DIODES EV1 Evaluation Board User Guide

DIODES EV1 Evaluation Board

Summary

General Description
Based on Primary Side Regulation (PSR) Flyback topology, the 10W Charger EV1 Evaluation board is designed as an MP-form-factor, cost-effective, optimal efficiency, charger reference design to facilitate further customization by users. AP3983R PSR Switcher, co-packaged a 700V N-MOSFE and a PSR control die, along with APR3415B Synchronous Rectification (SR) Switcher, co-packaged a MOS die with an SR controller, enable high-efficiency and small size form-factor 10W charger designs. The overall efficiency of the evaluation board can meet DOE VI and CoC Tier 2 energy efficiency requirements.

Key Features

• 90 ~264VAC input range
• Primary side regulation without an Opto-coupler.
• Co-package PSR controller with 700V MOS die in SO-7 Package
• Multi-Mode PFM method operations, the switching frequency between 24Khz and 80Khz.
• With Valley-on detection for switching at Valley-on region to improve power converting efficiency & EMI performance.
• Burst mode operation and low start-up operating quiescent current to achieve 75mW low standby power.
• Three-mode operation to provide accurate constant voltage (CV) regulation & constant current (CC) performance.
• Soft start during startup process and built-in Jittering Frequency function to improve EMI emission.
• Internal Auto Recovery OCP, OVP, OLP, OTP Power Protection, cycle by cycle current limit, also with DC polarity protection
• Built–in Cable Compensation mode.
• Brown out Protection.

APR3415B

• Synchronous rectification of DCM Operation
• Co-package 50V 17mΩ Rdson MOS die with SR Controller in SO-8 package
• Eliminate resonant ring interference
• Fast detection of supply voltage
• Minimum supporting components

Applications

• Switching AC-DC Adaptors & Chargers
• Home Appliances system powers
• Auxiliary Vcc power supply for large power systems
  Parameter| Value
  ---|---
  Input Voltage| 90 to 264VAC
  Input standby power| 75mW
  Main output Vo / Io| 5V – 2.0A
  Efficiency| ~ 85%
  Total Output Power| 10W
  Protections| OCP, OVP, OLP,OTP
  XYZ Dimension| 29 x 32 x 15 mm
  ROHS Compliance| Yes

Evaluation Board Picture:

Power Supply Specification

Specification and Test Results

Parameter| Test conditions| Min| Nom| Max| Eff /DOE

Level VI

| Eff /CoC

V5 Tier2

| Test

Summary

---|---|---|---|---|---|---|---
VACIN Input Voltage| –| 90 VRMS| 115/230| 264 VRMS| –| –| –
FLINE Frequency| –| 47Hz| 50/60| 64Hz| –| –| –
IIN Input Current| –| –| –| 0.23 ARMS| –| –| Pass

No load Pin

| At 230Vac/50Hz, @ 5V,

Pin < 75mW

| ****

–

| ****

–

| ****

75mW

| ****

–

| ****

–

| Pass, 230Vac:

46mW

5VDC / 2A

@115Vac/230Vac Average efficiency

| ****

Board end

| ****

–

| ****

5V/2A

| ****

–

| ****

78.7%

|  | Pass, 115Vac:

84.65%

230Vac:

84.39%

Thermal Performance| 5V-2A

@ 90Vac

| AP3983R IC =86.4C

@85Vac

|  | AP3983R IC=88.0C

@264Vac

|  |  | ****

Pass

EMI Scan Data

| 5V-2A

@115Vac L & N

|  | Under Limit line

< -6db

|  |  |  | ****

Pass

 | 5V-2A

@230Vac L & N

|  | Under Limit line

< -6db

|  |  |  | ****

Pass

 | | | | | | |

• DoE VI Eff ≥ 0.0834xLn(Po)-0.0014xPo+0.609 <Vo<6V
• DoE VI Eff ≥ 0.071xLn(Po)-0.0014xPo+0.67 Vo>6V

Transformer Specification

AP3983R (90 VAC ~ 265VAC one outputs 10W Transformer Spec.)

1. Core and Bobbin: EE16C, 2+2+2 pin
2. Transformer Parameters

3. Primary Inductance (Pin5-Pin6), all other windings are open Lp =1.05mH ± 7 % @1KHz
   EE16C （ Ae = 19mm^2 ）

NO Winding

|

NAME

| TERMINAL NO.| WINDING
START| FINISH| WIRE| TURNS| Layers
1| Np1| 5| 6| Φ 0.21mm| 60Ts| 3
2| Na| 2| 1| Φ 0.19mm x 2| 11 Ts| 1
3| Shield| 1（GND）| NC| Φ 0.19mm x 1| 8T| 1
4| Ns| 3(+)| 4| Φ 0.7W x 1| 4 Ts| 1

Primary Inductance

| Pin 5-6,all other windings open, measured at 1kHz, 0.4VRMS| 1.05mH ± 7 %
Primary Leakage Inductance| Pin 5-6, all other windings shorted, measured at 10kHz, 0.4VRMS|

80 uH (Max.)

Schematic

Evaluation Board Schematic

Bill of Material (BOM)

Item| QTY per board| REF. DES.| Description| MFG or Supplier| MFG P/N or Supplier P/N Digi key #
---|---|---|---|---|---
1| 1| C1| 10uf /400V 8 x 12mm| Wurth Electro|
2| 1| C2| 10uf /400V 8 x 12mm| Wurth Electro|
3| 1| C3| 1nf /250V 0805 X7R| Holy Stone|
4| 1| C4| 4.7uF/50V 1206 X7R| Holy Stone|
5| 1| C5| 10nf / 50V, 0603 X7R| Holy Stone|
6| 1| C6| 820uf /6.3V E-cap| Wurth Electro|
7| 1| C7| 1nf / 50V, 0603 X7R| Holy Stone|
8| 1| C8| 0.1uf / 50V, 0603 X7R| Holy Stone|
9| 1| R1| 1.5M ohm 0805| Yageo|
10| 1| R2| 3.3M ohm 1206| Yageo|
11| 1| R3| 82R hom 1206| Yageo|
12| 1| R4| 300kohm 0805| Yageo|
13| 1| R5| 1R ohm 0603| Yageo|
14| 1| R6| 56K ohm 0603| Yageo|
15| 1| R7| 27K ohm, 0603| Yageo|
16| 1| R8| 200K ohm, 0603| Yageo|
17| 1| R9| 3R ohm 0805| Yageo|
18| 1| R10| 2.7R ohm 0805| Yageo|
19| 1| R11| 20R ohm 0805| Yageo|
20| 1| R12| 3.2K ohm, 0603| Yageo|
21| 1| R13| 20R ohm 0603| Yageo|
22| 1| R14| 43K ohm 0603| Yageo|
23| 1| R15| 20R ohm 1206| Yageo|
24| 1| BD1| ABS210| Diodes 2A-600V|
25| 2| D5, D6| 1N4007| Diodes 1A-600V|
26| 1| FR1| 3.3R hom| Fuse resistor|
27| 1| L1| 220uh| Inductor|
28| 1| CY1| 100pf/250Vac Y1| Holy Stone|
29| 1| U1| AP3983RMTR-G1 sop-7| Diodes|
30| 1| U2| AP3415BTM-G1 sop-8| Diodes|
31| 1| T1| EE16 core PC40|  |

The Evaluation Board (EVB) Connections

Evaluation Board PCB Layout

Quick Start Guide Before Connection

1. The evaluation board is preset at 5V/2A from output + & –
2. Ensure that the AC source is switched OFF or disconnected before doing connection.
3. Connect the AC line wires of power supply to “L and N” on the left side of the board.
4. Turn on the AC main switch.
5. Measure Red & Black wires to ensure correct output voltages at 5V respectively.

Testing the Evaluation Board

Input & Output Characteristics

Input Standby Power

Input Power Efficiency at Different Loading

AC input

| Efficiency (%)| Avg.

Efficiency

---|---|---
10%| 25%| 50%| 75%| 100%
90VAC/60Hz|  |  |  |  |  |
115VAC/60Hz| 82.65%| 84.97%| 84.37%| 84.61%| 84.65%| 84.65%
230VAC/50Hz| 78.65%| 82.21%| 84.44%| 85.22%| 85.69%| 84.39%
264VAC/50Hz|  |  |  |  |  |
Avg. Efficiency|  |  |  |  |  |

OCP Current set point with at different AC line

PSU Output Characteristics:

Line Regulation (at full loading condition):

Cross Load Regulation (at nominal line AC input voltage):

Note : All output voltages are measured at output PCB END.

Key Performance Waveforms:

System start – up time

System main switching Voltage Stress on AP3983R Pin 5 & 6

The system voltage stress on U2 D-S

System Output Ripple performance

System Dynamic Response performance with Vout @ 0A-2A

Thermal Test data at room Temperature after running 1 hr

System EMI Scan

System EMI L – Line Scan Data @115Vac

System EMI N – Line Scan Data @ 115Vac

System EMI L – Line Scan Data @ 230Vac

System EMI N-Line Scan Data @230Vac

10W Cost- Effective Charge AP3983R + APR3415B EV1 Evaluation Board User Guide

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