ACT512 - Active-Semi

ACT512
Rev 4, 13-Feb-14
ActiveQRTM Quasi-Resonant PWM Controller
ACT512 integrates comprehensive protection. In
case of over temperature, over voltage, winding
short, current sense resistor short, open loop and
overload conditions, it would enter into auto restart
mode including Cycle-by-Cycle current limiting.
FEATURES
• CCM and Quasi-Resonant Operation
• Adjustable up to 75kHz Switching Frequency
• OCP/OLP Protection
• Integrated Patented Frequency Foldback
ACT512 is to achieve no overshoot and very short
rise time even with a big capacitive load with the
built-in fast and soft start process.
Technique
• Integrated Patented Line Compensation
• Built-in Soft-Start Circuit
• Line Under-Voltage, Thermal, Output OverCurrent Sense Resistor Short Protection
In full load condition, ACT512 is able to be
designed to work in both CCM mode and DCM
mode to meet different types of applications. QuasiResonant (QR) operation mode can improve
efficiency during DCM operation, and reduce EMI
and further reduce the components in input filter.
Transformer Winding Short Protection
ACT512 is ideal for applications up to 60 Watts.
100mW Standby Power
Figure 1:
Complies with Global Energy Efficiency and
CEC Average Efficiency Standards
Simplified Application Circuit
voltage, Output Short Protections
•
•
•
•
• Tiny SOT23-6 Packages
APPLICATIONS
• AC/DC Adaptors/Chargers for Cell Phones,
Cordless Phone, PDAs, E-books
• Adaptors for Portable Media Player, DSCs,
Set-top boxes, DVD players, records
• Linear Adapter Replacements
GENERAL DESCRIPTION
The ACT512 is a high performance peak current
mode PWM controller. ACT512 applies ActiveQRTM
and frequency foldback technique to reduce EMI
and improve efficiency. ACT512’s maximum design
switching frequency is set at 75kHz. Very low
standby power, good dynamic response and
accurate voltage regulation is achieved with an
opto-coupler and the secondary side control circuit.
The idle mode operation enables low standby
power of 100mW with small output voltage ripple.
By applying frequency foldback and ActiveQRTM
technology, ACT512 increases the average system
efficiency compared to conventional solutions and
exceeds the latest ES2.0 efficiency standard with
good margin.
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Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
ORDERING INFORMATION
PART NUMBER
TEMPERATURE RANGE
PACKAGE
PINS
PACKING
METHOD
ACT512US-T
-40°C to 85°C
SOT23-6
6
TUBE & REEL
TOP MARK
FSHT
PIN CONFIGURATION
SOT23-6
ACT512US
PIN DESCRIPTIONS
PIN
NAME
DESCRIPTION
1
CS
2
GND
Ground.
3
GATE
Gate Drive. Gate driver for the external MOSFET transistor.
4
VDD
Power Supply. This pin provides bias power for the IC during startup and steady state operation.
5
VDET
Valley Detector Pin. Connect this pin to a resistor divider network from the auxiliary winding to
detect zero-crossing points for valley turn on operation.
6
FB
Current Sense Pin. Connect an external resistor (RCS) between this pin and ground to set peak
current limit for the primary switch.
Feedback Pin. Connect this pin to optocouplers’s collector for output regulation.
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ACT512
Rev 4, 13-Feb-14
ABSOLUTE MAXIMUM RATINGSc
PARAMETER
VALUE
UNIT
FB, CS, VDET to GND
-0.3 to + 6
V
VDD, GATE to GND
-0.3 to + 28
V
0.45
W
-40 to 150
˚C
220
˚C/W
-55 to 150
˚C
300
˚C
Maximum Power Dissipation (SOT23-6)
Operating Junction Temperature
Junction to Ambient Thermal Resistance (θJA)
Storage Temperature
Lead Temperature (Soldering, 10 sec)
c: Do not exceed these limits to prevent damage to the device. Exposure to absolute maximum rating conditions for long periods.
ELECTRICAL CHARACTERISTICS
(VDD = 14V, LM = 0.8mH, RCS = 0.87Ω, VOUT = 12V, NP = 56, NS =9, NA =10, TA = 25°C, unless otherwise specified.)
PARAMETER
SYMBOL
TEST CONDITIONS
MIN
TYP
MAX
UNIT
Supply
VDD Turn-On Voltage
VDDON
VDD Rising from 0V
11.3
12.3
13.3
V
VDD Turn-Off Voltage
VDDOFF
VDD Falling after Turn-on
6.7
7.4
8.1
V
VDD Over Voltage Protection
VDDOVP
VDD Rising from 0V
25
VDD = 10V, before VDD Turn-on
8
Start Up Supply Current
IDDST
IDD Supply Current
IDD
V
15
µA
VDD = 15V, after VDD Turn-on ,FB
floating
0.6
mA
IDD Supply Current at Standby
IDDSTBY
FB = 1.3V
0.4
mA
IDD Supply Current at Fault
IDDFAULT
Fault mode, FB Floating
250
µA
Feedback
FB Pull up Resistor
RFB
15
kΩ
CS to FB Gain
ACS
3
V/V
3 + VBE
V
VFB at Max Peak Current
FB Threshold to Stop Switching
VFBBM1
1.32
V
FB Threshold to Start Switching
VFBBM2
1.41
V
4.2
V
320
ms
Output Overload Threshold
OverLoad/Over Voltage Blanking
Time
TOVBLANK
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ACT512
Rev 4, 13-Feb-14
ELECTRICAL CHARACTERISTICS CONT’D
(VDD = 14V, LM = 0.8mH, RCS = 0.87Ω, VOUT = 12V, NP = 54, NS = 9, NA = 10, TA = 25°C, unless otherwise specified.)
PARAMETER
SYMBOL
TEST CONDITIONS
MIN
TYP
MAX
UNIT
VCSLIM
0.91
0.96
1.01
V
TCSBLANK
240
300
360
ns
Current Limit
CS Current Limit Threshold
Leading Edge Blanking Time
GATE DRIVE
Gate Rise Time
TRISE
VDD = 10V, CL = 1nF
150
250
ns
Gate Falling Time
TFALL
VDD = 10V, CL = 1nF
115
200
ns
Gate Low Level ON-Resistance
RONLO
ISINK = 30mA
7
Ω
Gate High Level ON-Resistance
RONHI
ISOURCE = 30mA
40
Ω
GATE = 25V, before VDD
turn-on
Gate Leakage Current
1
µA
Oscillator
Maximum Switching Frequency
fMAX
Switching Frequency Foldback
fMIN
75
kHz
fMAX/3
kHz
75
%
100
mV
3.5
µs
1
µA
2
µs
CS Short Detection Threshold
0.115
V
CS Open Threshold Voltage
1.73
V
Abnormal OCP Blanking Time
150
ns
Thermal Shutdown Temperature
135
˚C
Maximum Duty Cycle
FB = 2.3V+VBE
DMAX
65
Valley Detection
ZCD Threshold Voltage
VDETTH
After valley detection time
window, if no valley detected, forcedly turn-on
main switch
Valley Detection Time Window
VDET Leakage Current
Protection
CS Short Waiting Time
Line UVLO
IVDETUVLO
0.1
mA
Line OVP
IVDETOVP
2
mA
VDET Over Voltage Protection
VDETVOOVP
2.448
2.72
2.992
V
VDET Vo Short Threshold
VDETVOshort
0.406
0.58
0.754
V
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ACT512
Rev 4, 13-Feb-14
FUNCTIONAL BLOCK DIAGRAM
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Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
FUNCTIONAL DESCRIPTION
switching. After it stops, as a result of a feedback
reaction, the feedback voltage increases. When the
feedback voltage reaches VFBBM2, ACT512 start
switching again. Feedback voltage drops again and
output voltage starts to bounds back and forward
with very small output ripple. ACT512 leaves idle
mode when load is added strong enough to pull
feedback voltage exceed VFBBM2.
ACT512 is a high performance peak current mode
low-voltage PWM controller IC. The controller
includes the most advance features that are
required in the adaptor applications up to 60 Watt.
Unique fast startup, frequency foldback, QR
switching technique, accurate peak current line
compensation, idle mode, short winding protection,
OCP, OTP, OVP and UVLO are included in the
controller.
Figure 2:
Idle Mode
Startup
Startup current of ACT512 is designed to be very
low so that VDD could be charged to VDDON
threshold level and device starts up quickly. A large
value startup resistor can therefore be used to
minimize the power loss yet reliable startup in
application. For a typical AC/DC adaptor with
universal input range design, two 1MΩ, 1/8 W
startup resistors could be used together with a VDD
capacitor(4.7uF) to provide a fast startup and yet
low power dissipation design solution.
During startup period, the IC begins to operate with
minimum Ippk to minimize the switching stresses
for the main switch, output diode and transformers.
And then, the IC operates at maximum power
output to achieve fast rise time. After this, VOUT
reaches about 90% VOUT , the IC operates with a
‘soft-landing’ mode(decrease Ippk) to avoid output
overshoot.
Vo 12V
Io
2A
0A
Vfb
Vfb_olp
Vfb_fl
Vfbbm2
Vfbbm1
Ip Ilim
Ip_FL
t
Primary Inductor Current Limit
Compensation
The ACT512 integrates a primary inductor peak
current limit compensation circuit to achieve
constant OLP over wide line and wide inductance.
Constant Voltage (CV) Mode Operation
Frequency Foldback
In constant voltage operation, the ACT512
regulates its output voltage through secondary side
control circuit . The output voltage information is
sensed at FB pin through OPTO coupling. The error
signal at FB pin is amplified through TL431 and
OPTO circuit. When the secondary output voltage is
above regulation, the error amplifier output voltage
decreases to reduce the switch current. When the
secondary output voltage is below regulation, the
error amplifier output voltage increases to ramp up
the switch current to bring the secondary output
back to regulation. The output regulation voltage is
determined by the following relationship:
When the load drops to 75% of full load level,
ACT512 starts to reduce the switching frequency,
which is proportional to the load current ,to improve
the efficiency of the converter.
VOUTCV
R
= VREF _ TL 431 × (1 + F 1 )
RF 2
ACT512’s load adaptive switching frequency
enables applications to meet all latest green energy
standards. The actual minimum average switching
frequency is programmable with output
capacitance, feedback circuit and dummy load
(while still meeting standby power).
Valley Switching
ACT512 employed valley switching from no load to
heavy load to reduce switching loss and EMI. In
discontinuous mode operation, the resonant voltage
between inductance and parasitic capacitance on
MOSFET source pin is coupled by auxiliary winding
and reflected on VDET pin through feedback
network R5, R6. Internally, the VDET pin is
connected to an zero-crossing detector to generate
the switch turn on signal when the conditions are
met.
(1)
where RF1 (R15) and RF2 (R16) are top and bottom
feedback resistor of the TL431.
No Load Idle Mode
In no load standby mode, the feedback voltage falls
below VFBBM2 and reaches VFBBM1, ACT512 stop
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Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
FUNCTIONAL DESCRIPTION CONT’D
Figure 3:
Valley Switching
V
Vdrain_gnd
DC voltage
Possible Valley turn on
Ton
t
T
Protection Features
The ACT512 provides full protection functions. The
following table summarizes all protection functions.
Auto-Restart Operation
ACT512 will enter into auto-restart mode when a
fault is identified. There is a startup phase in the
auto-restart mode. After this startup phase the
conditions are checked whether the failure is still
present. Normal operation proceeds once the
failure mode is removed. Otherwise, new startup
phase will be initiated again.
To reduce the power loss during fault mode, the
startup delay control is implemented. The startup
delay time increases over lines.
PROTECTION
FUNCTIONS
FAILURE
CONDITION
PROTECTION
MODE
VDD Over Voltage
VDD > 25V
(4 duty cycle)
Auto Restart
VVDET Over Voltage/No Voltage
VVD > 2.72V or
No switching
for 4 cycles
Auto Restart
Over Temperature
T > 135˚C
Auto Restart
Short Winding/
Short Diode
Over Load/Open
Loop
Output Short
Circuit
VDD Under Voltage
VCS > 1.72V
Auto Restart
IPK = ILIMIT or
VFB = 3.5V + VBE
for 320ms
Auto Restart
VDET < 0.58V
Auto Restart
VDD < 7.4V
Auto Restart
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ACT512
Rev 4, 13-Feb-14
TYPICAL APPLICATION
Where ŋ is the estimated circuit efficiency, fL is the
line frequency, tC is the estimated rectifier
conduction time, CIN is empirically selected to be
47µF electrolytic capacitors.
Design Example
The design example below gives the procedure for
12V/2A flyback converter using ACT512. Refer to
application circuit Figure 4, the design for an
adapter application starts with the following
specification:
Input Voltage Range
The maximum duty cycle is set to be 45% at low
line voltage 90VAC and the circuit efficiency is
estimated to be 86%. Then in CCM the primary to
secondary turn ratio NP/NS:
90VAC - 265VAC, 50/60Hz
× V IN
Output Power, PO
24W
Np
Output Voltage, VOUTCV
12V
Ns
Full Load Current, IOUTFL
2A
0 . 45 × 90
=
= 6 . 136
( 1 − 0 . 45 ) × 12
OCP Current, IOUTMAX
2.3-2.6A
System Efficiency CV, η
0.86
V INDC
=
_ MIN
2 × 90
V IN ( MAX
=
) DC
Np ≥
2
2 V INAC
_ MIN
_ max
( 1 − D CCM
_ max
_ min
) × Vo
(4)
fmax
V in _ min × DCCM _ max × 10 8
× Δ B max × Ae min ( gaus × cm 2 )
90 × 0 . 45 × 10 8
= 42 T
=
75000 × 2500 × 0 . 51
(5)
VDD voltage is set to 13V, base on the data we can
get primary, secondly and auxiliary turns:
N A Vdd + Vd _ aux
13 + 0.7
=
=
= 1 .1
Ns
Vo + Vd _ sec
12 + 0.45
(6)
Np = 56T , Ns = 9T , Na = 10T
(7)
We set DCM/CCM boundary is 185Vac,then the
duty at full load is:
DCCM =
=
Vo × N p
VINDC × N s + Vo × N p
(8)
12 × 56
= 0.22
185 × 1 .414 × 9 + 12 × 56
The peak current of primary is:
I ppk =
2 × Vo × Io
Vin × DDCM × η
(9)
2 × 12 × 2
= 0 .97 A
=
185 × 1.414 × 0.22 × 0.86
The primary inductance is:
2 POUT (
=
D CCM
EF25 core is selected for the transformer. The core
minimum Ae is 0.51cm^2. The minimum turn of the
primary winding is:
The operation for the circuit shown in Figure 4 is as
follows: the rectifier bridge D1−D4 and the capacitor
C1/C2 convert the AC line voltage to DC bus
voltage. This voltage supplies the primary winding
of the transformer T1 and the startup circuit of R7/
R8 and C4 to VDD pin of ACT512. The primary
power current path is formed by the transformer’s
primary winding, Q1, and the current sense resistor
R9. The resistors R3, R2, diode D5 and capacitor
C3 create a snubber clamping network that protects
Q1 from damage due to high voltage spike during
Q1’s turn off. The network consisting of capacitor
C4, diode D6 and resistor R4 provides a VDD
supply voltage for ACT512 from the auxiliary
winding of the transformer. The resistor R4 is
optional, which filters out spikes and noise to makes
VDD more stable. C4 is the decoupling capacitor of
the supply voltage and energy storage component
for startup. During power startup, the current
charges C4 through startup resistor R7/R8 from the
rectified bus voltage. The diode D8 and the
capacitor C5/L2/C6 rectify filter the output voltage.
The resistor divider consists of R15 and R16
programs the output voltage.
Since a bridge
rectifier and bulk input capacitors are used, the
resulting minimum and maximum DC input voltages
can be calculated:
1
- tC )
2 fL
η × C IN
=
Lm =
(2)
Vindc × Duty 185 ×1.414 × 0.22
=
= 0.8mH
Ippk × fsw
0.97 ×75000
(10)
1
- 3 . 5 ms )
2 × 47
≈90 V
0 . 86 × 47 μ F
2 × 24 × (
2
=
-
2 × V IN ( MAX
) AC
2 × ( 265 V AC ) = 375 V
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Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
TYPICAL APPLICATION CONT’D
ground lead, and the ACT512 GND pin to a single
point (star ground configuration).
Determining the value of the current sense resistor
(R7) uses the maximum current in the design. So
the input primary maximum current at maximum
load:
I p _ OCP =
2 × IOUT _ OCP × VOUT
=
LP × fsw × η
2 × 2.6 × 12
= 1.1 A (11)
0.8 × 75 × 0.86
Since the ACT512 internal current limit is set to
0.96V, the design of the current sense resistor is
given by:
RCS =
VCS
0 .96
=
≈ 0 .87 Ω
I p _ OCP
1 .1
(12)
The voltage feedback resistors are selected
according to the design. Because the line UVLO is
75VDC, the upper feedback resistor is given by:
R FB
_ UP
= V INDC
_ UVLO
×
NA
N p × I FB _ UVLO
(13)
60 × 10
=
≈ 54 . 9 k Ω
56 × 0 . 2 mA
The lower feedback resistor is selected as:
R FB _ LOW =
=
V FB
( VOUT + VD )
NA
- VFB
NS
R FB _ UP
(14)
2 .2
× 54 . 9 k Ω ≈ 11 . 7 k Ω
( 12 + 0 . 45 ) × 1 . 1 - 2 . 2
When selecting the output capacitor, a low ESR
electrolytic capacitor is recommended to minimize
ripple from the current ripple. The approximate
equation for the output capacitance value is given
by:
COUT =
IOUT
2
=
= 533 μF
fsw × V RIPPLE 75 k × 50 mV
(15)
Two 680µF electrolytic capacitors are used to
further reduce the output ripple.
PCB Layout Guideline
Good PCB layout is critical to have optimal
performance. Decoupling capacitor (C4) and
feedback resistor (R5/R6) should be placed close to
VDD and FB pin respectively. There are two main
power path loops. One is formed by C1/C2, primary
winding, mosfet transistor and current sense
resistor (R9). The other is secondary winding,
rectifier D8 and output capacitors (C5/C6). Keep
these loop areas as small as possible. Connecting
high current ground returns, the input capacitor
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ACT512
Rev 4, 13-Feb-14
Figure 4:
Universal VAC Input, 12V/2A Output Adaptor
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Active-Semi Proprietary―For Authorized Recipients and Customers
ActiveQRTM is a trademark of Active-Semi.
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Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
Table 1:
ACT512 12V24W Bill of Materials
ITEM REFERENCE
DESCRIPTION
QTY
MANUFACTURER
1
U1
IC, ACT512, SOT23-6
1
Active-Semi
2
C1
Capacitor, Electrolytic, 47µF/400V, 16 × 14mm
1
KSC
3
C3
Capacitor, Ceramic,1000pF/500V,0805,SMD
1
POE
4
C4
Capacitor, Electrolytic, 4.7µF/35V, 5 × 11mm
1
KSC
5
C5,C6
Capacitor, Electrolytic, 680µF/25V, 10 × 11.5mm
2
KSC
6
C8
Capacitor, Ceramic, 0.1µF/50V,0805,SMD
1
POE
7
C9
Capacitor, Ceramic,1000pF/100V,0805,SMD
1
POE
8
Cfb
Capacitor, Ceramic,1000pF/50V,0805,SMD
1
POE
9
D1-D4
Diode, Rectifier ,1000V2A, RL207, DO-41
4
Good-Ark
10
D5,D6
Diode, Ultra Fast, FR107,1000V/1.0A, DO-41
2
Good-Ark
11
D8
Diode, Schottky, 100V/20A, SBL20100, DO-220
1
Good-Ark
12
L1
13
Bead1,2
CM Inductor, 30mH, UU10.5
1
SoKa
T6*2*3, R5
2
SoKa
14
L3
DM Inductor, 3µH, R5
1
SoKa
15
Q1
Mosfet Transisor, 4N65, TO-220F
1
ST
16
PCB1
PCB, L*W*T = 48.5х29х1.6mm, Cem-1, Rev:A
1
Jintong
17
F1
Fusible, 2A/250V
1
TY-OHM
18
R12
Chip Resistor, 3.3kΩ, 0805, 5%
1
TY-OHM
19
R2
Carbon Resistor, 100kΩ, 2W, 5%
1
TY-OHM
20
R3
Chip Resistor, 100Ω, 0805, 5%
1
TY-OHM
21
R4
Chip Resistor, 4.7Ω, 0805, 5%
1
TY-OHM
22
R5
Chip Resistor, 54.9kΩ, 0805, 1%
1
TY-OHM
23
R6
Chip Resistor, 11.7kΩ, 0805, 1%
1
TY-OHM
24
R7,R8
Chip Resistor, 1MΩ, 0805, 5%
2
TY-OHM
25
R9
Chip Resistor, 0.87Ω,1W, 1%
1
TY-OHM
26
R10
Chip Resistor, 510Ω, 0805, 5%
1
TY-OHM
27
R14
Chip Resistor, 300kΩ, 0805, 5%
1
TY-OHM
28
R15
Chip Resistor, 23.7kΩ, 0805, 1%
1
TY-OHM
29
R16
Chip Resistor, 6.19kΩ, 0805, 1%
1
TY-OHM
30
Rgate
Chip Resistor, 47Ω, 0805, 5%
1
TY-OHM
31
T1
Transformer, LP = 0.8mH, RM8
1
32
NTC
Thermistor, SC053
1
TY-OHM
33
TVS
Varistor, 10471
1
TY-OHM
34
CX1
X capacitance, 0.22µF/400V,X1
2
35
CY1
Y capacitance, 2200pF/400V,Y1
1
SEC
36
U2
Opto-coupler, PC817C CTR = 200%
1
Sharp
37
U3
Voltage Regulator, TL431A, VREF = 2.5V
1
ST
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Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
TYPICAL PERFORMANCE CHARACTERISTICS
VDD ON/OFF Voltage vs. Temperature
Startup Supply Current (µA)
VDDON and VDDOFF (V)
11.5
10.5
9.5
8.5
VDDOFF
7.5
8
7
6
0
40
80
120
0
20
80
100
Supply Current at Idle/Fault Mode vs.
Temperature
Maximum Switching Frequency vs.
Temperature
0.3
Fault Mode
0
20
40
60
80
100
120
120
90
ACT512-004
ACT512-003
Idle Mode
0.2
80
70
60
0
20
Temperature (°C)
40
60
80
100
120
Temperature (°C)
VFB Threshold Voltage vs. Temperature
VCS Voltage vs. Temperature
VFB Threshold Voltage (V)
0.9
0.8
0.7
4
ACT512-006
5
ACT512-005
1.0
VCS Voltage (V)
60
Temperature (°C)
0.4
0.6
0
40
Temperature (°C)
Maximum Switching Frequency (KHz)
6.5
Supply Current (mA)
ACT512-002
VDDON
12.5
Startup Supply Current vs. Temperature
9
ACT512-001
13.5
OLP
3
Start Switching
2
Stop Switching
1
0
20
40
60
80
100
0
120
20
Temperature (°C)
Innovative PowerTM
60
80
100
120
Temperature (°C)
- 12 -
Active-Semi Proprietary―For Authorized Recipients and Customers
ActiveQRTM is a trademark of Active-Semi.
40
www.active-semi.com
Copyright © 2014 Active-Semi, Inc.
ACT512
Rev 4, 13-Feb-14
PACKAGE OUTLINE
SOT23-6 PACKAGE OUTLINE AND DIMENSIONS
Active-Semi, Inc. reserves the right to modify the circuitry or specifications without notice. Users should evaluate each
product to make sure that it is suitable for their applications. Active-Semi products are not intended or authorized for use
as critical components in life-support devices or systems. Active-Semi, Inc. does not assume any liability arising out of
the use of any product or circuit described in this datasheet, nor does it convey any patent license.
Active-Semi and its logo are trademarks of Active-Semi, Inc. For more information on this and other products, contact
[email protected] or visit http://www.active-semi.com.
is a registered trademark of Active-Semi.
Innovative PowerTM
- 13 -
Active-Semi Proprietary―For Authorized Recipients and Customers
ActiveQRTM is a trademark of Active-Semi.
www.active-semi.com
Copyright © 2014 Active-Semi, Inc.