5.

0V/1A Battery Charger Solution Using AP3708N

5V/1A Charger Solution Using AP3708N

System Engineering Department

BCD Semiconductor Manufacturing Limited

04/14/2009

Summary of Report

Specifications 85~265Vac, 5.0V/1A

Applications Charger
y Primary Side Regulation (PSR) solution without opto-coupler
y Pass Energy Star EPS 2.0 (>68.9%) because Pulse Frequency
Modulation (PFM) is adopted for high efficiency at light load
y ±2.6% Constant Voltage (CV) regulation and ±1.8% constant
current regulation with 1.8m AWG24 cable on normal temperature
Key features y Less than 0.14W no load input power for universal line
y Pass EN55022 Class B with over 6dB margin
y High reliability guaranteed by built-in multi-protection functions,
e.g. soft-start, OCkP (Open Circuit Protection) and SCP (Short
Circuit Protection) functions
y Cost effective total charger solution

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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. AP3708N 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 ........................................................................................................11
7.1. Active mode efficiency .............................................................................................11
7.2. Output I-V and regulation........................................................................................ 12
7.3. No load input power ................................................................................................ 12
8. Key Operating Waveforms ................................................................................................ 13
8.1. Output ripple voltage ............................................................................................... 13
8.2. Collector voltage of power transistor....................................................................... 14
8.3. Startup characteristics .............................................................................................. 14
8.4. Waveform of schottky.............................................................................................. 15
9. EMI test results ................................................................................................................... 16
9.1. Conducted EMI........................................................................................................ 16
9.2. Radiated EMI........................................................................................................... 17
10. Thermal performance ..................................................................................................... 18
11. Summary of test results .................................................................................................. 19
12. Revision history ............................................................................................................... 20

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1. Introduction
This report describes a 5W constant voltage/constant current universal input power
supply for cellphone charger or similar applications. This design was based on BCD’s high
precision Primary Side Regulation (PSR) controller, AP3708N. The mechanic dimensions are
50mm in length, 29 mm in width and 16mm in height.

Figure 1. Photo of 5.0V/1A demo board (Top view and bottom view)

The AP3708N is a high performance AC/DC power supply controller for the cost
effective battery charger and adapter total solutions. 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,
AP3708N 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 AP3708N 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 AP3708N 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 excellent CV regulation is also attributed to
a built-in cable voltage drop compensation circuit, which precisely offsets about 0.35Vdc at
60 kHz switching frequency. And the CC regulation is implemented by a fixed ratio between
the conduction time and off time of the secondary schottky rectifier. The detailed operation

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principle can refer to the datasheet of AP3708N.

The AP3708N consists of a 5V regulator, CV feedback and logic circuitry, constant
peak current setting circuit, leading edge blanking circuit, optimized BJT driver circuitry,
cable voltage drop compensation, 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 AP3708N 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 Min Typ Max Units Conditions
Input

Voltage 85 264 VAC

Frequency 47 50/60 63 Hz
No Load Input Power 150 mW

Output

Output Voltage 4.75 5.0 5.25 V

Output Ripple Voltage 150 mVpp 20M bandwidth
Output Current 1 1.1 1.2 A
Output Power (Pno) 5 W
Output Voltage rise Time 20 ms
Efficiency

Average Efficiency at Tested with

1.8m AWG 24
25,50,75 and 100 % of 68.2 %
cable
Pno (EPS 2.0) ---note 1

EMI Pass EN55022 Class B with 6dB margin

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 1< to <49W [0.075*Ln(Pno)]+0.561
nameplate Io≥ 550mA)
Standard Model 1< to <49W [0.0626*Ln(Pno)]+0.622

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3. Schematic

Figure 2. Schematic of 5V/1A charger solution

4. Circuit Description
The power supply use AP3708N to realize a primary side regulation flyback converter.

4.1. AC input filter:

The AC line voltage is rectified to a DC bus voltage by D4 to D7. C1, L1, L2 and C2
compose a Pi filter to achieve good EMI performance in attenuating the differential mode
EMI noise, in which L1 are mainly to limit EMI noise in middle frequency (less than 1M) and
L2 has good high frequency characteristic to eliminate EMI noise in high frequency. And R1
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 flyback 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. A
snubber circuit composed of R11, D2, R12 and C8 is added to suppress the spike voltage

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across the collector of Q1 and achieve good EMI performance as well by decreasing dv/dt of
Vce of Q1 and di/dt of leakage current during switching off period. By an optimized driving
circuitry within the AP3708N, the maximum allowable peak voltage across the collector of
Q1 is Vces, which makes the use of popular BJT transistor with 400V Vceo and 700V Vces
feasible.
The output rectification circuitry is made up of a schottky diode D1 and two electrolytic
capacitors C3/C5. A dummy load R13 is used to control the output voltage in no load
condition to an acceptable level. The adoption of the RC snubber composed of R4 and C7 is
to suppress the voltage spike across the schottky diode D1 and thereby attenuate the radiated
EMI noise.

4.3. AP3708N related circuitry:

To obtain tight CV regulation, two independent windings are adopted in this schematic
for CV feedback and bias supply respectively. In the CV feedback network, R15 and R16 are
required to use the resistors with 1% precision. And D3 and C4 constitute the bias supply
circuitry for the AP3708N. In order to ensure good driving effect for Q1, C4 should be placed
as close as possible to Vcc pin of the AP3708N.C10 is used to achieve good radiated EMI
performance.
R3 and R10 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 R2 with 1% precision. The ratio of R6 to R8 and that of R3 to R10
determine the line compensation to eliminate the variation of CC regulation with the line
voltage.R9 is parallel with R2 to adjust output current precisely.
The bias current is set by R14 and determines the driving capability of the AP3708N,
namely the lower R14, the higher driving capability for Q1. Generally, 200k~330k ohm
resistor is recommended to meet 5W~2W output power applications. The bypass capacitor C9
should be placed as close as possible to VDD pin.
As a part of the cable voltage drop compensation circuitry, the use of C6 is to composes
a low-pass filter for converting the ac Tons (conduction time of the Schottky rectifier) signal
to the DC voltage, which reflects the variation of the feedback voltage. Generally, 0.47u~1u
ceramic capacitor is recommended for this component.

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5. BOM and transformer specifications

5.1. BOM
Item Description Qty.
C1,C2 6.8uF 400V 85℃ 8×12, Electrolytic 2
C3 330uF 16V 105℃ 6×11, Low ESR, Electrolytic 1
C5 470uF 16V 105℃ 8×13, Low ESR, Electrolytic 1
C4 4.7uF 50V 105 ℃ 5×11, Electrolytic 1
C6,9 1uF 50V 0603 10%, Ceramic 2
C7 1nF 50V 0805 10%, Ceramic 1
C8,10 1nF 1kV , Ceramic 2
D1 APT360 DO-201, Schottky Diode 1
D2,4,5,6,7 1N4007 R1, Rectifier Diode 5
D3 FR103 DO-41, Fast Recovery Diode 1
R1 12 ohm 1W, surge 2kV , Fuse resistor 1
R2 1R2 1206 1%, resistor 1
R3 1M 0410 5%, resistor 1
R4 75ohm 1206 5% , resistor 1
R6 4.7kohm 0603 1%, resistor 1
R8 5.1M 1206 5%, resistor 1
R9 33ohm 0603 1%, resistor 1
R10 470k 1206 5%, resistor 1
R11 180 ohm 1206 5%, resistor 1
R12 82K 1206 5%, resistor 1
R13 1K ohm 1206 5%, resistor 1
R14 240k 0603 5%, resistor 1
R15 22K 0603 1%, resistor 1
R16 8.2K 0603 1%, resistor 1
L1 470uH 0410 10% Ferrite Core 1
L2 4.7uH 0410 10% Ferrite Core 1
Q1 APT13003E TO-126, Power BJT 1
T1 EE16 5+5 PIN 1.9 mH 8% , Transformer 1
IC1 AP3708N, SOP-8, BCD’s IC 1

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5.2. Transformer specifications

5.2.1. Electrical Diagram

Figure 3. Transformer electrical diagram

5.2.2. Electrical Specifications

Pin 1-2, all other windings open, measured at

Primary Inductance 1.9mH,±8%
1kHz, 0.4VRMS
Primary Leakage Pin1-2,all other windings shorted, measured at
50uH (Max)
Inductance 10kHz, 0.4VRMS

5.2.3. Materials

Item Description
[1] Core:EE16, PC40 or equivalent
[2] Bobbin: EE16, Horizontal, 10 Pin, (5/5)
[3] Wire: ø0.3mm, for internal Wire Shielding Winding

[4] Wire: ø0.14mm, for the Primary winding

[5] Wire: ø0.19mm, for the Auxiliary shielding

[6] Triple Insulated Wire: ø0.4mm for Secondary Winding

[7] Tape: 0.05mm thick, 8.0 mm wide
[8] Margin tape:1mm wide
[9] Glue: DELO DUOPOX_ AD895

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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 placed on
the left hand side, and secondary side o the bobbin is placed on the right hand side.
WD 1 Start at Pin 4. Wind 25 turns of ø0.3mm wire [3] from right to left. Leave the terminal
Wire shielding floating. Wind tightly & spread evenly
Insulation 1 Layers of insulation tape [7], 0.05mm thick, 8.0mm wide.

Margin tape Put 1mm wide tape [8] on both primary and secondary sides.

Start at Pin 2. Wind 39turns of ø0.14mm wire [4] from left to right. Wind another 39turns
WD 2
Primary winding on the next layer from right to left. Wind the last 52 turns from left to right. Finish on Pin
1. Wind tightly & spread evenly
Insulation 1 Layers of insulation tape [7], 0.05mm thick, 8.0mm wide.
WD 3 Start at Pin 3. Wind 13 turns of ø0.19mm*3 wire [5] from right to left. Finish on Pin 5
Auxiliary winding Wind tightly & spread evenly
Insulation 1 Layer of insulation tape [7], 0.05mm thick, 8.0mm wide.
WD4 Start at Pin 5. Wind 13 turns of ø0.19mm*3 wire [5] from right to left. Finish on Pin 4.
Feedback winding Wind tightly & spread evenly
Insulation 2 Layer of insulation tape [7], 0.05mm thick, 8.0mm wide.
WD 5
Start at Pin 10. Wind 13 turns of ø0.4mm Triple Insulated Wire [6] from right to
Secondary
left .Terminate on Pin 6. Wind tightly & spread evenly
winding
Insulation 1 Layers of insulation tape [7], 0.05mm thick, 8.0mm wide.

Glue Glue[9] core and bobbin

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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 R2 should be minimized
for better EMI performance
2. The R-RCD clamp snubber and output rectifier loop areas should be minimized to
achieve good EMI performance
3. The power ground and signal ground should be connected by one node.
4. C4 and C9 should be placed as close as possible to Vcc and VDD pin of the
AP3708N respectively.

Figure 5. Printed circuit layout

7. Electrical performance
All the test results were obtained at room temperature unless otherwise specified, with
50 Hz line voltage and 1.8m AWG24 cable.

7.1. Active mode efficiency

The charger system passes active mode average efficiency criteria of Energy Star EPS
2.0 final version. Since this power supply has nameplate Vo< 6V and nameplate Io> 550mA,

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the active efficiency criteria follows the formula for low voltage mode and can be calculated
as 68.17%.

Table 2. Average active mode efficiency

% of Full Efficiency (%)
Load 115Vac 230Vac
25 70.28 68.04
50 70.13 69.51
75 69.17 69.45
100 68.10 68.94
Average 69.42% 68.99%

7.2. Output I-V and regulation

85Vac
Vout (V)

3 115Vac
230Vac
265Vac
2 Min
Max

0
0.0 0.2 0.4 0.6 0.8 1.0
Iout (A)

Figure 6. Typical CV/CC Characteristic @25℃

The CV regulation is about ±2.6%, and CC regulation is about ±1.8%.

7.3. 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.

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Table 3. No Load Input Power

Input Voltage
Input Power(mW)
(V)

85 49.3
115 56.9
145 67.4
180 82.9
230 112.2
265 139.2

8. Key Operating Waveforms

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

Figure 7. Ripple, 85Vac, Full Load, 4ms, Figure 8. Ripple, 85Vac, Full Load, 40us,
50mV/div, peak-peak: 83mV 50mV/div, peak-peak: 71mV

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Figure 9. Ripple, 265Vac, Full Load, 4ms, Figure 10. Ripple, 265Vac, Full Load, 40us,
50mV/div, peak- peak: 85mV 50mV, peak-peak: 80mV

8.2. Collector voltage of power transistor

Figure 11. Collector voltage, 85Vac, Full Figure 12. Collector voltage 265Vac, Full
Load, 50V, 20us/div, peak voltage: 230Vdc Load, 100V, 20us/div, peak voltage: 518Vdc

8.3. Startup characteristics

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The output loading uses electronic load set at 5ohm in CR mode.

Figure 13. Rise time, 85Vac, Full Load, Figure 14. Rise time, 265Vac, Full Load,
1V, 4ms/div 1V, 4ms/div

8.4. Waveform of schottky

The result was recorded at the condition that output is load is 1A , and the input voltage
is 265Vac.

Figure 15. Reverse voltage of SB360

265Vac, Full Load, 20V, 20us/div, peak voltage: 52Vdc

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9. EMI test results

9.1. Conducted EMI

Figure 16. Conducted EMI, 230VAC/50Hz, full load, Neutral

Figure 17. Conducted EMI, 230VAC/50Hz, full load, Line

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9.2. Radiated EMI

Figure 18. Radiated EMI, Figure 19. Radiated EMI,

230VAC/50Hz, full load, Vertical 230VAC/50Hz, full load, Horizontal

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10. Thermal performance

The thermal performance was measured in a carton when room temperature is 25℃,and after
the power supply had worked for 1 hour under full load condition.

Figure 20. Bottom board Figure 21. Top board

265Vac/50Hz, full load 265Vac/50Hz, full load

Figure 22. Bottom board Figure 23. Top board

90Vac/60Hz, full load 90Vac/60Hz, full load

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11. Summary of test results

Description Min Typ Max Units Tested results

Input

Voltage 85 265 VAC

Frequency 47 50/60 63 Hz
No Load Input Power 150 mW <120@230Vac

Output

Output Voltage 4.75 5.0 5.5 V Pass

Output Ripple Voltage 150 mVpp < 100
Output Current 1.0 1.1 1.2 A Pass
Output Power (Pno) 5 W Pass
Output Voltage rise Time 20 ms Pass
Efficiency

Average Efficiency at
25,50,75 and 100 % of 68.2 % Pass
Pno (EPS 2.0) ---note 1

EMI Pass EN55022 Class B with 6dB margin Pass

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12. Revision history

Description
Versions Date Author Reviewed
for changes

Version 1.0 04/14/2009 Liu Lei Initial release Charles Sun

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