User Guide - Active-Semi

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
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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
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1. DEMO BOARD PHOTO
2. SCHEMATICS
3. PCB LAYOUT
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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
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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
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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
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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
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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
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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
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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
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ACT520 quick changer 1.5A
7.2.
Radiation Test
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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
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