Universal AC input AP3125A

12V/2A,5V/0.2A EV1 Board User Guide

General Description AP3125A universal AC input EV1
Specifications (CV mode)
Based on flyback topology, the AP3125A EV1
board is designed to serve as an example for Parameter Value
cost-effective power solutions suitable for IoT Input Voltage 90 to 265VAC
applications. Rated at 25W power output, Input standby power 0.2 W
AP3125A EV1 board accepts universal AC Main output Vo / Io 12V - 2A
voltage input while delivers 12V@2A and Second output Vos/Ios 5V - 0.2A
5V@0.2A for IoT main functions as well as for Efficiency >85%
IoT connectivity. The AP3125A EV1 meets Total Output Power 25W
DOE VI and CoC Tier 2 energy efficiency Protections OCP, OVP, OLP,OTP
requirement with standby power lower than XYZ Dimension 69 x 42 x 24 mm
0.2W. ROHS Compliance Yes
Key Features
Evaluation Board
 90 ~265VAC input range
 Current mode control & 65KHz operation
switching frequency
 Over 85% Efficiency
 Very low standby input power <0.2W
 Low start-up operating and quiescent
currents
 Soft start during startup process.
 Working at CCM mode when AC input is
lower and at DCM mode when AC input is
higher
 Frequency fold back for high average
efficiency
 Built-in Jittering Frequency
 Soft Switching for Reducing EMI
Figure 1: Top View
 Internal Auto Recovery OCP, OVP, OLP,
OTP Power Protection, cycle by cycle
current limit, also with DC polarity protection

Applications

 Switching AC-DC Adaptor & Charger

 Power home Appliances
 Set-top box power supply
 Open frame switching power supply
 Gaming system

Figure 2: Bottom View

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide

AP3125 (90 VAC ~ 230VAC 2 outputs 25W Transformer Spec.)

1) C o r e & Bobbin: RM8, 6+6 pin

2) Transformer Parameters
1. Primary Inductance (Pin1-Pin6), all other windings are open
Lp = 0.85mH ± 5%@1KHz

3) Transformer Winding Construction Diagram

Item Windings Winding Specification

1 WD1-Primary Winding Start from Pin 1, 28# AWG*1, 26Ts Two layers, end at Pin 2.
2 Insulation 1 Layer of insulation tape

3 Shielding Winding Start from Pin 4, 34# AWG*2 with full layer winding, end flowing wire.

4 Insulation 1 Layer of insulation tape

5 WD2 Aux Winding Start from Pin 5, 32# AWG x2, 11TsT one layers, end at Pin 4.
6 Insulation 2 Layers of insulation tape
WD3 NS1 Secondary Start from FL1 with white tube, triple of insulation 26# AWG*2, 8Ts, one layer,
7
Winding end fold back to top side with black tube.
WD4 NS2 Secondary Start from FL3, triple of insulation 32# AWG*2, 4Ts, one layer, end fold back
8
Winding to top side with FL4 with black tube.
9 Insulation 2 Layers of insulation tape
10 WD5-Primary Winding Start from Pin 2, 28# AWG*1, 26Ts, Two layers, end at Pin 6.
11 Insulation 2 Layers of insulation tape

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide
Evaluation Board Schematic

Figure 3: Evaluation Board Schematic

Evaluation Board Layout

Figure 4: PCB Board Layout Top View Figure5: PCB Board Layout Bottom View

Quick Start Guide

1. The evaluation board is preset at 12V/2A from TH1 ~TH3 & 5V/0.2A from TH2~TH3
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 left side of the board.
4. Turn on the AC main switch.
5. Measure TH1~TH3 and TH2~TH3 to ensure correct output voltages at 12V and 5V, respectively.

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide
Build of Material:
Item Qty Reference AP3125A EV1 08-05-2016 Size Company
1 1 C1 68µF/400V, AL Cap 16 * 25mm Wurth

2 1 C2 6.8µF/25V, Ceramic Cap X7R, ±10%, SMD0805 X7R, ±10%

3 1 C4 680µF/16V, Polymer Cap 10 * 13mm Wurth

4 1 C3 220µF/16V, AL Cap 8 * 11mm Wurth

5 1 C6 10µF/50V, AL Cap 5 * 11mm Wurth

6 1 C7 2.2nF/50V X7R, ±10%, 0805 Wurth

7 1 C8 0.1µF/50V X7R, ±10%, 0805 Wurth

8 1 C9 180pF/50V X7R, ±10%, 0805 Wurth

9 1 C10 & C11 2.2nF/500V X7R, ±10%, 1206

10 1 C13 0.1µF/50V X7R, ±10%, 0805 Wurth

11 1 C14 NULL

12 1 C15 & C16 10µF/16V, SMDCap Y5U, ±10%, SMD0805

13 1 C17 33pF NPO, ±10%, SMD0805

14 1 R1 & R2 NULL

15 1 R3 & R4 1M ohm SMD 1206

16 1 R5 & R6 NULL

17 1 R7 10Ω ±5%, SMD0805

18 1 R8 20Ω ±5%, SMD0805

19 1 R9 33Ω ±5%, SMD0805

20 1 R10 10KΩ ±5%, SMD0603

21 1 R11 NULL ±5%, SMD0805

22 1 R12 6.8KΩ ±5%, SMD0805

23 1 R12A/B/C 2.2Ω / 2.2Ω/ 2.2Ω ±1%, SMD1206

24 1 R13 270KΩ ±5%, SMD1206

25 1 R14 33Ω ±5%, SMD1206

26 2 R15A/B 300KΩ ±5%, SMD1206

27 1 R17 680Ω ±5%, SMD0805

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide

28 1 R18 5.6KΩ ±5%, SMD0805

29 1 R19 562KΩ , 5% 1%, SMD0805

30 1 R20 10KΩ ±5%, SMD0805

31 1 R21 10.5KΩ, 1% ±1%, SMD0805

32 1 R22 41.2KΩ, 1% ±1%, SMD0805

33 1 RT2 100KΩ ±5%, SMD0805

34 1 Q1 MOSFET, DMG9N65CT TO220F Diodes

35 1 IC1 PWM, AP3125AK, SOT23-6 Diodes

36 1 IC2 Opto PC817C, DIP

37 1 IC3 AZ431, SOT-23 SMD Diodes

38 1 T1 RM8, 850µH

39 1 BD1 Bridge, KBP206G, 2A-600V DIP Diodes

40 1 D1 1N4007, 1A, 1,000V DIP Diodes

41 1 D2 S1M, 1A, 1,000V SMD Diodes

42 1 D3, D12 1N4148WS, 75V, SOD323 SMD Diodes

43 1 D13 Schottky, ST10100, TO220-2 DIP

44 1 D14 SBRB1100 1A, 100V, DOS123 SMD Diodes

45 1 LF1 11mH 0.9A COM chock DIP Wurth

46 1 L1 & L2 L1 = 4.7µH , L2 shorted DIP

47 1 NTC Shorted

48 1 CY1 1000pF/Ycap DIP 250V/Y1

49 1 Xcap 0.1µF/Xcap DIP 275/X1 305Vac

50 1 Mov 14D471 DIP

51 1 F1 Fuse 2A/250V DIP Slow

52 1 JP1 Terminal Block 2P DIP

53 2 JP2 Terminal Block 3P DIP

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 Universal AC input AP3125A
12V/2A,5V/0.2A EV1 Board User Guide
Input & Output Characteristics
Input Standby Power

Input Voltage 115Vac/60Hz 230Vac/50Hz Note

Pin (w) 78mW 154mW No loading

Input power Efficiency at different loading

Efficiency (%) Eff_avg at four
AC input
10% 25% 50% 75% 100% conditions
90VAC/60Hz 85,2%
115VAC/60Hz 82.9% 86.9% 87.4% 86.6% 86.5% 86.8%
230VAC/50Hz 78.8% 88.0% 87.1% 87.2% 87.3% 87.4%
264VAC/50Hz 87.5%
Eff_avg

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

AC input Voltage 90VAC/60Hz 115VAC/60Hz 230VAC/50Hz 264VAC/50Hz Note

5.00Vo 5.52V/0.2A 5.50V/0.2A 5.52V/0.2A 5.52V/0.2A 0.5%<

outputs
12.00Vo 12.01V/2A 12.01V/2A 12.02V/2A 12.01V/2A 0.5%<

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

Loading 12V= FL & 5V=10%FL 12V=10% FL & 5V= FL

conditions
12V/2A & 5V/0.02A 12V/0.2A & 5V /0.2A

115VAC 12.04V / 2A + 5.708V/0.02A 12.13V/0.2A + 4.94V/0.2A

230VAC 12.04V /2A + 5.714V/0.02A 12.13V/0.2A + 4.94V/0.2A

Current setting with at different AC line

AC input 90VAC 115VAC 230VAC 264VAC Note

I _max 2.67A 2.69A 2.73A 2.78A

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

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide

Key Performance Waveforms:

Fig:6 Vds at full load by using DF probe 1:100 at 115VAC Fig:7 Vds at full load by using DF probe 1:100 at 230VAC

Fig:8 Vds at full load using DF probe 1:100 at 265VAC Fig:9 Vcs at 90VACin at FL

Fig:10 Vcs at 115VACin at FL Fig:11 Vcs at 264VACin at FL

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide

Fig:12 Turn on VAC_in, IAC_in, 12Vo at 115Vac at FL Fig:13 Turn on VAC_in, IAC_in, 12Vo at 230Vac at FL

Output Performance Waveforms

All of the 12V ripple by using a 1:1 Probe in a 100mV/division.

Figure:14 12V Ripple at 115Vac at FL . Figure:15 12V Ripple at 230Vac at FL

Figure:16 5Vo Ripple at 115Vac at FL Figure:17 5V Ripple at 230Vac at FL

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide

Please see the recommand Application note for reference (Web page -
http://www.diodes.com/appnote_dnote.html)
1) For AP3125 operation & set up, please review the Application note:
Application note 1120 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

Thermal Test data at room Temperature after running 1 hr

Figure:18 SMD components UP side Figure:19 SMD side Vin=115VAC, Test time=1hour

Figure:20 Board Top components side Figure:21 Vin=115VAC, Testing time = 1.15 hour

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 Universal AC input AP3125A
12V/2A , 5V/0.2A EV1 Board User Guide

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