korea Dialog Semiconductor Korea Phone: +82 2 3469 8200 Email [email protected] Web site: www.dialog-semiconductor.com Evaluation Board Summary www.dialog-semiconductor.com Rev. 1.0 7 of 7 China Dialog Semiconductor (Shenzhen) Phone: +86 755 2981 3669 Dialog Semiconductor (Shanghai) Phone: +86 21 5424 9058 18-May-2016 © 2016 Dialog Semiconductor