Application Note 1028

Basic Steps to Design a PSR Flyback Converter Using AP3706/08N

Prepared by Su Qinghua and Dong Wenhui
System Engineering Department

Introduction Vdri is a simplified driving signal of primary transis-

AP3706/08N uses Pulse Frequency Modulation
(PFM) method to realize Discontinuous Conduction
Mode (DCM) operation for flyback power supplies;
uses Primary Side Regulation (PSR) to provide Con-
stant Voltage (CV) and Constant Current (CC) regula-
tion. The principle of PFM is different from that of
Pulse Width Modulation (PWM), so the design steps of
the transformer for PFM operation is also different
from that for PWM operation. In the other side,
AP3706/08N uses PSR to provide CV/CC regulation
without requiring opto-coupler and loop compensa-
tion, which makes the design of transformer more crit-
ical than that with PWM. The following design steps
focus on the transformer design. Some design guides
to select diodes and transistor are also included.
Figure 1 is a simplified flyback converter controlled
by AP3706 with a 3-winding transformer: Primary
winding (NP), Secondary winding (NS) and Auxiliary
winding (NAUX). The AP3706 senses the Auxiliary
winding feedback voltage at FB pin and obtains power
supply at VCC pin. In the circuit:
tor.
IP is the primary side current.
IS is the secondary side current.
VS is the voltage of secondary side.
Figure 2 shows the relatively ideal operation wave-
forms to illustrate some parameters used in the follow-
ing design steps. The nomenclature of the parameters
in Figure 2 are listed as below:
TSW is the period of switching frequency
Tonp is the time of primary side “ON”
Tons is the time of secondary side “ON”
Toff is the discontinuous time
Ipk is the peak current of primary side
Ipks is the peak current of secondary side
VS equals the sum of VO and forward voltage of recti-
fication diode
The only difference between AP3706 and AP3708N
is cable compensation. AP3708N has built-in it, while
AP3706 has not. Their design steps are quite similar.

Vg VS Vd IO
+ -
VIN +
+ IS +
NP NS
VO
+
LM LS
-
Vdri VAux
VCC
CS OUT NAux

AP3706 iP
BIAS FB

GND COMP VDD

RCS

Figure 1. Simplified Flyback Converter Using AP3706

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 Application Note 1028

Figure 2. Ideal Operation Waveforms for a Simplified Flyback Converter

Basic Design Step

LM
Tonp = Ipk ×
Step 1: Select a Reasonable Ipk of Fly- Vg
back Converter Using AP3706/08N
where
LM is the inductance of primary winding.
1-1. Calculate the Maximum Turn Ratio of the
Transformer Vg is the rectified DC voltage of input.
The maximum turn ration of the transformer should
be calculated first to ensure the system working in When Vg is at the minimum value, the maximum
DCM under all working conditions, especially at the Tonp can be obtained. So,
minimum input voltage and full load.
LM ......(2)
Tonp _ max = Ipk ×
If the system meets equation (1) at minimum input Vg _ min
voltage and full load, the circuit can work in DCM in
all working conditions. For the secondary side current,

......(1) LS ......(3)
TSW ≥ Tonp + Tons Tons = Ipks ×
VS
For the primary side current,
where

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 Application Note 1028
LS is the inductance of secondary winding.
VO × I O ......(9)
VS=VO+Vd, Vd is the forward voltage of secondary PIN =
η
diode.

For (3), in CV regulation, the VS is a constant where η is the system efficiency.

voltage, so Tons is a constant value with different
At the full load, the system will work in the
input voltage.
boundary of CC regulation. IO is determined by:
In Flyback converter, the energy stored in the 1 Tons
magnetizing inductance LM when the primary IO = × × Ipks
2 TSW
transistor turns ON. So the power transferring from
the input to the output is given by:
Then, Ipks can be defined as:
1
PI N = × LM × Ipk 2 × f SW ......(4)
2 Ipks = k × I O ......(10)
then,
In the design of AP3706/08N,
1 LM × Ipk 2 2 × TSW
TSW = = k= = 3 .5
f SW 2 × PIN Tons
Substitute TSW, Tonp and Tons in equation (1) with
With (8), (9) and (10), it can be obtained:
(4), (2) and (3):
k ×η 1
N PS ≤Vg _ min× ( − ) ......(11)
2 × VO VS
LM × Ipk 2
L LM
≥Ipks × S + Ipk ×
2 × PIN Vs Vg _ min So, the maximum turn ration of primary and
secondary side can be obtained:
......(5)
k ×η 1
Because the peak current and inductance of primary N PS _ MAX = Vg _ min× ( − )
2 × VO VO + Vd
side and secondary side have the following
(k ≈4)
relationship:
......(12)
Ipks = N PS × Ipk ......(6)
Because above calculations are all based on ideal
conditions without considering power loss, k is given
here, NPS=NP/NS is the turn ratio of primary to an approximately value 4 instead of the real value 3.5.
secondary sides, then
1-2. Calculate the Peak Current of Primary
L
LS = M2
......(7) Side and Current Sense Resistor
N PS Ipk can be calculated by the output current:

From (5), (6) and (7): Ipks k × IO

Ipk = = ......(13)
N PS _ MAX N PS _ MAX
Ipk
≥
1
+
1 ......(8)
2 × PIN VS × N PS Vg here, k=4.

In AP3706/08N, 0.5V is an internal reference

Because voltage. If the sensed voltage VCS reaches to 0.5V, the

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 Application Note 1028
power transistor (APT13003 for this application) will The turns of primary winding is:
be shut down and Tonp will be ended. So, RCS can be
calculated as: LM × Ipk ×108 ......(18)
NP =
Ae × ∆B
RCS =
0.5V ......(14)
Ipk The turns of secondary winding is:

NP
Then, select RCS with a real value from the standard NS = ......(19)
N PS
resistor series. After RCS determined, Ipk should be
modified according to the selected RCS.
The turns of Auxiliary winding is:

Step 2: Design Transformer N S × VAUX

N AUX = ......(20)
VS
2-1. Calculate the Inductance of Primary Side-
--LM here,
The primary side inductance LM is relative with the VAUX can be set to its typical value 15V.
stored energy. LM should be big enough to store Vs is equal to VO+Vd.
enough energy, so that PO_max can be obtained from Ae can be obtained automatically after core-type is
this system. selected.

From equation (9), the output power can be

obtained from: Step 3: Select Diode and Primary
1
Transistor
PO = × LM × Ipk 2 × f SW ×η ......(15)
2
3-1. Select Diodes of Secondary and Auxiliary
Sides
Then, LM is: Maximum reverse voltage of secondary side is:

2 × PO Vg _ max× N S
LM = Vdr = VO + ......(21)
Ipk × f SW ×η
2
......(16) NP

To achieve good overall system performance, the Maximum reverse voltage of Auxiliary side is:
optimum switching frequency fSW is recommended to
Vg _ max× N AUX
be 50 to 60kHz under full load. Vdar = VAUX + ......(22)
NP
2-2. Re-calculate the Turn Ratio of Primary to
Secondary Side---NPS
VS × N P
From formula (13), the turn ratio of primary and Vdc _ max = Vdc _ spike + Vg _ max +
NS
secondary side NPS should be re-calculated.
......(23)
k × IO In (21) and (22), the maximum DC input voltage
N PS = (k ≈4) ......(17)
Ipk should be used.

2-3. Calculate the Turns of Primary,

Secondary and Auxiliary Windings 3-2. Select the Primary Side Transistor
First, select the reasonable core-type and ∆B . Then, It should be noted that the value of Vdc_spike will
decide the turns of 3-winding transformer be different in circuits with different snubber.
respectively.

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 Application Note 1028
Design Example
0.5V ......(14)
RCS =
Ipk
Design Specification
RCS ≈ 2.1Ω
Input Voltage 85 to 265 VAC
Output Voltage VO=5.5V Re-calculate peak current of primary side,
Output Current IO=0.5A Ipk = 238mA
Efficiency 75%
Step 2: Design Transformer
Settings Selected by Users
2-1. Calculate the Inductance of Primary Side-
Switching Frequency fSW=55kHz --LM
Forward Voltage of Secondary
Vd=0.4V
Diode 2 × PO
LM = ......(16)
Forward Voltage of Auxiliary Diode Vda=1V Ipk 2 × f SW ×η
Feedback Voltage of Auxiliary
VAUX=15V
Winding LM = 2.35mH
EE16
Core_type
(Ae=19.2mm2) 2-2. Re-calculate the Turn Ratio of Primary to
Secondary Side---NPS
∆B ∆B=2850GS
Vdc_spike 200V
k × IO ......(17)
N PS = (k ≈4)
Ipk

Design Step N PS = 8.4

Step 1: Select a Reasonable Ipk for 2-3. Calculate the Turns of Primary,
the Flyback Converter Using AP3706 Secondary and Auxiliary Windings

1-1. Calculate the Maximum Turn Ratio of the LM × Ipk ×108

NP = ......(18)
Transformer Ae × ∆B

k ×η 1 N P = 102T
N PS _ MAX = Vg _ min× ( − ) ......(12)
2 × Vo Vo + Vd
(k ≈4) NP ......(19)
NS =
N PS
Vg _ min = VIN _ min× 2 − 40
N S = 12T
N PS _ MAX = 8.259
N S × VAUX ......(20)
N AUX =
1-2. Calculate the Peak Current of Primary VS
Side and Current Sense Resistor
N AUX = 31T
Ipks k × IO ......(13)
Ipk = =
N PS _ MAX N PS _ MAX

Ipk = 242mA

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 Application Note 1028
Step 3: Select Diode and Primary Maximum reverse voltage of secondary side.
Transistor Vg _ max × N AUX
Vdar = V AUX + ......(22)
NP
3-1. Select Diodes of Secondary and Auxiliary
Sides
Maximum reverse voltage of secondary side. Vdar = 129V

Vg _ max× N S 3-2. Select the Primary Side Transistor

Vdr = VO + ......(21)
NP
VS × N P
Vdc _ max = Vdc _ spike + Vg _ max + ......(23)
Vg _ max = VIN _ max× 2 NS

Vdr = 50V Vdc _ max = 625V

Design Results Summary

1. Calculate the Maximum Peak Current of Primary Side and RCS

Peak Current of Primary Side Ipk=238mA
Current Sense Resistor RCS=2.1Ω

2. Design Transformer
Inductance of Primary Side LM=2.35mH(+/-8%)
Turn Ratio of Primary to Secondary Windings NPS=8.4
Turns of Primary Side NP=102T
Turns of Secondary Side NS=12T
Turns of Auxiliary Side NAUX=31T

3. Select Diode and Primary Transistor

Maximum Reverse Voltage of Secondary Diode Vdr=50V
Maximum Reverse Voltage of Auxiliary Diode Vdar=129V
Voltage Stress of Primary Transistor Vdc_max=625V

Sep. 2009 Rev. 1.1 BCD Semiconductor Manufacturing Limited