5V/2.4A+1A Dual Output CV/CC Car Charger with USB Auto Detect Application Report ACT4525 FEATURES Wide input voltage range from 6V to 32V Transparent input voltage surge up to 40V 5.1V output voltage 4.75V-5.25V during input and load transients 125kHz switching frequency Standby input current <2mA 2.4A+1A dual output with separate CC regulation USB Auto-detect supports Apple, Samsung and BC1.2 Good EMC performance Under voltage protection at output short <6mA average output current at output short Output over voltage protection Output cord compensation Thermal shutdown protection SPECIFICATION DESCRIPTION CONDITION Input Voltage MIN 6 Switching Frequency Standby Input current Output Voltage TYP MAX UNITS 32 V 125 kHz Vin=10V, no load 2 mA Vin=24V, no load 1 mA 4.85 5.1 5.25 V Output1 current limit range 2400 2650 2900 mA Output2 current limit range 1050 1200 1350 mA Ripple Voltage Efficiency at full load Active-Semi, Inc. No cable, full load range Vin=10V, Iout1=2.4A, Iout2=1A 45 Vin=24V, Iout1=2.4A, Iout2=1A 55 Vin=10V, Iout1=2.4A, Iout2=1A 89 % Vin=24V, Iout1=2.4A, 88 % mVpp -1- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect Iout2=1A ENVIRONMENTAL ESD Contact 8 kV Through air 15 kV 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. Output1 Regulation ........................................................................................................................................... 5 5.2. Output2 Regulation ........................................................................................................................................... 5 5.3. Efficiency (Ta=25℃) ......................................................................................................................................... 5 5.4. Power Loss ........................................................................................................................................................ 6 5.5. Constant Current and Constant Voltage (Ta=25℃) ........................................................................................... 6 5.6. Standby Input Current ....................................................................................................................................... 7 5.7. Ripple and Noise ............................................................................................................................................... 7 5.8. Load Dynamic Response ................................................................................................................................... 8 5.9. Line Dynamic Response(Vin change from 12V to 40V，1V/uS)................................................................... 10 5.10. Key Components Temperature Test (Ta=40℃, burning for 2 hours) .............................................................. 10 EMI TEST ................................................................................................................................................................... 11 6.1. Radiated EMI Test ........................................................................................................................................... 11 Active-Semi, Inc. -2- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect 1. DEMO BOARD PHOTO 2. SCHEMATI +Vin F1 3A 6 2 3 CSN2 CSN1 VIN U1 ACT4525 SOP-8EP GND C3 2.2µF 25V C1 47µF 35V C2 10µF 25V EP DP 4 C5 22nF/25V 8 HSB SW R2 0Ω R4 50mΩ L1 7 33µH/4.5A CSP DM 1 D1 SSC54 C4 2.2nF 25V R1 5.1Ω 5 R4A 50mΩ USB1 5V/2.4A R3 50mΩ C6 470µF 10V C7 10µF 10V 4 3 C9 2.2µF 10V 2 DD+ 1 USB2 5V/1A GND 4 3 C10 2.2µF 10V 2 DD+ 1 3. PCB LAYOUT TOP LAYER Active-Semi, Inc. BOTTOM LAYER -3- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect 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, SSC54,40V/5A, SMC 1 Vishay 3 C1 Electrolytic capacitor,47uF/35V,6.3x8mm 1 Koshin 4 C2 Ceramic capacitor,10uF/25V, X7R,1206 1 Koshin 5 C3 Ceramic capacitor,2.2uF/25V, X7R,0805 1 Murata/TDK 6 C4 Ceramic capacitor, 2.2nF/25V, X7R,0603(optional) 1 Murata/TDK 7 C5 Ceramic capacitor, 22nF/25V, X7R, 0603 1 Murata/TDK 8 C6 Electrolytic capacitor,470uF/10V,7x11.5mm 1 Murata/TDK 9 C7 Ceramic capacitor, 10uF/10V, X7R, 0805 1 Murata/TDK 10 C9/C10 Ceramic capacitor, 2.2uF/10V, X7R, 0805 2 Murata/TDK 11 F1 Fuse,3A,1206 ( Replaced by 0Ω 0805 chip resistor ) 1 Murata/TDK 12 R1 Chip Resistor, 5.1Ω, 1/10W, 5%, 0603(optional) 1 Murata/TDK 13 R2 Chip Resistor, 0Ω, 1/10W, 5%, 0603 1 Murata/TDK 14 R3/R4/R4A Chip Resistor, 50mΩ, 1/4W, 1%, 1206 1 Murata/TDK 15 R5/R7 Chip Resistor, 43.2KΩ, 1/16W ,1%,0603 1 Murata/TDK 16 R6/R8 Chip Resistor, 49.9KΩ, 1/16W ,1%,0603 1 Murata/TDK 17 U1 IC, ACT4525,SOP-8-EP 1 ACT 18 USB USB Rev: A 2 Active-Semi, Inc. Description -4- Active-Semi. Confidential-Do Not Copy or Distribute QTY Manuf. www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect 5. FUNCTIONAL TEST 5.1. Output1 Regulation Minimum Maximum Output Voltage Output Voltage 10V 5.071 5.083 0.2% 16V 5.073 5.084 0.2% 24V 5.074 5.084 0.2% Minimum Maximum Output Voltage Output Voltage 10V 5.083 5.135 1.0% 16V 5.082 5.137 1.1% 24V 5.084 5.138 1.1% VIN Load regulation Iload 0A-3.4A 5.2. Output2 Regulation VIN Load regulation Iload 0A-3.4A 5.3. Efficiency (Ta=25℃) VIN Efficiency (%) Io=100mA Io=1000mA Io=2100mA Io=2400mA Io=3400mA 10V 93.82 93.19 90.87 90.40 89.19 16V 88.52 92.37 90.19 89.89 88.78 24V 74.92 88.75 89.06 88.63 88.05 Active-Semi, Inc. -5- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect 5.4. Power Loss Power loss (W) Vin Io=0mA Io=100mA Io=1000mA Io=2100mA Io=2400mA Io=3400mA Vin=10V 0.07 0.11 0.37 0.93 1.14 1.75 Vin=16V 0.08 0.13 0.47 1.04 1.24 1.85 Vin=24V 0.13 0.20 0.60 1.19 1.41 2.00 5.5. Constant Current and Constant Voltage (Ta=25℃) Vin=10V Vin=16V Vin=24V Vout Iout1 Iout2 Vout Iout1 Iout2 Vout Iout1 Iout2 (V) (mA) (mA) (V) (mA) (mA) (V) (mA) (mA) 5.08 0 0 5.08 0 0 5.08 0 0 CC 5.08 100 100 5.08 100 100 5.08 100 100 Load 5.08 1000 500 5.08 1000 500 5.08 1000 500 5.08 2100 700 5.08 2100 700 5.08 2100 700 5.08 2400 1000 5.08 2400 1000 5.08 2400 1000 4.85 2630 1193 4.85 2627 1192 4.85 2630 1194 4.75 2630 1193 4.75 2627 1192 4.75 2630 1194 4.5 2630 1193 4.5 2627 1192 4.5 2630 1194 CV 4 2630 1193 4 2627 1192 4 2630 1194 Load 3.5 2630 1193 3.5 2627 1192 3.5 2630 1194 3 2630 1193 3 2627 1192 3 2630 1194 2.5 2630 1193 2.5 2627 1192 2.5 2630 1194 2.4 0 0 2.4 0 0 2.4 0 0 Active-Semi, Inc. -6- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect 5.6. Standby Input Current Test Conditions Input Current（mA） Power Loss at No Load (mW) Vin=10V 0.76 7.6 Vin=16V 0.64 10.3 Vin=24V 0.54 13 5.7. Ripple and Noise CH1:Vout1, CH2:Vout2, CH3:Vsw Vin=10V Iout1=0A Iout2=1A Vin=16V Iout1=0A Iout2=1A Active-Semi, Inc. Vin=10V Iout1=2.4A Iout2=0A Vin=16V Iout1=2.4A Iout2=0A Vin=10V Iout1=2.4A Iout2=1A Vin=16V Iout1=2.4A Iout2=1A -7- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect Vin=24V Iout1=0A Iout2=1A Vin=24V Iout1=2.4A Iout2=0A Vin=24V Iout1=2.4A Iout2=1A Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Test Conditions Iout1=0A,Iout2=1A Iout1=2.4A,Iout2=0A Iout1=2.4A,Iout2=1A Output Ripple Vout1(mV) Vout2(mV) Vout1(mV) Vout2(mV) Vout1(mV) Vout2(mV) Vin=10V 32 30 42 36 46 42 Vin=16V 36 30 46 40 54 48 Vin=24V 36 30 46 40 54 48 5.8. Load Dynamic Response CH1:Vout1, CH2:Vout2, CH4:Iout Iout2=0A dynamic load on output1 Vin=10V, load step 0A-0.5A-0A Vin=10V, load step 1A-1.5A-1A Active-Semi, Inc. Vin=10V, load step 0.5A-1A-0.5A Vin=10V, load step 1.5A-2.4A-1.5A -8- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect Iout2=1A dynamic load on output1 Vin=10V, load step 0A-0.5A -0A Vin=10V, load step 0.5A-1A-0.5A Vin=10V, load step 1A-1.5A-1A Vin=10V, load step 1.5A-2.4A-1.5A Iout2=0A dynamic load on output1 Vin=24V, load step 0A-0.5A -0A Vin=24V, load step 1A-1.5A-1A Active-Semi, Inc. Vin=24V, load step 0.5A-1A-0.5A Vin=24V, load step 1.5A-2.4A-1.5A -9- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect Iout2=1A dynamic load on output1 Vin=24V, load step 0A-0.5A -0A Vin=24V, load step 0.5A-1A-0.5A Vin=24V, load step 1A-1.5A-1A Vin=24V, load step 1.5A-2.4A-1.5A 5.9. Line Dynamic Response(Vin change from 12V to 40V，1V/uS) CH1:Vsw, CH2:Vout1,CH3:Vout2 Iout1=0A,Iout2=1A Iout1=2.4A,Iout2=0A ℃, burning for 2 hours) 5.10. Key Components Temperature Test (Ta=40 Active-Semi, Inc. Iout1=2.4A,Iout2=1A Vin/Iout Ambient PCB IC Schottky Inductor 12V/3.4A 44.5 84.1 106.2 103.8 96.3 24V/3.4A 46.2 90 114.9 116.5 106.5 - 10 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4525 5V/2.4A+1A Dual Output Car Charger with USB Auto Detect 6. EMI TEST 6.1. Radiated EMI Test Vin=12V Io=3.4A Horizontal Vin=12V Io=3.4A Vertical Active-Semi, Inc. - 11 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com