ACT4524 5V/3.4A Car Charger Solution Application Report Car Charger Using ACT4524 FEATURES Wide input voltage range from 6.5V to 36V Transparent input voltage surge up to 40V 4.75V-5.25V during input and load transients Dual 5.1V outputs with 1% accuracy 2.65A constant current regulation for VOUT1 1.2A constant current regulation for VOUT2 Hiccup mode protection at output short 90% efficiency at full load 0.5mA low standby input current 5.7V over voltage protection Cord voltage drop compensation Meet EN55022 Class B radiated EMI standard SOP-8EP package SPECIFICATION DESCRIPTION CONDITION MIN Input Voltage TYP 10 Switching Frequency MAX UNITS 40 V 125 kHz No-load Standby Input current Vin=12V no load 0.48 mA Vin=24V no oad 0.44 mA Output Voltage CSP 5.1 V Output1 Current CS1, Rcs1=25mΩ 2.5 2.65 2.8 A Output2 Current CS2, Rcs1=50mΩ 1.1 1.2 1.3 A Ripple Voltage Efficiency at full load Vin=12V, Io=3.4A 29 Vin=24V, Io=3.4A 33 Vin=12V, Io=3.4A 90.21 % Vin=24V, Io=3.4A 89.75 % Contact 4 kV Through air 8 kV mVpp ENVIRONMENTAL ESD Ambient Temperature Active-Semi, Inc. Free convection 0 -1- 50 ºC www.active-semi.com ACT4524 5V/3.4A TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. Demo Board Photo ........................................................................................................................................................ 3 Schemati........................................................................................................................................................................ 3 PCB Layout ................................................................................................................................................................... 3 Bill of Materials ............................................................................................................................................................ 4 Functional Test .............................................................................................................................................................. 5 5.1. Output Regulation ............................................................................................................................................. 5 5.2. Efficiency (Ta=25C) .......................................................................................................................................... 5 5.3. Constant Current and Constant Voltage (Ta=25C) ............................................................................................ 6 5.4. Current Limit vs. Input Voltage ......................................................................................................................... 8 5.5. Power Loss ........................................................................................................................................................ 9 5.6. Standby Input Current ....................................................................................................................................... 9 5.7. Ripple and Noise ............................................................................................................................................. 10 5.8. Load Dynamic Response ................................................................................................................................. 11 5.9. Line Dynamic Response(Vin change from 12V to 40V，1V/uS)................................................................... 11 5.10. Key Components Temperature Test (Ta=40C, burning in for 2 hours with CLA) .......................................... 12 EMI TEST ................................................................................................................................................................... 12 6.1. Radiated EMI Test ........................................................................................... Error! Bookmark not defined. Active-Semi, Inc. -2- www.active-semi.com ACT4524 5V/3.4A 1. DEMO BOARD PHOTO 2. SCHEMATIC 3. PCB LAYOUT TOP LAYER Active-Semi, Inc. BOTTOM LAYER -3- www.active-semi.com ACT4524 5V/3.4A 4. BILL OF MATERIALS Item Reference 1 L1 Choke Coil, Dip,T11.5*5*4mm, phi=0.8mm, L=33uH 1 2 D1 Schottky Diode, S54, 40V/5A, SMC 1 Vishay 3 C1 Electrolytic capacitor, 47uF/35V, 7x8mm 1 Koshin 4 C2 Ceramic capacitor, 22uF/35V, X7R,1206 1 Murata/TDK 5 C3 Ceramic capacitor, 0.1uF/35V, X7R, 0603 1 Murata/TDK 6 C4 Ceramic capacitor, 2.2nF/25V, X7R, 0603(NA) 1 Murata/TDK 7 C5 Ceramic capacitor, 22nF/25V, X7R, 0603 1 Murata/TDK 8 C6 Electrolytic capacitor, 220uF/10V, 6.3x7mm 1 Murata/TDK 9 C7,C9,C10 Ceramic capacitor, 22uF/10V, X7R, 1206 3 Murata/TDK 10 C8 Ceramic capacitor, 0.1uF/10V, X7R, 0603 1 Murata/TDK 11 F1 Fuse, 3A,1206 ( Replaced by 0Ù 0805 chip resistor ) 1 Murata/TDK 12 R1 Chip Resistor, 10Ù, 1/8W, 5%, 0805(NA) 1 Murata/TDK 13 R2 Chip Resistor, 0Ù, 1/10W, 5%, 0603 1 Murata/TDK 14 R3,R3A,R4 Chip Resistor, 50mÙ, 1/4W, 1%, 1206 3 Murata/TDK 15 R9,R11 Chip Resistor, 43.2KÙ, 1/10W, 1%, 0603 2 Murata/TDK 16 R10,R12 Chip Resistor, 49.9KÙ, 1/10W, 1%, 0603 2 Murata/TDK 17 U1 IC, ACT4524,SOP-8-EP 1 ACT 18 USB1, USB2 USB Rev:A 1 Active-Semi, Inc. Description -4- QTY Manuf. www.active-semi.com ACT4524 5V/3.4A 5. FUNCTIONAL TEST 5.1. Output Regulation Output1 Voltage(V) Output1 Voltage (V) Load at Max. load at No load regulation 12V 5.084 5.101 0.33% 18V 5.084 5.101 0.33% 24V 5.84 5.101 0.33% Output2 Voltage(V) Output2 Voltage (V) Load at Max. load at No load regulation 12V 5.038 5.101 1.24% 18V 5.038 5.101 1.24% 24V 5.038 5.101 1.24% VIN VIN Iload(max) 2.4A Iload(max) 1.2A 5.2. Efficiency (Ta=25C) Efficiency (%) Active-Semi, Inc. VIN Io=100mA Io=1000mA Io=2100mA Io=2400mA Io=3100mA Io=3400mA 12V 92.7 94.0 91.7 91.2 90.6 90.2 18V 90.1 92.0 90.8 90.5 90.2 89.9 24V 88.4 91.2 90.4 90.3 90.0 89.8 -5- www.active-semi.com ACT4524 5V/3.4A 5.3. Constant Current and Constant Voltage (Ta=25C) Output1 Vin=12V CC Load CV Load Active-Semi, Inc. Vin=18V Vin=24V Vout(V) Iout(mA) Vout(V) Iout(mA) Vout (V) Iout(mA) 5.092 0 5.093 0 5.096 0 5.090 1000 5.090 1000 5.094 1000 5.089 1500 5.090 1500 5.092 1500 5.090 2100 5.092 2100 5.094 2100 5.091 2400 5.093 2400 5.095 2400 5.0 2609 5.0 2603 5.0 2607 4.9 2607 4.9 2600 4.9 1605 4.5 2603 4.5 2597 4.5 2601 4.3 2601 4.3 2596 4.3 2599 4 2598 4 2595 4 2595 3.5 2596 3.5 2592 3.5 2592 3 2595 3 2591 3 2589 2.8 2593 2.8 2590 2.8 2588 2.6 2593 2.6 2589 2.6 2588 2.5 0 2.5 0 2.5 0 -6- www.active-semi.com ACT4524 5V/3.4A Output2 Vin=12V CC Load CV Load Active-Semi, Inc. Vin=18V Vin=24V Vout(V) Iout(mA) Vout(V) Iout(mA) Vout (V) Iout(mA) 5.091 0 5.092 0 5.095 0 5.051 200 5.075 200 5.077 200 5.072 500 5.071 500 5.072 500 5.056 800 5.055 800 5.056 800 5.046 1000 5.045 1000 5.046 1000 5.0 1177 5.0 1182 5.0 1178 4.9 1177 4.9 1182 4.9 1178 4.5 1177 4.5 1181 4.5 1177 4.3 1177 4.3 1180 4.3 1176 4 1177 4 1180 4 1176 3.5 1177 3.5 1179 3.5 1176 3 1177 3 1179 3 1176 2.8 1177 2.8 1178 2.8 1176 2.6 1176 2.6 1178 2.6 1176 2.5 0 2.5 0 2.5 0 -7- www.active-semi.com ACT4524 5V/3.4A 5.4. Current Limit vs. Input Voltage Output1 :No Wind ( Test Condition : CV load 4.5V, Ta=25C) Vin(V) 10 12 14 16 18 20 24 27 30 32 34 Iout1(A) 2.618 2.615 2.613 2.609 2.608 2.606 2.600 2.598 2.597 2.596 2.595 36 2.594 Output2 :No Wind ( Test Condition : CV load 4.5V, Ta=25C) Vin(V) 10 12 14 16 18 20 24 27 30 32 34 Iout2(A) 1.178 1.178 1.178 1.178 1.178 1.178 1.177 1.177 1.177 1.177 1.176 Active-Semi, Inc. -8- 36 1.176 www.active-semi.com ACT4524 5V/3.4A 5.5. Power Loss Vin Power loss (W) Io=0mA Io=100mA Io=1000mA Io=2400mA Io=3100mA Io=3400mA Vin=12V 0.01 0.04 0.32 1.18 1.63 1.88 Vin=18V 0.01 0.06 0.44 1.28 1.72 1.96 Vin=24V 0.01 0.07 0.49 1.32 1.75 1.98 5.6. Standby Input Current Test Conditions Active-Semi, Inc. Input Current（mA） Power Loss at No Load (mW) Vin=10V 0.50 5.00 Vin=12V 0.48 5.76 Vin=18V 0.44 7.92 Vin=24V 0.44 10.56 Vin=30V 0.43 12.9 -9- www.active-semi.com ACT4524 5V/3.4A 5.7. Ripple and Noise Vin=12V 1A output load CH1:SW CH2:Vout Vin=12V 3.8A output load Vin=24V 1A output load Vin=24V 3.8A output load Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Active-Semi, Inc. Test Conditions Output Ripple at 1A Load (mV) Output Ripple at 3.8A Load (mV) Vin=12V 34 62 Vin=24V 52 84 - 10 - www.active-semi.com ACT4524 5V/3.4A 5.8. Load Dynamic Response CH1:Vout CH4:Iout Vin=12V load step 80mA-1A -80mA Vin=12V load step 1A-2.4A-1A Vin=24V load step 80mA-1A -80mA Vin=24V load step 1A-2.4A-1A 5.9. Line Dynamic Response(Vin change from 12V to 40V，1V/uS) CH1:Vout CH3:Vin Iout=1A Active-Semi, Inc. Iout =2.4A - 11 - www.active-semi.com ACT4524 5V/3.4A 5.10. Key Components Temperature Test (Ta=27C, burning in for 2 hours with CLA) Vin/Iout 12V/2.4A+1A 24V/2.4A+1A 36V/2.4A+1A IC 77.5 76.6 76.9 Tempreture(℃） Diode Inductor 75.1 85.8 77.6 90.2 92.8 79.7 PCB 67.9 68.0 68.4 6. EMI TEST Vin=12V Io=2.4A+1.2A Horizontal Vin=12V Io=2.4A+1.2A Vertical Active-Semi, Inc. - 12 - www.active-semi.com