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Contents
1. Introduction........................................................................................................................... 3 2. Specifications......................................................................................................................... 5 3. Schematic............................................................................................................................... 6 4. Circuit Description ............................................................................................................... 6 4.1. AC input filter: ........................................................................................................... 6 4.2. Power converter: ........................................................................................................ 6 4.3. AP3766 related circuitry: ........................................................................................... 7 5. BOM and transformer specifications.................................................................................. 8 5.1. BOM .......................................................................................................................... 8 5.2. Transformer specifications......................................................................................... 9 5.2.1. Electrical Diagram......................................................................................... 9 5.2.2. Electrical Specifications ................................................................................ 9 5.2.3. Materials........................................................................................................ 9 5.2.4. Transformer Build Diagram ........................................................................ 10 5.2.5. Transformer Construction............................................................................ 10 6. PCB layout............................................................................................................................11 7. Electrical performance ....................................................................................................... 12 7.1. Current Test &Active mode efficiency .................................................................... 12 7.2. No load input power ................................................................................................ 13 8. Thermal performance ........................................................................................................ 14 9. Key Operating Waveforms ................................................................................................ 14 9.1. Output ripple Current............................................................................................... 14 10. EMI test results................................................................................................................. 17 10.1. Conducted EMI...................................................................................................... 17 11. Summary of test results .................................................................................................. 18 12. Revision history ............................................................................................................... 18
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1. Introduction
This report describes a 3W constant current universal input power supply for LED Driver or similar applications. This design was based on BCDs new generation 5-Star Primary Side Regulation (PSR) controller, AP3766. The mechanic dimensions are 26mm in length, 17 mm in width and 18mm in height.
Figure 1. Photo of 10.5V 350mA Led Driver demo board (Top view and bottom view) The AP3766 is a general use AC/DC power supply controller for the cost effective battery charger and adapter application. It can achieve constant voltage and constant current (CV and CC) regulation without requiring an opto-coupler and secondary control circuitry. Meanwhile, it also eliminates the need of loop compensation circuitry while maintaining system stability. With the unique random frequency dithering technique, AP3766 system can get good EMI performance. Compared with the traditional Pulse Width Modulation control for CV and CC control technique, this device uses Pulse Frequency Modulation (PFM) technique to achieve tight CV and CC regulation, which guarantees high efficiency at light loading and makes the charger system built with AP3766 easily to pass the active mode efficiency criteria of Energy Star EPS 2.0. Designed to work in Discontinuous Current Mode (DCM), the power system using the AP3766 operates with constant primary peak current and the CV regulation is realized by modulating switching frequency. So the switching frequency presents a linear characteristic with the change of the loading. The CC regulation is implemented by a fixed ratio between the conduction time and off time of the secondary schottky rectifier. The detailed operation principle can refer to the datasheet of AP3766. The AP3766 consists of a 5V regulator, CV feedback and logic circuitry, constant peak
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current setting circuit, leading edge blanking circuit, optimized BJT driver circuitry, over voltage/open circuit protection (OVP/OCkP) circuitry and a PFM controller for CV and CC frequency modulation. With the built-in soft-start, OVP, OCkP and SCP (Short Circuit Protection) functions, the AP3766 can achieve high reliability in abnormal conditions without additional components and cost. This document contains the power supply specification, schematic, BOM (bill of materials) including transformer architecture, PCB layout and key performance features with detailed test data and waveforms.
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2. Specifications
Description Input Voltage Frequency No Load Input Power Output Output Voltage Output Ripple Voltage Output Current Output Power (Pno) Output Voltage rise Time Efficiency Average Efficiency at 25,50,75 and 100 % of Pno (EPS 2.0) ---note 1 EMI Surge test ESD 70 % 315 350 3.5 20 8.4 10 11 300 385 V mApp 20M bandwidth mA W ms 85 47 50/60 264 63 150 VAC Hz mW Min Typ Max Units Conditions
Pass EN55022 Class B with 6dB margin IEC61000-4-5 Class 3 IEC6100-4-2 Class 4
Note 1: The active mode average efficiency criterion of Energy Star EPS 2.0 was calculated as follow: Table 1. EPS 2.0 Active Mode Efficiency Criteria
Low voltage Model (Nameplate Vo< 6V and nameplate Io 550mA) Standard Model
[0.075*Ln(Pno)]+0.561 [0.0626*Ln(Pno)]+0.622
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3. Schematic
FR1 R1 C1 + AC L1 BD1 R2 C3 D2 R3 R8 D1 T1 APT27 TO-92
1 4 5
C4
R9
C2
R6 OUT
U1 3
Vcc Out
Q1
AP3766 SOT-23-5
CS FB GND
RV1
R4
R5
R7
4. Circuit Description
The power supply use AP3766 to realize a primary side regulation flyback converter.
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an acceptable level.
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5.2.3. Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core:EPC13, PC40 or equivalent Bobbin: EPC13, Horizontal, 10 Pin, (5/5) Wire: 0.1mm, for Auxiliary Winding Wire: 0.1mm, for Primary Winding Triple Insulated Wire: 0.25mm for Secondary Winding Tape: 0.05mm thick, 7.0 mm wide Copper film: 0.05mm thick, 6.5 mm wide 27mm longth Glue
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Insulation Glue
1 Layers of insulation tape [6], 0.05mm thick, 7.0mm wide. Glue core and bobbin[8]
6. PCB layout
The PCB layout rules are highlighted as follow: 1. The loop area composed by the input capacitor, the primary winding of the transformer, power transistor Q1 and current sense resistor R7 should be minimized for better EMI performance 2. The power ground and signal ground should be connected by one node.
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7. Electrical performance
All the test results were obtained at room temperature unless otherwise specified, with 50 Hz line voltage Load 3 LED..
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1#
2#
8. Thermal performance
The thermal performance was measured in a carton without the airflow, which was put into a 75 C chamber, and after the power supply had worked for 1 hour under full load condition. Two thermocouples were attached to the case of U1 and Q1 firmly. Table 4. Thermal performance of key components Item U1 (AP3766) Q1 (APT27) D1 (SS110) T1 TA 115Vac 98 C 94 C 98 C 98 C 75 C
O
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Trace1:
Att 10 dB RBW 9 kHz MT 1 s PREAMP OFF
FREQUENCY LEVEL AV
-10
10
20
30
40
50
60
70 6DB
dBV 70
1 MHz
10 MHz
EN55022Q
60
1 Quasi Peak
SGL
EN55022A
1 PK CLRWR 2 AV CLRWR 50 40 30 20 10 0 -10 0 30
TDF
6DB
Att 10 dB
EDIT PEAK LIST (Final Measurement Results) EN55022Q EN55022A --FREQUENCY 322 kHz 326 kHz 378 kHz 378 kHz 1.146 MHz 1.146 MHz 3.898 MHz 4.726 MHz 6.746 MHz 6.746 MHz 24.058 MHz 24.062 MHz LEVEL dBV 39.12 48.14 48.10 42.21 44.09 35.89 46.08 33.16 42.96 27.19 33.78 33.73 DELTA LIMIT dB -10.53 -11.41 -10.21 -6.11 -11.90 -10.10 -9.91 -12.83 -17.03 -22.80 -26.21 -16.26
FREQUENCY LEVEL AV
Average Quasi Peak Quasi Peak Average Quasi Peak Average Quasi Peak Average Quasi Peak Average Quasi Peak Average
1 1 2 1 2 1
-10
10
20
30
40
50
60
70 6DB
dBV 70
1 MHz
10 MHz
2
SGL
EN55022Q
60
EN55022A
1 PK CLRWR 2 AV CLRWR 50 40 30 20 10 0 -10 150 kH 30 MH
1 2 1
TDF
6DB
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