DIODES AP3301 Premium Settop Box Networking Adaptor User Guide

DIODES AP3301 Premium Settop Box Networking Adaptor

Specifications:

• Input Voltage: 90 ~ 265VAC
• Main Output Voltage/Current: 12V/3.5A
• Standard Power Efficiency
• Total Output Power
• Protections: XYZ
• Dimensions
• ROHS Compliance

Product Usage Instructions

Quick Start Guide

1. The evaluation board is preset at 12V/3.5A from output side of Block Terminal TH1 ~TH2
2. Ensure that the AC source is switched OFF or disconnected.
3. Connect the AC line wires of power supply to L and N on the AC side of Block Terminal.
4. Turn on the AC main switch.
5. Measure TH1~TH2 Block Terminal pins voltage to ensure correct output voltages at 12V.

General Description

The AP3301 EV1 board is a Quasi-Resonant Flyback converter, operating under CCM and DCM, the valley switching on mode function will be appeared at all DCM region of variable load & high input AC line voltage conditions, it is employed with the peak-current control & multi-mode PWM control functions. Based on above the high performances are optimized & achieved. It is designed to serve as an example for High Efficiency, cost-effective & components less consumer home appliance systems. Its output power is rated at 42W with 12V-3.5A and peak power can be reach to 48W at peak time. Its input power consumption is less than 100mW at no load and meets DOE VI and CoC Tier 2 energy efficiency requirement.

Key Features

• 90 ~265VAC input range
• Multi-Mode PWM method operation & QR valley switching cover full range of AC input at heavy load, the switching frequency between 20Khz ~120Khz.
• With Valley Switching Turn on function that improving power converting efficiency, the 90% Efficiency can be reached.
• During the burst mode operation the 100mW low standby input power can be achieved.
• Dynamic response is improved during work at three mode operation.
• Low start-up operating and low quiescent currents at turn on moment.
• Soft start during startup process.
• Provide accurate constant voltage regulation & accurate constant current (CC) regulation.
• Frequency fold back for high average efficiency
• Built-in Jittering Frequency function is built in to reduce EMI emission.
• Valley-on Soft Switching for Reducing EMI.
• Internal Auto Recovery OCP, OVP, OLP, OTP Power Protection, cycle by cycle current limit, also with DC polarity protection
• With a Brown out Protection.

Applications

• Switching AC-DC Adaptor & Charger
• Power home Appliances systems
• Set-top box & TV power supply
• Open frame switching power supply

Universal AC input QR 12V-3.5A Power Specifications (CV & CC mode) 

Evaluation Board Picture

AP3301 (90 VAC ~ 265VAC one output 42W Transformer Spec.)

1. C or e & Bobbin: RM8 , 6+2 pin
2. Electrical Diagram:
3. Transformer Parameters
   Primary Inductance (Pin2-Pin1), all other windings are open Lp = 0.7mH ± 5 % @1KHz

RM8 （ Ae = 64mm^2 ）

NO

Winding

| ****

NAME

| TERMINAL NO.| WINDING
START| FINISH| WIRE| TURNS| Layers
1| Np1| 1| 2| Φ 0.35 ( 27# AWG )| 21 x 2= 42Ts| 2
2| Na| 4 ( Gnd )| 5| Φ 0.23| 9 Ts| 1
3| Shield| 4 （ GND ）| NC| Φ 0.2 2| （均匀分布）| 1
4| Ns| FL2 （ G ）

顶部飞线

| FL1 (+)

顶部飞线

| *Φ 0.5W 2 (24# AWG)| 7 Ts| 1
5| Np2| 2| 3| Φ 0.35**

(27# AWG)

| 20| 1
 |  |  |  |  |  |
Primary Inductance| Pin 3-1,all other windings open, measured at 1kHz, 0.4VRMS| 650~700uH±5%
Primary Leakage Inductance| Pin 3-1, all other windings shorted, measured at 10kHz, 0.4VRMS| 20 uH (Max.)

Evaluation Board Schematic

Evaluation of PCB Board Layout

Quick Start Guide

1. The evaluation board is preset at 12V/3.5A from output side of Block Terminal TH1 ~TH2
2. Ensure that the AC source is switched OFF or disconnected.
3. Connect the AC line wires of power supply to “L and N” on the AC side of Block Terminal.
4. Turn on the AC main switch.
5. Measure TH1~TH2 Block Terminal pins voltage to ensure correct output voltages at 12V

Build of Material

AP3301 42W SYSTEM BOM – 10/15/2018 with schematic

Item No| Item| Type| Quantity (Unit)| part number #
1| C1| 120uF/420V, AL CAP| 1| Wurth 860021381021 18x33mm
2| C2| 4.7uF/35V, AL CAP

5x11mm

| 1| Wurth 860020572002 5 x11
3| C3| 2.2nF/500V/1206 ,ceramic| 1| Holy Stone
4| C4| 100pF/25V, 0805ceramic| 1| Wurth – 885012007057
5| C5| 470pF/25V,0805,ceramic| 1| Wurth – 885012007061
6| C6//C7| 680uF/16V, AL CAP| 2| Wurth – 870025375009
7| C8| 1nF/200V,1206,ceramic| 1| Wurth – 885012007063
8| C9 & C12| 0.1uF/50v 0805 ceramic| 2| Wurth – 885012207098
9| C10| 68nF/50V 0805 ceramic| 1| Wurth – 885012207097
10| C13| 22uf/16V 1206 X5R| 1| Holy Stone
11| R1/R2| 2.2Mohm,1206| 2| Yageo
12| R3/R4| 1.8Mohm,1206| 1| Yageo
13| R5, R5A,R5B| 1R0//1R0//1R6 ohm, 1206| 3| Yageo
14| R6| 2.2 ohm, 1206| 1| Yageo
15| R7| 100Kohm,0603| 1| Yageo
16| R8| 15Kohm,0603| 1| Yageo
17| R9| 20 ohm 0603| 1| Yageo
18| R10| 10Kohm,0603| 1| Yageo
19| R11| 2k ohm, 0603| 1| Yageo
20| R12| 1.5Kohm, 0603| 1| Yageo
21| R13| 43 ohm, 1206| 1| Yageo
22| R14, R14A| 470Kohm,1206| 2| Yageo
23| R19 , R27/off| 1.0Kohm,0603| 1| Yageo
24| R21/R25| 12.1Kohm,0603 1%| 2| Yageo
25| R22| 43.2Kohm,0603| 1| Yageo
26| R24| 287Kohm,0603 1%| 1| Yageo
27| R26| 20ohm, 1206| 1| Yageo
28| R28 & R31| 3.9Kohm,0805| 2| Yageo
29| R23| 5.1Kohm 0805| 1| Yageo
30| R29| 100Kohm,0603| 1| Yageo
31| R30| 20 ohm 0603| 1| Yageo
32| R34| 18 ohm 0805| 1| Yageo
33| CX1| 0.22uF/250Vac| 1| Wurth 890324024002 15x7mm
34| CY1| 1nF/Y1| 1| Holy Stone
35| CY2| 10pF/Y1| 1| Holy Stone
36| U1| AP3301, SOT-6, DIODES| 1| Diodes
37| U2| LTV-356T| 1| Lite-on SMD
38| U3| APR345,SOT-6, DIODES| 1| Diodes
39| U4| AS431,SOT-3, DIODES| 1| Diodes SOT-23
40| Q1| DMG10N60SCT DMJ65H600SCTI| 1| Diodes
---|---|---|---|---
41| Q2| DMT10H10LCT| 1| Diodes
TO220|  |
42| Q3| MMBT2222A(0Rcross c,e)| off| Diodes SOT-23
43| T1| RM 8, 650uH| 1|
44| BD1| GBU406,DIODES| 1| Diodes
45| D1| S1MWF, DIODES| 1| Diodes
46| D3| IN4148WS Diodes SOD323| 1| Diodes
47| D6| S1MWF, DIODES| 1| Diodes
48| NTC| SHORT|  |
49| LF1| 9.654, 7T| 1| Part number?
50| LF2| 10mH common mode 1A| 1| Wurth 744822110 17.5 x 13mm,

Holy Stone MOX-VTI-2212-100DSO

51| F1| 3.15A/250V| 1|
52| L1| 1045 100uH| 1| Part number?
53| PCB|  | 1|
54| Block

connector

| Two P| 2| OSTTA020161—ED2561-ND#
55| ZD2| DDZ9698 11Vz| off| Diodes SOD123
56| ZD1| DDZ9707 20Vz| 1| Diodes SOD123
57| TVS1| DFLT18A| off| Diodes PowerDI123
TOTAL (AP3301)|  |  |  |

Input & Output Characteristics

Input Standby Power

Input power Efficiency at different loading

PSU Output Characteristics:
Line Regulation (at full loading condition):

Load condition| 12V/3.5| 12V/2.625A| 12V / 1.75A| 12V / 0.875A| Note
---|---|---|---|---|---
115V AC| 12.12V / 3.5A| 12.15V/2.625A| 12.16V/1.75A| 12.17V/0.875A| 0.5% <
230V AC| 12.13V / 3.5A| 12.15V/2.625A| 12.16V/1.75A| 12.17V/0.875A| 0.5% <

Load Regulation (at nominal line AC input voltage):

Load condition| 12V/3.5| 12V/2.625A| 12V / 1.75A| 12V / 0.875A| Note
---|---|---|---|---|---
115V AC| 12.12V / 3.5A| 12.15V/2.625A| 12.16V/1.75A| 12.17V/0.875A| 0.5% <
230V AC| 12.13V / 3.5A| 12.15V/2.625A| 12.16V/1.75A| 12.17V/0.875A| 0.5% <

OCP Current setting with at different AC line

AC input| 90V AC| 115V AC| 230V AC| 264V AC| Note
---|---|---|---|---|---
I _max| 4.10A| 4.15A| 4.28A| 4.41A|

Note : All output voltages are measured at output PCB board Edge.

OCP curve with at different AC Input

Key Performance Waveforms:

Output Performance Waveforms

Thermal Test data at room temperature after running 1 hr

The AP3301 12V-3.5A EMC scaned data: 115Vac/60Hz 12V-3.5A Line L

Please see the recommand Application note for reference (Web page – http://www.diodes.com/appnote_dnote.html)

1. For AP3301 operation & set up, please review the Application note:
   AN1120 Green Mode PWM Controller

2. For PSU PCB layout consideration, please review the App note:
   AN1062 High Voltage Green Mode PWM Controller AP3105

3. For the basic Flyback topology calculation, please review the App note:
   AN1045 Design Guidelines for Off-line AC-DC Power Supply Using BCD. PWM Controller AP3103

4. Revision 1.1 charge list

5. Add in new alternate Mosfet.

6. Add in R23=5.1K for improving load regulation.

7. Updated schematic date into 10-15-2018.

IMPORTANT NOTICE

• DIODES INCORPORATED MAKES NO WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, WITH REGARDS TO THIS DOCUMENT, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
• PARTICULAR PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION).
• Diodes Incorporated and its subsidiaries reserve the right to make modifications, enhancements, improvements, corrections or other changes without further notice to this document and any product described herein. Diodes Incorporated does not assume any liability arising out of the application or use of this document or any product described herein; neither does Diodes Incorporated convey any license under its patent or trademark rights, nor the rights of others. Any Customer or user of this document or products described herein in such applications shall assume all risks of such use and will agree to hold Diodes Incorporated and all the companies whose products are represented on Diodes Incorporated website, harmless against all damages.
• Diodes Incorporated does not warrant or accept any liability whatsoever in respect of any products purchased through unauthorized sales channel.
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• Products described herein may be covered by one or more United States, international or foreign patents pending. Product names and markings noted herein may also be covered by one or more United States, international or foreign trademarks.
• This document is written in English but may be translated into multiple languages for reference. Only the English version of this document is the final and determinative format released by Diodes Incorporated.

LIFE SUPPORT
Diodes Incorporated products are specifically not authorized for use as critical components in life support devices or systems without the express written approval of the Chief Executive Officer of Diodes Incorporated. As used herein:

1. Life support devices or systems are devices or systems which:
2. are intended to implant into the body, or
3. support or sustain life and whose failure to perform when properly used in accordance with instructions for use provided in the labeling can be reasonably expected to result in significant injury to the user.
4. A critical component is any component in a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or to affect its safety or effectiveness.

Customers represent that they have all necessary expertise in the safety and regulatory ramifications of their life support devices or systems, and acknowledge and agree that they are solely responsible for all legal, regulatory and safety-related requirements concerning their products and any use of Diodes Incorporated products in such safety-critical, life support devices or systems, notwithstanding any devices- or systems-related information or support that may be provided by Diodes Incorporated. Further, Customers must fully indemnify Diodes Incorporated and its representatives against any damages arising out of the use of Diodes Incorporated products in such safety-critical, life support devices or systems.

Copyright © 2016, Diodes Incorporated

www.diodes.com

AP3301 EV1 Rev1.1 10-15-2018

www.diodes.com

FAQ

Q: What is the input voltage range for this product?
A: The input voltage range is 90 ~ 265VAC.

Q: What are the key features of this product?
A: The key features include Multi-Mode PWM operation, Quasi-Resonant switching, and applications in various power supply systems.

Q: How do I ensure the correct output voltage?
A: You can measure the Block Terminal pins voltage to ensure the correct output voltage of 12V.

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