Innovative Green Power Solutions AC/DC Charger/Adapter Reference Designs ACT36X, ACT33X Rev 2.5 Oct 2012 www.active-semi.com ActivePSR TM High Efficiency AC/DC Primary Switching Solutions Application Change Note Revision History Page 12~13 2012-Oct– 19 Rev 2.5 Update SCH and Transformer ( Lp and NP/NS/NAUX ) Update BOM List( C1,C2,R5,R6,R9,R10 ) Page 14~15 Update SCH and Transformer ( Lp and NP/NS/NAUX ) Update BOM List( R5,R6,R9,R10 ) Cover page Change title For information regarding Active-Semi products, sales and authorized distributors, please contact: [email protected]. ActivePSR TM High Efficiency AC/DC Primary Switching Solutions AC/DC Converters – ActivePSRTM ● ● ● ● Applications Part Number ACT361 ACT364 Chargers for Cell Phones, PDAs, MP3, PMPs, DSCs, and Other Portable Devices RCC Adapter or Linear Adapter Replacements Standby and Auxiliary Supplies White LED Lighting Output Power Technology Standby Power Consumption Switching Frequency Package 6.0W PSRc < 150mW @ VAC = 230V Adjustable to 40kHz SOT23-6 6.5W PSR c < 150mW @ VAC = 230V Adjustable to 80kHz SOT23-6 c < 150mW @ VAC = 230V Adjustable to 80kHz SOP8 ACT365 12.5W PSR ACT366 14.5 W PSRc < 150mW @ VAC = 230V Adjustable to 80kHz SOP8-EP ACT334 6.5W PSRc < 30mW @ VAC = 230V Adjustable to 80kHz SOT23-6 ACT336 7.0W PSRc < 30mW @ VAC = 230V Adjustable to 80kHz SOP8 PSRc < 30mW @ VAC = 230V Adjustable to 80kHz SOP8 ACT337 12.5W c: PSR is Primary-Side Regulation Table of Contents 1. ACT361 5V 1000mA Universal Charger ……………………………………………..………….…………….…………4 2. ACT364 5V 1000mA Universal Charger ……………………………………………..………….…………….…………6 3. ACT365 5V 2100mA Universal Charger……………………………….………………………………….……...………8 4. ACT366 12V 1000mA Universal Charger …………….…………………..…….…….……………...………..………..10 5. ACT334 5V 700mA Universal Charger …………………….…………..…….…….…………………………..…….....12 6. ACT334 5V 1000mA Universal Charger …………………….…….…..…….…….…………………………..…….....14 7. ACT336 5V 1200mA Universal Charger ……….…………………..…….…...………...…………………..………….16 8. ACT337 5V 1500mA Universal Charger ……….……………………..…….…...……………………….....………….18 9. ACT337 5V 2100mA Universal Charger ……….……………………..…….…...……………………….....………….20 Active-Semi (Shanghai) Office Contact Information Fast Technical Support Contact Person: Peter (Director of Product Line) Tel: (86-21) 5108 2797#865; Mobile Phone: 135 8558 2743; E-mail box: [email protected]. Address: RM1202,Sunplus Building,No.1077 Zuchongzhi Road, Zhangjiang High Tech Park, Shanghai 201203, China For information regarding Active-Semi products, sales and authorized distributors, please contact: [email protected]. ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT361 5V/1000MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT361 150mW 5V 5W EE16 Flyback Key Component Selection The maximum output current is decided by formula(1). 0 .9 * 0 .396 2 η × FSW 1 ) ) ×( IOUTCC = × LP × ( (1) VOUTCC RCS 2 L=51.0mm W=31.1mm H=14.2mm Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R4 in the schematic. Fsw is the switching frequency, which design value is 45kHz. ŋ is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R8, R9 as shown in formula (2). N R VOUTCC = VREF × (1 + 8 ) × S − VSEC _ R (2) N AUX R9 Operation and Application Figure 1 is the schematic of an offline charger using ACT361 to provide output power of 5V1000mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (D1D4,C1, L1, L2, C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D7, C6) and the IC control circuit. ACT361 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Optocoupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Resistance of R7 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, DSCs, and Other Portable Devices and Appliances. Np/Ns/Naux (140/10/14) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 1000mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -4- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT361 5V/1000MA CHARGER Electrical specifications Bill of Materials REF DESCRIPTION Item MFTR C1,C2 Capacitor, Electrolytic, 6.8µF/400V, 10x12mm KSC C3 Capacitor, Ceramic,1000pF/500V,1206,SMD POE C4 Capacitor, Electrolytic,10µF/50V,5x11mm KSC C5 Capacitor, Electrolytic, 680µF/10V, 8x12mm KSC C6 Capacitor, Electrolytic, 220µF/10V, 5x11mm KSC C7 Capacitor, Ceramic,1000pF/50V, 0805, SMD POE Good-Ark D5,D6 Diode,Ultra Fast, FR107,1000V/1.0A, DO-41 Good-Ark D8 Diode, schottky, 40V/2A, SB210, DO-15 L1 Axial Inductor, 2.2mH, 0410,Dip Amode Tech L2 Axial Inductor, 220µH, 0410,Dip Amode Tech Q2 Transistor, HFE 20-25, NPN,D13003X,TO-126 R1 Chip Resistor, 750kΩ, 1206, 5% TY-OHM R2,R3 Chip Resistor, 5.1MΩ, 1206, 5% TY-OHM R4 Chip Resistor, 0.787Ω, 1206,1% TY-OHM R5 Chip Resistor, 22Ω, 0805, 5% R6 Chip Resistor, 22Ω, 0603, 5% R7 Chip Resistor, 162kΩ, 0805, 5% R8 Chip Resistor, 54.9kΩ, 0805,1% TY-OHM 75µH TY-OHM TY-OHM Chip Resistor, 9.76kΩ, 0805, 1% Chip Resistor, 1.2kΩ, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM Chip Resistor, 2.2kΩ ohm, 0805, 5% TY-OHM STANDBY POWER Active-Semi. Transformer Specitication USB 3 Inductance between pins 3 and 5 with pins 1-2 and 6-8 shorted TY-OHM R9 IC, ACT361,SOT23-6 1.7mH±%7 P1 Leakage Inductance TY-OHM R11 U1 P1 Inductance Typical Performance Characteristics Jintong TY-OHM Transformer, Lp=1.7mH, EE16 2 Huawei Wire Round Resistor,1W,10Ω ,KNP, 5% T1 3000Vac Inductance between pins 5 and 3 at 1Vac & 1kHz Good-Ark PCB, L*W*T=58x31.2x1.6mm,Cem-1,Rev:A R14,R15 Limits PCB Top and Bottom Layers Diode,Rectifier,1000V/1A,1N4007, DO-41 FR1 Condition 50Hz, 1 minute, from primary and secondary 1 D1-D4 PCB1 Description Electrical Strength USB, Rev:A Core(SH2) 5 Reverse P1 3 S1 NC 1 6 P2 EFFICIENCY 8 4 P2 2 Pin1 Build up Winding Terminal Wire Start Finish Insulation Turns Type Size*QTY Layer Thick/Wide Lay er 3 --> 47 2UEW 0.15Φ*1 1 0.025*8.5W <-- <-- 47 2UEW 0.15Φ*1 1 0.025*8.5W --> 5 46 2UEW 0.15Φ*1 1 0.025*8.5W SH1 2 NC 8 2UEW 0.12Φ*1 1 0.025*8.5W 2 S1 8 6 10 TEX-E 0.50Φ*1 1 0.025*8.5W 2 4 2 14 2UEW 0.15Φ*2 1 0.025*8.5W 2 1 4 Core 5 1 Conductor 0.15Φ*1 1 0.025*10 2 P1 P2 SH2 2 CC/CV CURVE Note:1.SH1,SH2 are shielding; P1 & P2 are primary and S1 is secondary.(Bobbin:EE16) -5- EVALUATION KITS Vin Vo Io ACT361-01 85-264Vac 4.75-5.25V 1000-1268mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT364 5V/1000MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT364 150mW 5V 5W EPC13 Flyback Key Component Selection The maximum output current is decided by formula(1). 1 0.9 * 0.396 2 η × FSW IOUTCC = × LP × ( ) ×( ) (1) 2 RCS VOUTCC L=41.3mm W=28.1mm H=13.2mm Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz. ŋ is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT364 to provide output power of 5V1000mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (BD1,C1, L1,C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8,C5,C6) and the IC control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, DSCs, and Other Portable Devices and Appliances. VOUTCC=VREF ×(1 + R5 N ) × S −VSEC_R R6 NAUX (2) Np/Ns/Naux (147/9/24) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 1000mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -6- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT364 5V/1000MA CHARGER Electrical specifications Bill of Materials DESCRIPTION MFTR Item C1 Capacitor, Electrolytic, 4.7µF/400V,8 ×12mm Koshin C2 Capacitor, Electrolytic, 6.8µF/400V,8 ×12mm Koshin C3 Capacitor, Ceramic,1000pF/500V,1206,SMD POE C4 Capacitor, Ceramic,4.7uF/35V,0805,SMD POE Capacitor, Solid, 330µF/6.3V, 6.3 ×9mm KSC Capacitor, Ceramic,1000pF/50V,0805,SMD POE C5,C6 C9 BD1 Bridge,B6S,600V/0.5A,MDI,SMD D5,D6 Condition Limits 50Hz, 1 minute, from primary and secondary 3000Vac 2 P1 Inductance Inductance between pins 1 and 4 at 1Vac & 1kHz 1.75mH±%7 3 P1 Leakage Inductance Inductance between pins 1 and 4 with pins 2-3 and 6-10 shorted 75µH 1 PCB Top and Bottom Layers PANJIT Diode, Ultra Fast, RS1M,1000V/1.0A, SMA Good-Ark D8 Diode, Schottky, 40V/3A, SK34, SMB L1 Axial Inductor, 1.5mH, 0410, DIP Q1 Transistor, NPN, 700V,1.5A, D13003, TO-251AB PCB1 Description Electrical Strength Good-Ark Amode Tech Huawei PCB, L*W*T=42x28 x1.0mm, FR-4,Rev:ACT364_00_1 Jintong FR1 Fusible Resistor, 1W, 10Ω, 5% TY-OHM R1,R4 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 470Ω, 0805, 5% TY-OHM R3 Chip Resistor, 750k Ω, 0805, 5% TY-OHM R5 Chip Resistor, 61k Ω, 0805, 1% TY-OHM R6 Chip Resistor, 11. 8kΩ, 0805, 1% TY-OHM R7,R8 Chip Resistor, 5.1MΩ, 0805, 5% TY-OHM R9 Chip Resistor, 1.07Ω, 1206, 1% TY-OHM R10 Chip Resistor, 162k, 0805, 5% TY-OHM R11 Chip Resistor, 1.1k, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM R14 Bead, GZ2012D121,0805 Typical Performance Characteristics Standby Power Vs Input Voltage 120.00 Standy Power (W) REF 100.00 80.00 60.00 40.00 20.00 0.00 90 115 230 264 Input Voltage (VAC) STANDBY POWER KC T1 Transformer, LP = 1.75mH±7%, EPC13 U1 IC, ACT364US-T, SOT23-6 Active-Semi Transformer Specitication EFFICIENCY V-I Characteristic Vs Vin(25℃) Output Voltage(V) 6.00 Build up Terminal Winding Wire Insulation Turns Start 4 Finish --> Type 49 2UEW Size*QTY 0.12Φ*1 Layer 1 Thick/Wide Lay er 90V 5.00 115V 4.00 230V 3.00 264V 2.00 High limit 1.00 Low limit 0.025*8.5W 0.00 0 P1 <-- <-- 49 2UEW 0.12Φ*1 1 0.025*8.5W --> 1 49 2UEW 0.12Φ*1 1 0.025*8.5W SH1 2 NC 49 2UEW 0.12Φ*1 1 0.025*8.5W P2 2 3 24 2UEW 0.12Φ*1 1 0.025*8.5W 1 S1 10 6 9 TEX-E 0.40Φ*1 1 0.025*8.5W 2 SH2 2 Core 1 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Output Current(mA) CC/CV CURVE 3 Note:1.SH1,SH2 are shielding; P1 & P2 are primary and S1 is secondary.(Bobbin:EPC13) -7- EVALUATION KITS Vin Vo Io ACT364_00_1 85-264Vac 4.75-5.25V 1000-1300mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT365 5V/2100MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT365SH 150mW 5V 10.5W EPC17 Flyback Key Component Selection The maximum output current is decided by formula (1). 0.9 * 0.396 2 η × FSW 1 (1) ) ) ×( IOUTCC = × LP × ( VOUTCC RCS 2 L=40.0mm W=28.1mm H=22.1mm Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz. η is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT365 to provide output power of 5V2100mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (BD1,C1, C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT365SH is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Optocoupler. Pin 6 and Pin 2,4,7 are the VDD and ground pins to provide power for the IC. Pin 8 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 3 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, Shaver, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 N AUX (2) Np/Ns/Naux (110/8/18) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 2100mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -8- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT365 5V/2100MA CHARGER Bill of Materials Electrical Specifications REF DESCRIPTION MFTR C1, C2 Capacitor, Electrolytic, 10µF/400V, 10×16mm KSC C3 Capacitor, Ceramic,1000pF/500V,1206,SMD POE C4 Capacitor, Ceramic, 10µF/35V,1206,SMD KSC C5 Capacitor, Electrolytic, 1000µF/6.3V, 8 ×16mm KSC C6 Capacitor, Electrolytic, 820µF/6.3V, 6.3 × 16mm KSC C9 Capacitor, Ceramic,1000pF/50V,0805,SMD POE CY1 Safety Y1,Capacitor,1000pF/400V,Dip UXT BD1 Condition Limits 50Hz, 1 minute, from primary and secondary 3000Vac 2 P1 Inductance Inductance between pins 1 and 3 at 1Vac & 1kHz 1.25mH±%7 3 P1 Leakage Inductance Inductance between pins 1 and 3 with pins 4-5 and A-B shorted 75µH PCB Top and Bottom Layers Bridge Rectifier,D1010S,1000V/1.0A,SDIP PANJIT Fast Recovery Rectifier, RS1M,1000V/1.0A, RMA PANJIT D6 Fast Recovery Rectifier,RS1D,200V/1.0A,SMA PANJIT D8 Diode, Schottky, 45V/10A, S10U45S, SMD Diodes L1 Choke Coil, 1.5mH, ¢6x8mm, DIP Amode PCB, L*W*T=40x28.1x1.6mm,Cem-1,Rev:A Jintong Q1 Transistor, NPN, 700V,D13005,TO-126 Huawei F1 Fuse:1A 250V 3.6*10mm With Pigtail, ceramic tube R1 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 300k,1206, 5% TY-OHM R3 Chip Resistor, 390Ω,1206, 5% TY-OHM R4 Chip Resistor, 15Ω, 0805, 5% TY-OHM R5 Chip Resistor, 80.6k,0805, 1% TY-OHM R6 Chip Resistor,19.1k,0805, 1% TY-OHM R7 Chip Resistor, 10MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 0.65Ω,1206, 1% TY-OHM R10 Chip Resistor, 162k,0805, 5% TY-OHM R11 Chip Resistor, 1.1k, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM T1 Description Electrical Strength 1 D5 PCB1 Item walter Typical Performance Characteristics STANDBY POWER Transformer, LP = 1.25mH±7%, EPC17 USB Double-layer USB Rev:A S/H1 AL HeatSink, LxWxH=7.5x17x2.0mm U1 IC, ACT365SH-T, SOP-8 ACT Transformer Specitication Pin4(SH2) 3 P3 P1 2 Reverse A 1 NC 5 S1 EFFICIENCY SH1 P2 B 4 Core Build up Terminal Winding Wire Insulation Turns Start Finish Type Size*QTY Layer P1 2 3 SH1 --> S1 Thick/Wide 74 2UEW 0.22Φ*1 1 0.025*8.5W Layer 2 4 0.9 Copper 0.7mm 1 0.025*8.5W 2 B A 8 TEX-E 0.75Φ*1 1 0.025*8.5W 2 P2 5 4 18 2UEW 0.14¢*3 1 0.025*8.5W 2 P3 3 1 36 2UEW 0.22¢*1 1 0.025*8.5W 2 SH2 4 core 3 Copper wire 0.15Φ*1 1 0.025*8.5W 5 Note:1.SH1,SH2 are shielding; P1, P2 are primary and S1 is secondary.(Bobbin:EPC17) -9- EVALUATION KITS Vin Vo Io ACT365-01 85-264Vac 4.75-5.25V >2100mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT366 12V/1000MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT366HY 150mW 12V 12W EE20 Flyback Key Component Selection The maximum output current is decided by formula (1). 1 0 .9 * 0.396 2 η × FSW IOUTCC = × LP × ( ) ×( ) (1) 2 RCS VOUTCC L=45.8mm W=33.3mm H=22.4mm Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 I the schematic. Fsw is the switchin frquency,which design value is 75kHz. η is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT366YH to provide output power of 12V1000mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (BD1,C1, C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT366YH is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 6 and Pin 2,4,7 are the VDD and ground pins to provide power for the IC. Pin 8 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 3 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones,PDAs, MP3,Portable Media Players, Shaver, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 N AUX (2) Np/Ns/Naux (96/9/12) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 12V and Ioutcc_min equal to 1000mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -10- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT366 12V/1000MA CHARGER Electrical specifications Bill of Materials REF DESCRIPTION MFTR C1 Capacitor, Electrolytic, 10µF/400V, 10 × 12mm KSC C2 Capacitor, Electrolytic, 15µF/400V, 10 × 12mm KSC C3 Capacitor, Ceramic,1000pF/500V,1206, SMD POE C4 Capacitor, Electrolytic, 47µF/35V, 5 × 11mm KSC C5 Capacitor, Electrolytic, 330µF/25V, 8 × 12mm? KSC C9 Capacitor, Ceramic,1000pF/50V,0805,SMD POE CY1 Safety Y1,Capacitor,1000pF/400V,Dip UXT BD1 Bridge,Rectifier,1000V/1A,MB10M, SMD 1 Diode, Ultra Fast, FR107,1000V/1.0A, DO-41 Good-Ark D6 Diode, Switching,75V/150mA,LL4148, MICRO-MELF Good-Ark D8 Diode, Schottky, 60V/5A, SB560, DO-201AD L1 Common choke mode, UU9.8,20mH, DIP PCB, L*W*T=45.8x33.3x1.6mm,Cem-1,Rev:A Jintong Q1 Transistor, NPN, 700V,1.5A, D13003, TO-220 Huawei Fuse:1A 250V 3.6*10mm With Pigtail, ceramic tube Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 300k, 1206, 5% TY-OHM R3 Chip Resistor, 0Ω, 1206, 5% TY-OHM R4 Chip Resistor, 10Ω, 0805, 5% TY-OHM R5 Chip Resistor, 59k, 0805, 1% TY-OHM R6 Chip Resistor, 9.09k, 0805, 1% TY-OHM R7 Chip Resistor, 2.7MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 0.604Ω, 1206, 1% TY-OHM R10 Chip Resistor, 330k, 0805, 5% TY-OHM R11 Chip Resistor, 5K, 0805, 5% TY-OHM R12,R14 Chip Resistor, 2.2K, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM AL HeatSink, LxWxH=15x23x2.0mm U1 2 P1 Inductance 3 P1 Leakage Inductance Condition Limits 50Hz, 1 minute, from primary and secondary 3000Vac Inductance between pins 4 and 5 at 1Vac & 1kHz 1.2mH±%7 Inductance between pins 4 and 5 with pins 2-1 and A-B shorted 75µH Typical Performance Characteristics F1 R1 S/H1 Electrical Strength PANJIT PCB1 Transformer, LP = 1.2mH±7%, EE20 Description PCB Top and Bottom Layers D5 T1 Item IC, ACT366YH-T, SOP8-EP walter STANDBY POWER Active-Semi Transformer Specitication SH1 EFFICIENCY Build up Terminal Winding Wire Insulation Turns Start Finish Type Size*QTY Layer Thick/Wide Laye r 5 --> 32 2UEW 0.25Φ*1 1 0.025*8.5W --> 3 32 2UEW 0.25Φ*1 1 0.025*8.5W 2 SH1 --> 1 0.9 Copper 0.7mm 1 0.025*8.5W 2 S1 B A 9 TEX-E 0.4Φ*2 1 0.025*8.5W 2 P2 2 1 12 2UEW 0.25Φ*3 1 0.025*8.5W 2 P1 3 4 32 2UEW 0.25Φ*1 1 0.025*8.5W 2 SH2 1 core 3 Conductor 0.25Φ*1 1 0.025*10 5 P1 CC/CV CURVE Note:1.SH1 and SH2 are shielding; P1 & P2 are primary and S1 is secondary.(Bobbin:EE20) -11- EVALUATION KITS Vin Vo Io ACT366-01 85-264Vac 11.4-12.6V >1000mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT334 5V/700MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT334 30mW 5V 3.5W EPC13 Flyback Key Component Selection The maximum output current is decided by formula(1). 1 0.9 * 0.396 2 η × FSW (1) IOUTCC = × LP × ( ) ×( ) 2 RCS VOUTCC L=41.3mm W=28.1mm H=13.2mm Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz. η is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT334 to provide output power of 5V/700mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (D1,D2,D3,D4,C1,L1, C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT334 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 N AUX (2) Np/Ns/Naux (147/9/24) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 700mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs Figure 1: Schematic of Charger -12- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT334 5V/700MA CHARGER Electrical specifications Bill of Materials REF DESCRIPTION C1, C2 MFTR Capacitor, Electrolytic, 4.7µF/400V, 8 × 12mm KSC C3 Capacitor, Ceramic,220pF/500V,1206,SMD POE C4 Capacitor, Ceramic,, 4.7µF/35V, 1206, SMD POE Capacitor, Electrolytic, 220µF/10V, 6.3 × 8mm KSC Capacitor, Ceramic,1000pF/50V,0805,SMD POE C5,C6 C9 D1-D5 Item Condition Limits 50Hz, 1 minute, from primary and secondary 3000Vac 2 P1 Inductance Inductance between pins 1 and 4 at 1Vac & 1kHz 1.5mH±%7 3 P1 Leakage Inductance Inductance between pins 1 and 4 with pins 2-3 and 6-10 shorted 75µH 1 PCB Top and Bottom Layers Diode,Rectifier,1000V/1A,1N4007, DO-41 Good-Ark D6 Diode, Ultra Fast, FR107,1000V/1.0A, DO-41 Good-Ark D8 Diode, Schottky, 40V/3A, SB340, SMA Good-Ark L1 Axial Inductor, 1.5mH, 0410, DIP PCB1 Description Electrical Strength Amode Tech PCB, L*W*T=41.3x28.1x1.6mm,Cem-1,Rev:A Jintong Q1 Transistor, NPN, 700V,1.5A, D13003, TO-251AB Huawei FR1 Fusible Resistor, 1W, 10Ω, 5% TY-OHM R1,R4 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 1.0M, 1206, 5% TY-OHM R3 Chip Resistor, 470Ω, 1206, 5% TY-OHM R5 Chip Resistor, 43.4K, 0805, 1% TY-OHM R6 Chip Resistor, 8.25K, 0805, 1% TY-OHM R7,R8 Chip Resistor, 15MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 1.0Ω, 1206, 1% TY-OHM R10 Chip Resistor, 80.6K, 0805, 5% TY-OHM R11 Chip Resistor, 3.9K, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM T1 Transformer, LP = 1.5mH±7%, EPC13 5+5pin U1 IC, ACT334US-T, SOT23-6 Typical Performance Characteristics STANDBY POWER Active-Semi Transformer Specitication EFFICIENCY Build up Terminal Winding Wire Insulation Turns Start Finish Type Size*QTY Layer Thick/Wide Lay er 4 --> 49 2UEW 0.12Φ*1 1 0.025*8.5W <-- <-- 49 2UEW 0.12Φ*1 1 0.025*8.5W --> 1 49 2UEW 0.12Φ*1 1 0.025*8.5W SH1 2 NC 49 2UEW 0.12Φ*1 1 0.025*8.5W P2 2 3 24 2UEW 0.12Φ*1 1 0.025*8.5W 1 S1 10 6 9 TEX-E 0.40Φ*1 1 0.025*8.5W 2 SH2 2 Core 1 P1 CC/CV CURVE 3 Note:1.SH1,SH2 are shielding; P1 & P2 are primary and S1 is secondary.(Bobbin:EPC13) -13- EVALUATION KITS Vin Vo Io ACT334-01 85-264Vac 4.75-5.25V 700-900mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT334 5V/1000MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT334 30mW 5V 5W EPC13 Flyback Key Component Selection The maximum output current is decided by formula(1). 1 0.9 * 0.396 2 η × FSW (1) IOUTCC = × LP × ( ) ×( ) 2 RCS VOUTCC L=41.3mm W=28.1mm H=13.2mm Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz. η is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT334 to provide output power of 5V1000mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (D1,D2,D3,D4,C1, L1, C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT334 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 N AUX (2) Np/Ns/Naux (147/9/24) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 1000mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs Figure 1: Schematic of Charger -14- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT334 5V/1000MA CHARGER Bill of Materials REF DESCRIPTION Capacitor, Electrolytic, 6.8µF/400V, 8 × 12mm KSC C3 Capacitor, Ceramic,220pF/500V,1206,SMD POE C4 Capacitor, Ceramic,, 4.7µF/35V, 1206, SMD POE Capacitor, Electrolytic, 330µF/10V, 6.3 × 8mm KSC C5,C6 C9 Capacitor, Ceramic,1000pF/50V,0805,SMD D1-D5 Item Condition Limits 50Hz, 1 minute, from primary and secondary 3000Vac 2 P1 Inductance Inductance between pins 1 and 4 at 1Vac & 1kHz 1.55mH±%7 3 P1 Leakage Inductance Inductance between pins 1 and 4 with pins 2-3 and 6-10 shorted 75µH 1 PCB Top and Bottom Layers POE Diode,Rectifier,1000V/1A,1N4007, DO-41 Good-Ark D6 Fast Recovery Rectifier,RS1D,200V/1.0A,SMA Good-Ark D8 Diode, Schottky, 40V/3A, SB340, SMA Good-Ark L1 Axial Inductor, 1.5mH, 0410, DIP PCB1 Description Electrical Strength Amode Tech PCB, L*W*T=41.3x28.1x1.6mm,Cem-1,Rev:A Jintong Q1 Transistor, NPN, 700V,1.5A, D13003, TO-251AB Huawei FR1 Fusible Resistor, 1W, 10Ω, 5% TY-OHM R1,R4 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 1.0MΩ, 1206, 5% TY-OHM R3 Chip Resistor, 470Ω, 1206, 5% TY-OHM R5 Chip Resistor, 60.4kΩ, 0805, 1% TY-OHM R6 Chip Resistor, 11.3kΩ, 0805, 1% TY-OHM R7,R8 Chip Resistor, 15MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 1.0Ω, 1206, 1% TY-OHM R10 Chip Resistor, 80.6kΩ, 0805, 5% TY-OHM R11 Chip Resistor, 3.9kΩ, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM T1 Transformer, LP = 1.55mH±7%, EPC13 5+5pin U1 IC, ACT334US-T, SOT23-6 Typical Performance Characteristics STANDBY POWER Average Efficiency Vs Vin 72.00% Efficiency C1, C2 Electrical specifications MFTR Active-Semi Transformer Specitication 70.00% Efficiency Vs Vin 115V,230" 68.00% 66.00% 110 135 160 185 210 235 Vin EFFICIENCY Build up Terminal Winding Wire Insulation Turns Start Finish Type Size*QTY Layer Thick/Wide Lay er 4 --> 49 2UEW 0.12Φ*1 1 0.025*8.5W <-- <-- 49 2UEW 0.12Φ*1 1 0.025*8.5W --> 1 49 2UEW 0.12Φ*1 1 0.025*8.5W SH1 2 NC 49 2UEW 0.12Φ*1 1 0.025*8.5W P2 2 3 24 2UEW 0.12Φ*1 1 0.025*8.5W 1 S1 10 6 9 TEX-E 0.40Φ*1 1 0.025*8.5W 2 SH2 2 Core 1 P1 CC/CV CURVE 3 Note:1.SH1,SH2 are shielding; P1 & P2 are primary and S1 is secondary.(Bobbin:EPC13) -15- EVALUATION KITS Vin Vo Io ACT334-02 85-264Vac 4.75-5.25V 1000-1200mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT336 5V/1200MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT336 30mW 5V 7W EFD15 Flyback Key Component Selection L=26.4mm W=24.4mm H=26.0mm The maximum output current is decided by formula (1). 1 0.9 * 0.396 2 η × FSW IOUTCC = × LP × ( ) ×( ) (1) 2 RCS VOUTCC Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz.η is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT336 to provide output power of 5V1200mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (BD1,C1, L2,C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT336 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 6 and Pin 2,4,7 are the VDD and ground pins to provide power for the IC. Pin 8 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 3 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, Shaver, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 NAUX (2) Np/Ns/Naux (140/8/23) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 1200mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -16- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT336 5V/2100MA CHARGER Electrical specifications Bill of Materials DESCRIPTION MFTR Item C1,C2 Capacitor, Electrolytic, 6.8µF/400V, 8x12mm Koshin C3 Capacitor, Ceramic,220pF/500V,0805,SMD POE C4 Capacitor, Ceramic,4.7µF/35V,0805,SMD POE C5,C6 Capacitor, Electrolytic, 330µF/10V, 8x12mm C9 Capacitor, Ceramic,1000pF/50V,0805,SMD BD1 POE Bridge,B6S,600V/0.5A,MDI,SMD D5,D6 Diode,Ultra Fast, FR107,1000V/1.0A,DO-41 Diode, schottky, 40V/5A, SK54, SMC 3000Vac 2 P1 Inductance Inductance between pins 2 and 4 at 1Vac & 1kHz 1.53mH±%7 3 P1 Leakage Inductance Inductance between pins 1 and 3 with pins 2-4 and A-B shorted 75µH Good-Ark PANJIT L1 Axial Inductor, 1.5mH,0410,Dip Q1 Transistor, HFE 20-25, NPN,D13003X,TO-251 PCB1 PCB, L*W*T=26.4x24.4x0.8mm,Cem-1,Rev:A FR1 Limits PCB Top and Bottom Layers PANJIT D8 Condition 50Hz, 1 minute, from primary and secondary 1 KSC Description Electrical Strength Amode Tech Huawei Jintong Wire Round Resistor,1W,10 ohm,KNP, 5% TY-OHM R1 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 1MΩ, 0805, 5% TY-OHM R3 Chip Resistor, 330Ω, 0805, 5% TY-OHM R4 Chip Resistor, 22Ω, 0805, 5% TY-OHM R5 Chip Resistor, 65kΩ, 0805,1% TY-OHM R6 Chip Resistor, 11.3kΩ, 0805,1% TY-OHM R7,R8 Chip Resistor, 15MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 0.91Ω, 1206,1% TY-OHM R10 Chip Resistor, 162kΩ, 0805, 5% TY-OHM R11 Chip Resistor, 3.6kΩ, 0805, 5% TY-OHM R13 Chip Resistor, 10 ohm, 0805, 5% TY-OHM T1 Transformer, Lp=1.53mH, EFD15 U1 IC, ACT336SH,SOP-8 Typical Performance Characteristics STANDBY POWER Average Efficiency Vs Vin Active-Semi. 74.00% Efficiency REF Transformer Specitication 2 Reverse P1 B 4 NC 3 72.00% 70.00% 68.00% 110 S1 NC Efficiency Vs Vin 115V,230" 135 160 185 210 235 Vin A P2 EFFICIENCY 1 Build up Terminal Winding P2 P1 Start Finish Wire Turns Type Insulation Size*QTY Layer Thick/Wide Layer 2 3 1 23 2UEW 0.12Φ*2 1 0.025*8.5W 4 --> 47 2UEW 0.15Φ*1 1 0.025*8.5W <-- <-- 47 2UEW 0.15Φ*1 1 0.025*8.5W 2 --> 2 46 2UEW 0.15Φ*1 1 0.025*8.5W SH1 1 NC 17 2UEW 0.12Φ*3 1 0.025*8.5W 2 S1 A B 8 TEX-E 0.30Φ*2 1 0.025*8.5W 2 SH2 NC 1 21 2UEW 0.12Φ*3 1 0.025*8.5W 2 Note:1.SH1 and SH2 are shielding; P1 ,P2 and P3 are primary and S1 is secondary.(Bobbin:EFD15) -17- EVALUATION KITS Vin Vo Io ACT336-01 85-264Vac 4.75-5.25V >1200mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT337 5V/1500MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT337 30mW 5V 7.5W EE16 Flyback Key Component Selection L=50.6mm W=26.2mm H=20.9mm The maximum output current is decided by formula (1). 1 0.9 * 0.396 2 η × FSW IOUTCC = × LP × ( ) ×( ) (1) 2 RCS VOUTCC Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz.η is the overall system efficiency,which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT337 to provide output power of 5V/1500mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (BD1,C1, L2,C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT337 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 6 and Pin 2,4,7 are the VDD and ground pins to provide power for the IC. Pin 8 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 3 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, Shaver, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 NAUX (2) Np/Ns/Naux (110/8/18) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 1500mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -18- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT337 5V/1500MA CHARGER Bill of Materials REF Electrical specifications DESCRIPTION MFTR C1 Capacitor, Electrolytic, 6.8µF/400V, 8×14mm Koshin C2 Capacitor, Electrolytic, 10µF/400V,10×14mm Koshin C3 Capacitor, Ceramic,220pF/500V,1206,SMD C4 Capacitor, Electrolytic, 10µF/35V,5x11mm KSC Capacitor, Electrolytic,680µF/10V, 8 ×16mm KSC C9 Capacitor, Ceramic,1000pF/50V,0805,SMD POE Bridge Rectifier,MB6S,600V/1.0A,SDIP PANJIT Fast Recovery Rectifier, FR107,1000V/1.0A, DIP PANJIT D6 Fast Recovery Rectifier,RS1D,200V/1.0A,SMA PANJIT D8 Diode, Schottky, 40V/5A, SS54, SMC L1 Choke Coil, 1.5mH, ¢6x8mm, DIP Limits 3000Vac 2 P1 Inductance Inductance between pins 2 and 3 at 1Vac & 1kHz 1.15mH±%7 3 P1 Leakage Inductance Inductance between pins 2 and 3 with pins 4-5 and 6-10 shorted 75µH Diodes Amode Tech PCB, L*W*T=50x26x1.6mm,Cem-1,Rev:A Jintong Q1 Transistor, NPN, 700V,D13005,TO-220 Huawei FR1 Fusible Resistor, 1W, 10Ω, 5% TY-OHM R1 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 1M,1206, 5% TY-OHM R3 Chip Resistor, 300Ω,1206, 5% TY-OHM R4 Chip Resistor, 15Ω, 0805, 5% TY-OHM R5 Chip Resistor, 66.7kΩ, 0805, 1% TY-OHM R6 Chip Resistor,12.4kΩ, 0805, 1% TY-OHM R7,R8 Chip Resistor, 15MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 0.708Ω,1206, 1% TY-OHM R10 Chip Resistor, 80k, 0805, 5% TY-OHM R11 Chip Resistor, 3.6k, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM T1 Condition 50Hz, 1 minute, from primary and secondary PCB Top Layer D5 PCB1 Description Electrical Strength 1 POE C5,C6 BD1 Item PCB Bottom Layer Typical Performance Characteristics Transformer, LP = 1.15mH±7%, EE16 USB Double-layer USB Rev:A U1 IC, ACT337SH-T,SOP-8 Active-Semi STANDBY POWER Transformer Specitication EFFICIENCY Build up Terminal Wind ing Wire Insulation Turns Type Size*QTY Layer Thick/Wide Laye r 74 2UEW 0.22Φ*1 1 0.025*8.5W 2 4 0.9 Copper 0.7mm 1 0.025*8.5W 2 B A 8 TEX-E 0.75Φ*1 1 0.025*8.5W 2 P2 5 4 18 2UEW 0.14¢*3 1 0.025*8.5W 2 P3 3 1 36 2UEW 0.22¢*1 1 0.025*8.5W 2 SH2 4 core 3 Copper wire 0.15Φ*1 1 0.025*8.5W 8 Start Finish P1 2 3 SH1 --> S1 CC/CV CURVE Note:1.SH1 and SH2 are shielding; P1 ,P2 and P3 are primary and S1 is secondary.(Bobbin:EE16) -19- EVALUATION KITS Vin Vo Io ACT337-01 85-264Vac 4.75-5.25V 1500-1800mA ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT337 5V/2100MA CHARGER Input Voltage Device Standby Power Output Voltage Power output Transformer Topology 85-264VAC ACT337 30mW 5V 10.5W EPC17 Flyback Key Component Selection L=40.0mm W=27.9mm H=22.0mm The maximum output current is decided by formula (1). 1 0.9 * 0.396 2 η × FSW IOUTCC = × LP × ( ) ×( ) (1) 2 RCS VOUTCC Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz.η is the overall system efficiency, which value is approximately equal to 70%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). Operation and Application Figure 1 is the schematic of an offline charger using ACT337 to provide output power of 5V2100mA. This circuit is a typical flyback power supply which includes the AC rectified circuit (BD1,C1, L2,C2),power drive circuit (BD pin, Q1), secondary rectified circuit (D8, C5,C6) and the IC control circuit. ACT337 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 6 and Pin 2,4,7 are the VDD and ground pins to provide power for the IC. Pin 8 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 3 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. This circuit can be used as universal charger for Cell Phones, PDAs, MP3,Portable Media Players, Shaver, DSCs, and Other Portable Devices and Appliances. VOUTCC = VREF × (1 + R5 N ) × S − VSEC _ R R6 NAUX (2) Np/Ns/Naux (110/8/18) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 5V and Ioutcc_min equal to 2100mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of Charger -20- ActivePSR TM High Efficiency AC/DC Primary Switching Solutions ACT337 5V/2100MA CHARGER Bill of Materials REF Electrical specifications DESCRIPTION C1, C2 C3 MFTR Capacitor, Electrolytic, 10µF/400V, 10×16mm KSC Capacitor, Ceramic,220pF/500V,1206,SMD POE C4 Capacitor, Ceramic, 10µF/35V,1206,SMD KSC C5 Capacitor, Electrolytic, 1000µF/6.3V, 8 ×16mm KSC C6 Capacitor, Electrolytic, 820µF/6.3V, 6.3 × 16mm KSC C9 Capacitor, Ceramic,1000pF/50V,0805,SMD POE CY1 Safety Y1,Capacitor,1000pF/400V,Dip UXT BD1 Bridge Rectifier,D1010S,1000V/1.0A,SDIP PANJIT D5 Fast Recovery Rectifier, RS1M,1000V/1.0A, RMA PANJIT D6 Fast Recovery Rectifier,RS1D,200V/1.0A,SMA PANJIT D8 Diode, Schottky, 45V/10A, S10U45S, SMD L1 Choke Coil, 1.5mH, ¢6x8mm, DIP PCB1 Item Condition Limits 50Hz, 1 minute, from primary and secondary 3000Vac 2 P1 Inductance Inductance between pins 2 and 3 at 1Vac & 1kHz 1.25mH±%7 3 P1 Leakage Inductance Inductance between pins 2 and 3 with pins 4-5 and 6-10 shorted 75µH 1 PCB Top and Bottom Layers Diodes Amode Tech PCB, L*W*T=40x27.9x1.6mm,Cem-1,Rev:A Jintong Q1 Transistor, NPN, 700V,D13005,TO-126 Huawei F1 Fuse:1A 250V 3.6*10mm With Pigtail, ceramic tube R1 Chip Resistor, 22Ω, 0805, 5% TY-OHM R2 Chip Resistor, 1MΩ,1206, 5% TY-OHM R3 Chip Resistor, 390Ω,1206, 5% TY-OHM R4 Chip Resistor, 15Ω, 0805, 5% TY-OHM R5 Chip Resistor, 80.6kΩ, 0805, 1% TY-OHM R6 Chip Resistor,18.2kΩ,0805, 1% TY-OHM R7 Chip Resistor, 30MΩ, 1206, 5% TY-OHM R9 Chip Resistor, 0.62Ω,1206, 1% TY-OHM R10 Chip Resistor, 162kΩ, 0805, 5% TY-OHM R11 Chip Resistor, 3kΩ, 0805, 5% TY-OHM R13 Chip Resistor, 10Ω, 0805, 5% TY-OHM T1 Description Electrical Strength walter Typical Performance Characteristics STANDBY POWER Transformer, LP = 1.25mH±7%, EPC17 USB Double-layer USB Rev:A S/H1 AL HeatSink, LxWxH=7.5x17x2.0mm U1 IC, ACT337SH-T,SOP-8 Active-Semi P3 Transformer Specitication SH1 EFFICIENCY Build up Terminal Winding Wire Insulation Turns Type Size*QTY Layer Thick/Wide Lay er 74 2UEW 0.22Φ*1 1 0.025*8.5W 2 0.9 Copper 0.7mm 1 0.025*8.5W 2 A 8 TEX-E 0.75Φ*1 1 0.025*8.5W 2 5 4 18 2UEW 0.14¢*3 1 0.025*8.5W 2 3 1 36 2UEW 0.22¢*1 1 0.025*8.5W 2 4 core 3 Copper wire 0.15Φ*1 1 0.025*8.5W 8 Start Finish P1 2 3 SH1 --> 4 S1 B P2 P3 SH2 Note:1.SH1 and SH2 are shielding; P1 ,P2 and P3 are primary and S1 is secondary.(Bobbin:EPC17) -21- EVALUATION KITS Vin Vo Io ACT365-02 85-264Vac 4.75-5.25V >2200mA