ACT520 QC 1.5A Application Report High Performance QR Mode 18W Quick Changer Using ACT520 FEATURES Quasi-Resonant PWM Controller Accurate CC with line and inductance compensation No-load Standby Power < 30mW Excellent Efficiency( >80%) with Low Cost 4N65 MOSFET Exceed CEC Average Efficiency Requirement with Lot of Margin Independent Output Short Protection OTP, OVP, BrownOut Protection, Rcs Short/Open Protection, Transformer Winding Short Protection, Output Diode Short/Open Protection, Open Loop Protection, OVP SPECIFICATION DESCRIPTION CONDITION MIN TYP MAX UNITS INPUT Voltage 90 264 VAC Frequency 47 63 Hz No-load Standby Power 230VAC, no Load, Vo=12/9V 75 230VAC, no Load, Vo=5V 30 mW OUTPUT Voltage V1 4.75 5 5.25 V V2 8.55 9 9.45 V V3 11.4 12 12.6 V 1.5 1.5 1.8 A Current Power 18 Ripple Voltage 120 Average Efficiency 115 or 230 VAC, Vo=5V ENVIRONMENTAL Conducted EMI Safety Y capacitor Surge ESD Ambient Temperature Active-Semi, Inc. W 80 mVpp % CISPR22/ FCC Part15 Class B EN60950/UL1950 Differential mode 2 kV Common mode 2 kV Contact 4 kV Through air 8 kV 50 ºC Free convection 0 -1- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A TABLE OF CONTENTS 1. 2. 3. 4. 5. Demo Board Photo …………………………………………………………………………………………........3 Schematics ……………………………………………………………………………………………………....................3 PCB Layout…………………………………………………………………………………………………………..…. 3 Bill of Materials…………………………………………………………………………………………………..............4 Transformer Specification …………………………………………………………………………………………………5 5.1. Schematics ……………………………………………………………………………………………………………5 5.2. Build-up Table …..………………………………………………………………………………………................ 5 5.3. Build-up Diagram…………………………………………………………………………………………………... 5 5.4. Electrical Specifications…………………………………………………………………………………………...5 6. Functional Test …………………………..……………………………………………………………………………….6 6.1. Standby Power …………………………………………………………………………………………………….6 6.2. Efficiency …………………………………………………………………………………………………………..6 6.3. Line and Load Regulation ………………………………………………………………………………………..7 6.4. Ripple and Noise ………………………………………………………………………………………………….7 6.5. Turn-on and Turn-off ………………………………………………………………………………………………8 6.6. Current Limit and Constant Current …………………………………………………………………….............8 6.7. Short Circuit Protection and Release …………………………………………………………………….……..10 6.8. Dynamic Load ……………………………………………………………………………………………………..10 6.9. Brown-out Test ……………………………………………………………………………………………………..10 7. EMC Test ………………………………………………………………………………………………………................10 7.1. Conduction Test………………………………………………………………………………………………..10 7.2. Radiation Test……………………………………………………………………………………………..12 7.3. Surge ……………………………………………………………………………………………..13 7.4. ESD……………………………………………………………………………………………..13 Active-Semi, Inc. -2- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 1. DEMO BOARD PHOTO 2. SCHEMATICS 3. PCB LAYOUT Active-Semi, Inc. -3- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 4. BILL OF MATERIALS Item Reference QTY Manufacturer 1 U1 IC, ACT520,SOP-8 1 Active-Semi. 2 U2 OPTO,EL3H7D,CTR:300-600%,4PIN SMD 1 EVERLIGHT 3 U3 TL431A, Ref=2.5V,1%,SOT23-3 1 TI 4 U4 IC, F75299,SOT-10 1 Finteck 5 C1,2 Capacitor, Electrolytic,15uF/400V, 8x15mm 2 RUBYCON 6 C11,C8 Capacitor, Ceramic, 1000pF/500V, 0805,SMD 2 POE 7 C4 Capacitor, Ceramic,10uF/50V, 1206 1 POE 8 C6 Capacitor, Solid, 470uF/16V, 8x12mm 1 KSC 9 C6 10 C9,10 Description Capacitor, Solid, 330uF/16V, 6.5x12mm 1 KSC Capacitor, Ceramic, 0.1uF/50V, 0805,SMD 2 POE 11 C7 Capacitor, Ceramic, 100pF/25V, 0805,SMD 1 POE 12 CY1 Safety Y1,Capacitor,1000pF/400V,Dip 1 UXT 13 BD1 BP06,1000V/1.0A,SDIP 1 PANJIT 14 D5,D6 Fast Recovery Rectifier, RS1M,1000V/1.0A, RMA 2 PANJIT 15 D7 NC 16 D8 Diode, Schottky, 100V/15A, TO-247AB 1 Diodes 17 LF1 CM Inductor, 27mH, EE8.3,D=0.2mm,90T 1 SoKa 18 Q1 N-Mosfet Transistor, 4N60,TO-220 1 AUK 19 Q2 N-Mosfet, Depletion mode,CSF501D,20mA/600V,SOT23 1 HuiJing 20 PCB1 PCB, L*W*T=39x39x1.0mm,FR-4,Rev:A 1 Jintong 21 F1 Fuse,2A/250V 1 TY-OHM 22 R3,3A,7 Carbon Resistor, 510K ohm, 1206, 5% 3 TY-OHM 23 R1,4 Chip Resistor, 22 ohm, 0805, 5% 2 TY-OHM 24 R2,23 Chip Resistor, 100 ohm, 0805, 5% 2 TY-OHM 25 R13 Chip Resistor, 10 ohm, 1206, 5% 4 TY-OHM 26 R5 Chip Resistor, 115K ohm, 0805,1% 1 TY-OHM 27 R6 Chip Resistor, 6.8K ohm, 0805, 1% 1 TY-OHM 28 R9,R9a Chip Resistor, 1.65 ohm,1206 , 1% 2 TY-OHM 29 R8,11 Chip Resistor, 510 ohm, 0805, 5% 2 TY-OHM 30 R12 Chip Resistor, 1.5k ohm, 0805,5% 1 TY-OHM 31 R14,26 Chip Resistor, 3.3k ohm, 0805, 5% 2 TY-OHM 32 R15 Chip Resistor, 10.5K ohm, 0805, 1% 1 TY-OHM 33 R16 Chip Resistor, 10.2K ohm, 0805, 1% 2 TY-OHM 34 R17 Chip Resistor, 6.34K ohm, 0805, 1% 1 TY-OHM 35 R18 Chip Resistor, 7.87K ohm, 0805, 1% 1 TY-OHM 36 R19,R20 Chip Resistor, 0 ohm, 0805, 5% 1 TY-OHM NC 1 TY-OHM TY-OHM NC 37 R21 38 R22,R27 39 R24 Chip Resistor, 20k ohm, 0805, 5% 1 40 R25 Chip Resistor, 1M ohm, 0805, 5% 1 TY-OHM 41 T1 Transformer, Lp=0.27mH, EI16+ 1 APY(安品源科技) 42 NR1 Thermal resistor, SC053 1 TY-OHM 43 VR1 10D471 1 TY-OHM 44 USB1 Small standard USB connector. 1 TY-OHM Active-Semi, Inc. -4- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 5. TRANSFORMER SPECIFICATION 6+ 6+ 5.1. Schematics 5.2. Build-up Table Terminal Wire Insulation Winding Start Finish Turns Type Size*QTY Layer Thick/Wide Layer P1 2 1 17 2UEW 0.22Ö*1 1 0.025*11W 1 4 NC 2UEW 0.10Ö*1 5 4 2UEW 0.10Ö*1 1 0.025*11W 1 S1 6 7 6 TEX-E 0.40Ö*1 1 0.025*11W 2 SH2 4 NC 10 2UEW 0.10Ö*3 1 0.025*11W 2 P3 1 3 17 2UEW 0.22Ö*1 1 0.025*11W 1 SH3 CORE 4 3 Copper wire 0.12Ö*1 1 0.025*11W 2 P2/SH1 16 Note:1.SH1,SH2,SH3 are shielding; P1,P2 & P3 are primary and S1 is secondary. 2. Reverse the direction of bobbin when do the S1,P2. 5.3. Build-up Diagram 5.4. Electrical Specifications Item Description Condition Limits 1 Electrical Strength 50Hz, 1 minute, from primary and secondary 3000 Vac 2 P1 Inductance Inductance between pins 3 and 2 at 1Vac & 1kHz 0.27mH±7% 3 P1 Leakage Inductance Inductance between pins 3 and 2 with pins 4-5 and 6-7 shorted 75µH Active-Semi, Inc. -5- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 6. FUNCTIONAL TEST 6.1. Standby Power VIN(AC) 90 115 230 264 Green Mode Limit (mW) Pass/Fail Vo=12V 48.52 49.8 51.2 58.2 75 Pass Vo=9V 35.22 36.44 39.56 44.22 75 Pass Vo=5V 20.11 23.44 25.42 29.12 30 Pass Standy Power mW) Standby Power Vs Input Voltage 60 50 40 30 20 10 Vo=5V Vo=9V Vo=12V 90 115 230 264 Input Voltage (VAC) 6.2. Efficiency(USB terminal) Average E,S 2.0 Eff(%) (average) 79.03% 80.99% 71.21% USB 80.60% 85.08% 81.86% 71.21% terminal 82.73% 81.06% 82.40% 78.49% USB terminal Vout Vac 10% Po 25% Po 50% Po 75% Po 100% Po V Io(mA) 150 375 750 1150 1500 115 79.88% 81.88% 82.82% 80.23% 230 76.77% 80.77% 81.00% 115 80.99% 82.99% 82.82% 5 9 12 Commend 230 77.88% 81.88% 82.98% 83.84% 84.06% 83.19% 78.49% 115 82.67% 84.48% 84.79% 84.08% 83.03% 84.09% 80.29% USB 230 78.19% 83.75% 84.46% 84.80% 84.79% 84.45% 80.29% terminal Efficiency Vs Po Efficiency 100.00% 80.00% 5V115VAC 5V230VAC 60.00% 9V115VAC 9V230VAC 12V115VAC 40.00% 12V230VAC 20.00% 10% Po 25% Po 50% Po 75% Po 100% Po Output Power Active-Semi, Inc. -6- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 6.3 Line and Load Regulation(USB terminal) Vout (V) VIN (VAC) 0% Po 25% Po 50% Po 75% Po 100% Po Voltage Limit (V) Pass/Fail 90 5.06 5.04 5.02 5.01 4.98 4.75V~5.25V Pass 115 5.06 5.04 5.02 5.01 4.99 4.75V~5.25V Pass 220 5.06 5.04 5.02 5.01 4.99 4.75V~5.25V Pass 264 5.06 5.04 5.02 5.01 4.99 4.75V~5.25V Pass 90 9.12 9.1 9.09 9.07 9.05 8.55V~9.45V Pass 115 9.12 9.1 9.09 9.07 9.05 8.55V~9.45V Pass 230 9.12 9.1 9.09 9.07 9.06 8.55V~9.45V Pass 264 9.12 9.1 9.09 9.07 9.06 8.55V~9.45V Pass 90 12.23 12.22 12.2 12.18 12.15 11.4V~12.6V Pass 115 12.21 12.19 12.17 12.15 12.14 11.4V~12.6V Pass 230 12.21 12.19 12.17 12.15 12.14 11.4V~12.6V Pass 264 12.21 12.19 12.17 12.15 12.14 11.4V~12.6V Pass 5 9 12 CV Regulation 14 12 5V90V 5V230V 9V90V 9V230V 12V90V 12V230V Vo(V) 10 8 6 5V115V 5V264V 9V115V 9V264V 12V115V 12V264V 4 2 0 0% Po 25% Po 50% Po 75% Po 100% Po Output Power 6.4 Ripple and Noise Active-Semi, Inc. -7- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A Vout(V) Ripple Limit VIN (VAC) 0% Po 25% Po 50% Po 75% Po 100% Po 90 26 17 16 23 34 80 Pass 115 25 15 15 18 25 80 Pass 230 22 15 18 18 22 80 Pass 264 26 42 54 66 68 80 Pass 90 19 24 34 48 56 100 Pass 115 16 22 30 44 56 100 Pass 230 17 24 28 46 58 100 Pass 264 18 24 30 48 52 100 Pass 90 24 55 77 82 90 120 Pass 115 24 50 71 85 92 120 Pass 230 28 48 75 80 88 120 Pass 264 30 44 72 80 88 120 Pass (mV) Pass/Fail 5 9 12 6.5 Turn-on and Turn-off Vin 6.6 Po Turn-on Turn-off Pass/Fail Delay (sec) Overshoot(mV) Delay (sec) Overshoot(mV) 90V, 0 1.18 0 10 0 Pass Po(W) 18 1.21 0 0.02 0 Pass 264V, 0 0.267 0 33 0 Pass Po(W) 18 0.258 0 0.16 0 Pass Current limit and constant current Condition 90 VAC(mA) 115VAC(mA) 230VAC(mA) 264 VAC(mA) 98% Vo 1639 1671 1688 1691 95% Vo 1647 1666 1681 1686 93% Vo 1646 1658 1680 1685 90% Vo 1639 1651 1685 1673 87% Vo 1635 1648 1688 1671 Active-Semi, Inc. -8- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 85% Vo 1637 1648 1683 1674 84% Vo 1628 1641 1660 1671 82% Vo 1631 1635 1658 1669 78% Vo 1630 1634 1656 1667 75% Vo 1628 1634 1654 1664 70% Vo 1625 1633 1651 1660 65% Vo 1626 1630 1645 1655 60% Vo 1627 1627 1637 1646 55%Vo 1622 1615 1627 1637 50% Vo 1612 1603 1617 1629 45% Vo 1605 1597 1614 1625 40% Vo 1597 1605 1620 1632 35% Vo 1599 1611 1626 1625 30% Vo 1595 1587 1593 1615 20% Vo 1650 1638 1622 1614 16% Vo 1669 1657 1631 1624 Output Voltage(V) V-I Characteristic Vs Vin(25℃) 13.00 12.00 11.00 10.00 9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 90V12V 115V12V 230V12V 264V12V 90V9V 115V9V 230V9V 264V9V 90V5V 115V5V 264V5V 230V5V limit1 limit2 0 300 600 900 1200 1500 1800 Output Current(mA) 6.7. Short Circuit Protection and Release Active-Semi, Inc. -9- www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A Protection 90 VAC 110 VAC 220VAC 264 VAC Pass/Fail Pin (W) 0.105 0.144 0.28 0.36 Pass Release Delay (mS) Overshoot(mV) 6 0 8 0 10 0 12 0 90 VAC, 0% Po Pass/Fail 0 90VAC, 100% Po 18 264 VAC, 0% Po 0 264 VAC, 100% Po 18 6.8. Dynamic Load(5Voutput,1ms,127.5mA/us,22AWG1.5m) Condition(Load%) Undershoot(mV) Overshoot(mV) 115VAC, 0%-100% 388mV 110mV 115VAC,50% -100% 150mV 98mV 230VAC,0%-100% 362mV 108mV 230VAC,50% -100% 146mV 114mV Pass/Fail 6.9. Brown-out Test Condition(100%Po) Pin (W) Vo (V) 90 VAC 22.945 12.04 85 VAC 23.266 12.04 80 VAC 23.641 12.03 70 VAC 24.66 12.02 60 VAC 25.26 12.01 50 VAC hiccup hiccup 7. EMC TEST 7.1. Conduction Test Active-Semi, Inc. - 10 - www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A Active-Semi, Inc. - 11 - www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 7.2. Radiation Test Active-Semi, Inc. - 12 - www.active-semi.com Rev 1.0 ACT520 quick changer 1.5A 7.3. Surge Condition Configuration Test Limit Pass/Fail Line – Neutral 2kV pass Condition Method Test Limit Pass/Fail 220 VAC, 100% Contact Po=18W Discharge 4kV Pass 8kV pass 220 VAC, 100% Po=18W 7.4. ESD 220 VAC, 100% Po=18W Active-Semi, Inc. Air Discharge - 13 - www.active-semi.com Rev 1.0