A Small-Size High-Efficiency Low-Cost Design with Digital Power Controller iW1691

iWattInc. LosGatos,CA95032 USA

Outline

Introduce iW1691 Design example- A 5V2A adaptor design Summary

Sep 21, 2010

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iWatt: A Digital Power Controller Company

Integrated Digital Power AC/DC Conversion DC/DC Conversion

Power Grid

Point Of Load

Communications and Control Opportunity to Repartition Power Distribution

Higher Efficiency Smaller Size Lower Cost of Ownership

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Digital Primary-Feedback Power Controller

A US-based technology company, located in Silicon Valley The first company to release Digital Power Control ICs for
ac/dc offline
- iW1689, iW1692, iW1690, iW1696, iW1698, iW1691 & iW1710 - LED offline drivers iW3620, iW3610

Provides Total System Solutions for low-power adapters and

chargers with low cost and high performance
- Patented digital primary-feedback control technology with Tight CV regulation - Patented Constant Current (CC) regulation with primary-feedback - Advanced multi-layer fault protection technology

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iW1691
a low cost quasi-resonant ac/dc digital green power controller

Design For EMI Design For Efficiency

Quasi-resonant control High margin to meet EPA 2.0 Flat efficiency curve cross line and load

Tight CC regulation
Protect Cell phone internal charger Avoid overheat

Tight CV regulation
+/-3% overall

Design for Green

Low no_load power consumption

Single Fault Protections

Active OVP Active short circuit Current over shoot control Latch function: SD ( OTP)

Adaptive Multi-Mode Operations

PWM, PFM, Deep PFM, Build-in adaptive loop compensation

Fast Dynamic Response

Adaptive digitalized Bang-bang mode control

Cable drop compensation Power application up to 25W

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A Simple Application Schematic

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iW1691 Pin-out and Package

iW1691, 8-lead SOIC package Soldering Temperature Resistance:
[a] Package is IPC/JEDEC Std 020D Moisture Sensitivity Level 1 [b] Package exceeds JEDEC Std No. 22-A111 for Solder Immersion Resistance; package can withstand 10s immersion < 270

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IC Block Diagram

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Intelligent Multi-Mode Operation

5V/0A

5V/0.07A

5V/0.39A

5V/0.55A

5V/0.93A

DPFM

PWM

VMS VMS

4V/1A

Multi Mode Operation PFM at light Load PWM CC Fast Dynamic response

2V/1A

PWM
1V/1A

Advanced internal loop compensation Fast dynamic response

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80+ Efficiency Cross Line and Load

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Design For Efficiency

Valley mode switching at CV heavy load (>45%) Valley mode switching at CC heavy load (Estimate>30%) Reduced switching frequency below 25% load Reduced switching frequency at high input voltage DPFM at light load

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Adaptive Valley Mode Switching

knee T1

0V

vms T2

T3 Tres Wont showup in operation

The transformer resets at time T1. The magnetizing inductance Lm and the capacitance seen from drain of If the switch turns on at T3 (so-called quasi-resonant or valley mode

power switch starts resonance at period Tres. At time T3, the resonant voltage reaches the lowest position. switching), the switching loss is minimized. Because of low dV/dt, the EMI can also be reduced comparing to the typical non-valley mode switching design. design and research practice.

iWatt has successful experience on valley mode switching from previous

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Patented Switching Frequency Map

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Design for EMI

Dynamic gate driver impedance to control the turn-on and

turn-off speed

Digitalized Frequency Spectrum Spread 130kHz maximum frequency limit Valley mode switching to reduce the turn-on spike

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Dynamic Gate Drive Impedance

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Conducted EMI Comparison

Traditional QR Solution

iW1691 Solution

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Adaptive Fast Load Transient Detection

HeavyLoadtoLightLoad

LightLoadtoHeavyLoad

Primary voltage feedback responds to the load change cycle-by-cycle A proprietary hysteresis control method to speed up the dynamic response in addition to the traditional Proportional-Integration-Differential (PID) control When the output voltage reaches the high limit, iW1691 increases the offtime immediately to reduce the output power; If the output voltage reaches the low limit. iW1691 increases the switching frequency immediately to quickly compensate for the output voltage drop.
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Result From Fast Dynamic Response

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Advanced Low Power Management

Low power management

Increase system output stability in no load condition to allow high pre-load resistance. Put system into sleep mode in between the long output trains.

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No_Load Power Consumption

No-Load Standby Power Consumption
120

110

100

Pin(mW)

No-Load standby power consumption is <100mW at 230Vac!

90

With pre-load 1k

80

70

60

90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270

Vin(Vac)
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Cable Drop Compensation

1691 Cable Drop Compensation for 5V
400.00
No CDC

350.00 300.00 250.00 CDC (mV) 200.00 150.00 100.00 50.00 0.00 13.0% 19.2% 25.3% 31.5% 37.7% 43.8% 50.0% 56.2% 62.3% 68.5% 74.7% 80.8%

300mV CDC

87.0%

93.2%

Output power (%)

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99.3%

0.7%

6.8%

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Design Example: iW1691 5V/2A design

Design Target
Description
Input Voltage Frequency No-load Input Power (264VAC) Output Output Voltage Output Current Output Ripple Voltage Total Output Power Continuous Output Power Over Current Protection Efficiency Environmental Conducted EMI Safety Ambient Temperature
Sep 21, 2010

Symbol
VIN fLINE

Min
90 47

Typ

Max
264

Units
VAC Hz W V A

Comment

50/60

63 0.15

VOUT_CV IOUT_CV VRIPPLE

4.85 2

5.25

Measured at the end of Cable

100

mVP_P

Measured at the End of DC Output cable IOUT=2A @TA = 25 20 MHz Bandwidth

POUT IOUT_MAX

10 2.5 80

W A %
Auto-restart Measured at end of PCB, VIN = 115VAC and 230Vac IOUT= 2A. (TA = 25 )

Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II TAMB 0 40

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Free convection, sea level

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A Typical Schematic

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Cross Regulation, Ripple and Efficiency

Note: Output voltage is measured at end of PCB
VIN (VAC) PIN (W) 0.05 3.08 6.06 9.16 12.36 0.06 3.09 6.04 9.05 12.13 0.08 3.20 6.28 9.18 12.13 0.01 3.27 6.39 9.31 12.27 VOUT (V) 5.03 5.02 5.03 5.04 5.05 5.02 5.02 5.03 5.04 5.05 5.00 5.02 5.03 5.04 5.05 5.00 5.02 5.03 5.04 5.05 IOUT (A) 0 0.500 1.000 1.500 2.000 0 0.500 1.000 1.500 2.000 0 0.500 1.000 1.500 2.000 0 0.500 1.000 1.500 2.000 VRIPPLE (mVP-P) 10 18 20 36 60 10 16 20 26 30 10 20 20 22 24 10 24 18 20 24
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POUT (W) 2.51 5.03 7.56 10.10 2.51 5.03 7.56 10.10 2.51 5.03 7.56 10.10 2.51 5.03 7.56 10.10

(% ) 81.49 83.00 82.53 81.72 81.23 83.28 83.54 83.26 78.44 80.10 82.35 83.26 76.76 78.72 81.20 82.31

OCP (A)

Average

(% )

90

2.29

82.2

115

2.28

82.8

230

2.28

81.0

264

2.29

79.7

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Easy to Meet EPA_2.0

EPA2.0 (Final) for Low Voltage Model (Pno=10W)

0.075 Ln(10W ) + 0.561 = 73.4%

VIN (VAC) IOUT (mA) 500 1000 1500 2000 500 1000 1500 2000 PIN (W) 3.090 6.040 9.050 12.130 3.200 6.280 9.180 12.130 VOUT_PCB (V) 5.02 5.03 5.04 5.05 5.02 5.03 5.04 5.05 Measure at end of PCB POUT_PCB (W) 2.51 5.03 7.56 10.10 2.51 5.03 7.56 10.10 EFF_PCB (%) 81.23 83.28 83.54 83.26 78.44 80.10 82.35 83.26 AV-EFF_PCB (%)

Meet EPA2.0 with lots of Margin!

Measure at end of Cable 26AWG/1.2m, RCable=0.35 VOUT_Cable POUT_Cable EFF_Cable AV-EFF_Cable (V) (W) (%) (%) 4.85 4.68 4.64 4.51 4.89 4.76 4.64 4.51 2.42 4.68 6.95 9.02 2.44 4.76 6.95 9.02 78.40 77.48 76.82 74.36 76.33 75.80 75.74 74.36

115

82.83

76.77

230

81.04

75.56

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Tight Output Current Regulation

* Note: Output voltage is monitored at end of PCB VIN=90Vac/50Hz VIN=264Vac/50Hz

5.25V 4.75V VOUT(1V/Div)

5.25V 4.75V VOUT(1V/Div) 2.00V

2.0A 2.5A

2.00V

IOUT(500mA/Div)

IOUT(500mA/Div)

2.0A

2.5A

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Fast Output Voltage Rise Time

90VAC, No Load 90VAC, Full Load

CH1: Output Current, 1A/Div CH3: Output Voltage, 2V/Div

CH1: Output Current, 1A/Div CH3: Output Voltage, 2V/Div

264VAC, No Load

264VAC, Full Load

CH1: Output Current, 1A/Div CH3: Output Voltage, 2V/Div

CH1: Output Current, 1A/Div CH3: Output Voltage, 2V/Div

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Advanced Fast Protection

Startup after output short Short after regulation

Vaux open

Vaux short

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Current Sensing Resistor Short Protection

Ch1: Iout, Ch2: Vout Ch3:Isense, Ch4:Vgate

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Conducted EMI Result

Vin=115Vac/50Hz, Live Vin=115Vac/50Hz, Neutral

QP SCAN

QP SCAN

AV SCAN

AV SCAN

Vin=230Vac/50HZ, Live

Vin=230Vac/50Hz, Neutral

QP SCAN

QP SCAN

AV SCAN

AV SCAN

Note: Resistive & Full load. output (-) is connected to Earth.

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Radiation RFI Result

230Vac/50Hz, Vertical 230Vac/50Hz, Horizontal

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Summary
iW1691 provides the most cost-effective solution to achieve the small size
high efficiency low-cost adapter design

The efficiency can be over 80+ cross line and load Easy EMI design Achieve tight output voltage regulation Incorporated the proprietary Digital Primary-Feedback technology
No Opto, No TL431, No secondary control circuits

Adaptive cycle-by-cycle Constant Current Regulations Multi-layer advanced protection features

Isense short circuit protection and other single-point fault protections Brown-out / recovery OVP, UVP, short circuit, Low cost, Less components

More Reliable

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Q&A

Sep 21, 2010

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