10.

5V 350mA Led Driver solution using AP3766

10.5V 350mA Led Driver solution using AP3766

BCD Semiconductor Manufacturing Limited 11/12/2009

Summary of Report Specifications 85~264Vac, 10.5V/350mA Applications Led Driver

Primary Side Regulation (PSR) solution without opto-coupler 10% constant current regulation Pass EN55022 Class B with over 6dB margin with output grounding High reliability guaranteed by built-in multi-protection functions, e.g. soft-start, OVP, OCkP (Open Circuit Protection) and SCP (Short Circuit Protection) functions Cost effective total charger solution ,22 components in all

Key features

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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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10.5V 350mA Led Driver solution using AP3766

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

1< to <49W 1< to <49W

[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

Figure 2. Schematic of 10.5V 350mA Led Driver demo board

4. Circuit Description
The power supply use AP3766 to realize a primary side regulation flyback converter.

4.1. AC input filter:

The AC line voltage is rectified by BD1 to a DC bus voltage. L1, and C1 compose a filter to achieve good EMI performance in attenuating the differential mode EMI noise. FR1 is used to limit the input surge current and also work as a fuse for ultimate protection in any catastrophic failure.

4.2. Power converter:

In the main power supply topology of a layback converter, the transformer T1 is magnetized and demagnetized by on/off control of the BJT transistor Q1. Thus the DC bus voltage in the primary side is converted to AC voltage on the secondary winding of T1. By an optimized driving circuitry within the AP3766, the maximum allowable peak voltage across the collector of Q1 is Vces, which makes the use of popular BJT transistor with 450V Vceo and 700V Vces feasible. The output rectification circuitry is made up of a schottky diode D2 and an electrolytic capacitors C2. A dummy load R6 is used to control the output voltage in no load condition to
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an acceptable level.

4.3. AP3766 related circuitry:

A common auxiliary winding is adopted in this schematic for both CV feedback and bias supply. CV feedback and bias supply can be separated as two windings to achieve tighter CV regulation. In the CV feedback network, R4 and R5 are required to use the resistors with 1% precision. And D1 and C3 constitute the bias supply circuitry for the AP3766. In order to ensure good driving effect for Q1, C3 should be placed as close as possible to Vcc pin of the AP3766 R1 and R3 compose the startup resistor and 1.5M ohm is recommended for the sum of these two resistors considering the tradeoff between a reasonable startup time and guaranteed reliable startup at low AC line. The primary peak current of the flyback converter is set by the current sense resistor R7 with 1% precision. The ratio of RV1 to R2 determine the line compensation to eliminate the variation of CC regulation with the line voltage.

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5. BOM and transformer specifications

5.1. BOM
Item C1 C2 C3 C4 D1 D2 BD1 L1 FR1 R1 R2 R3 R4 R5 R6 R7 R8 R9 RV1 T1 U1 Q1 Description 4.7uF/400V, 85C, 8*12 electrolytic 22uF/16V, 85C, Tan Capacitor 4.7uF/25V, 1206 X7R 1000pF/100V,1206,X7R RS1M Fast Recovery Diode SMD SS110, Schottky DIODE,SMA 1UB60, Diode Bridge 4.7mH,Inductor 12 ohm, 1/2 W, Fuse resistor 2Mohm, 1%,1206, resistor 5.1M ohm, 5%,0603, resistor 470Kohm, 5%, 0603, resistor 20K ohm, 5%, 0603, resistor 5.1k ohm, 5%, 0603, resistor 15k ohm, 5%,0603, resistor 2ohm, 1%,1206, resistor 10ohm 5%,0805, resistor 43 ohm, 5%,1206, resistor 4.7k ohm, 5%,0603, resistor EPC13 5+5pin 1.8mH 8%,Transformer AP3766KTR-G1, SOT23-5, BCDs IC APT27ZTR-G1, TO-92, BCDs BJT QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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5.2. Transformer specifications

5.2.1. Electrical Diagram

Figure 3. Transformer electrical diagram

5.2.2. Electrical Specifications

Primary Inductance Primary Leakage Inductance Electrical Strength Pin3-4 all other windings open, measured at 1kHz, 0.4VRMS Pin3-4,all other windings shorted, measured at 10kHz, 0.4VRMS 60 seconds, 60HZ, from Pin 3-4 to Pin9-8 50uH (Max) 3000Vac 1.8mH,8%

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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5.2.4. Transformer Build Diagram

Figure 4. Transformer Build Diagram

5.2.5. Transformer Construction

Winding Sequence: Begin from the central column of the Bobbin. Primary side of the bobbin is laced on the left hand side, and secondary side of the bobbin is placed on the right hand side. WD 1 Auxiliary winding Insulation Start at Pin2. Wind 44 turns of 0.1mm wire [3] from left to right. Wind tightly & spread evenly in the middle. 1 Layers of insulation tape [6], 0.05mm thick, 8.0mm wide. Start at Pin 4. Wind 48 turns of 0.1mm wire [4] from left to right. Wind WD 2 Primary Winding the next 46 turns on the next layer from right to left. Wind the last 44 turns from right to left on the side of primary. Finish on Pin 3. Wind tightly & spread evenly. Insulation Shield Insulation WD 3 Secondary winding 1 Layer of insulation tape [6], 0.05mm thick, 7.0mm wide. Copper shield [7], 6.5mm wide, 27mm long. Connected to Pin 1 on the side of primary. 3 Layers of insulation tape [6], 0.05mm thick, 7.0mm wide. Start at Pin 9. Wind 29 turns of 0.25mm Triple Insulated Wire [5] from right to left (to the opposite direction). Terminate on Pin 8. Wind tightly & spread evenly.

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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.

Figure 5. Printed circuit layout

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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..

7.1. Current Test &Active mode efficiency

The charger system passes active mode average efficiency criteria of Energy Star EPS 2.0 final version. The active efficiency criteria follow the formula for low voltage mode and can be calculated as 70%. Table 2. Iout and efficiency test results AC Vin(V) 85 90 110 150 180 230 240 264 Iout(mA) 349 352 357 360 361 348 342 342 Vout(V) 9.65 9.64 9.617 9.61 9.59 9.59 9.57 9.55 Pin(W) 4.647 4.613 4.566 4.494 4.48 4.657 4.752 4.83 Efficiency(%) 69.6 70.4 72.4 73.8 73.6 72.3 72.1 71.0

Figure 6. Vin Vs Iout

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Figure 7. Vin Vs Efficiency

7.2. No load input power

The readings of input power were recorded only after the power supply had worked for 5 minutes under no load condition. Table 3. No Load Input Power Input No. Voltage (V) 85 115 182 186 197 212 244 275 Input Power(mW) No. Input Voltage (V) 85 115 180 181 195 210 243 272 Input Power(mW)

1#

145 180 230 264

2#

145 180 230 264

Less than 300mW@230Vac

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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

230Vac 99 C 95 C 100 C 100 C 75 C

9. Key Operating Waveforms

9.1. Output ripple Current
All measurements were made with an oscilloscope with 20 MHz bandwidth and the output was bypassed at the connector with a 0.1 F ceramic disk capacitor and a 10 F electrolytic capacitor.

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Figure 8. Ripple,115Vac, Full Load, 20us, 50mA/div, peak-peak: 358mA

Figure 9. Ripple, 230Vac, Full Load, 20us 50mA/div, peak-peak: 434mA

9.2 Startup characterize

Figure 10. Vo start up waveform@Vin=115V Full load

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Figure 11 Vo start up waveform@Vin=230V full load

9.3. Collector voltage of power transistor

Figure 12. Collector voltage, Vin=265Vac, full load. 100V, 20us/div.

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10. EMI test results

10.1. Conducted EMI
EDIT PEAK LIST (Final Measurement Results) EN55022Q EN55022A --FREQUENCY 302 kHz 326 kHz 382 kHz 382 kHz 1.85 MHz 2.074 MHz 3.718 MHz 4.406 MHz 6.198 MHz 6.842 MHz 20.098 MHz 20.098 MHz LEVEL dBV 48.17 35.00 49.61 40.06 27.65 40.19 34.88 41.89 40.70 26.87 29.64 22.11 DELTA LIMIT dB -12.00 -14.54 -8.62 -8.17 -18.34 -15.80 -11.12 -14.10 -19.29 -23.12 -30.36 -27.88

Trace1:
Att 10 dB RBW 9 kHz MT 1 s PREAMP OFF

Trace2: Trace3: TRACE 1 Quasi Peak 2 Average

TDF

FREQUENCY LEVEL AV

24.0620000 MHz 37.69 dBV

1 Quasi Peak 2 Average 2 Average 1 Quasi Peak 2 Average

-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

1 Quasi Peak 2 Average 1 Quasi Peak 2 Average

TDF

6DB

Figure 13. Conducted EMI, 230VAC/50Hz, full load, Neutral

RBW 9 kHz MT 1 s PREAMP OFF

Att 10 dB

Trace1: Trace2: Trace3: TRACE 2

TDF

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

24.0620000 MHz 37.69 dBV

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

Figure 14. Conducted EMI, 230VAC/50Hz, full load, Line

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11. Summary of test results

Description Input Voltage Frequency No Load Input Power Output Output Voltage Output Ripple Current 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 70 % 72 at 115Vac; 72 at 230Vac (26# cable) Pass EN55022 Class B with 6dB margin Pass 315 350 3.5 20 8.4 10 11 300 385 V mApp mA W ms Pass <154 Pass Pass Pass 85 47 50/60 264 63 150 VAC Hz mW <110mW@230 Vac Min Typ Max Units Tested results

12. Revision history

Versions Version 1.0 Version 2.0 Date 12/25/2008 11/12/09 Author Jiao Yu Simon.Zhu Description for changes Initial release Update to AP3766 Reviewed

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