ACT4533C+CHY100 5V/2.1A&9V/1.5A Car Charger Solution Application Report Car Charger Using ACT4533C+CHY100 FEATURES Wide input voltage range from 10V to 36V 125kHz switching frequency eases EMI design Stable with low-ESR ceramic capacitors 2% feedback voltage accuracy Standby input current <10mA Thermal shutdown protection Over output voltage protection Cord compensation Over current protection Supports Qualcomm® Quick Charge 2.0 (QC2.0) high voltage dedicated charging port (HVDCP) Class A with voltage configuration of 5V ,9V and 12V USB battery charging specification revision 1.2 compatible Automatic USB DCP shorting D+ to D- line Default 5 V mode operation Fast discharge from 9V/12V to 5V at USB cable unplug or from a high voltage level to a lower level TYPICAL APPLICATIONS Car Charger in support QC2.0 Battery chargers for smart phones, tablets, net-books Digital cameras and blue-tooth accessories USB power output ports Active-Semi, Inc. -1- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution SPECIFICATION DESCRIPTION CONDITION Input Voltage MIN 10 Switching Frequency No-load Standby Input current Output Voltage Output Current Ripple Voltage Efficiency at full load TYP MAX UNITS 36 V 125 kHz Vin=12V no load 5.5 mA Vin=24V no load 4.0 mA D+=0.6V,D-=GND 4.75 D+=3.3V,D-=0.6V Vout=5V 5 5.25 9 2400 2900 Vout=9V 1500 Vin=12V, Vo=5V,Io=2.4A 50.0 Vin=24V, Vo=5V,Io=2.4A 54.0 Vin=12V, Vo=9V,Io=1.5A 28.4 Vin=24V, Vo=9V,Io=1.5A 55.0 Vin=12V, Vo=5V,Io=2.1A 88.9 Vin=24V, Vo=5V,Io=2.1A 87.6 Vin=12V, Vo=9V,Io=1.5A 95.0 Vin=24V, Vo=9V,Io=1.5A 92.8 V mA mVpp % ENVIRONMENTAL ESD Ambient Temperature Active-Semi, Inc. Contact 4 kV Through air 8 kV Free convection 0 -2- Active-Semi. Confidential-Do Not Copy or Distribute 50 ºC www.active-semi.com 5V/2.1A&9V/1.5A Solution TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. Demo Board Photo ........................................................................................................................................................ 4 Schematic ...................................................................................................................................................................... 4 PCB Layout ................................................................................................................................................................... 4 Bill of Materials ............................................................................................................................................................ 5 Functional Test .............................................................................................................................................................. 6 5.1. Output Regulation ............................................................................................................................................. 6 5.2. Efficiency (Ta=25C) .......................................................................................................................................... 6 5.3. Constant Current and Constant Voltage (Ta=25C) ............................................................................................ 7 5.4. Current Limit vs. Input Voltage ......................................................................................................................... 9 5.5. Power Loss ...................................................................................................................................................... 10 5.6. Standby Input Current ..................................................................................................................................... 11 5.7. Ripple and Noise ............................................................................................................................................. 12 5.8. Load Dynamic Response ................................................................................................................................. 13 5.9. Turn-on Delay Time ........................................................................................................................................ 14 5.10. Output Voltage Transition ................................................................................................................................ 15 5.11. Key Components Temperature Test (Ta=40C, burning for 2 hours)................................................................ 15 EMI TEST (RADIATED) ........................................................................................................................................... 16 6.1. Input 12V Output 5V/2.1A .............................................................................................................................. 16 6.2. Input 24V Output 5V/2.1A .............................................................................................................................. 18 6.3. Input 12V Output 9V/1.5A .............................................................................................................................. 20 6.4. Input 24V Output 9V/1.5A .............................................................................................................................. 22 Active-Semi, Inc. -3- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 1. DEMO BOARD PHOTO 2. SCHEMATIC 3. PCB LAYOUT Active-Semi, Inc. -4- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 4. BILL OF MATERIALS Item Reference 1 L1 Choke Coil, 6*3*3mm, L=68uH 3.5A 1 2 D1 Schottky Diode, SK54BL, 40V/5A, SMA 1 Diodes 3 C0 Ceramic capacitor, 0.1uF/35V, X7R, 0805 1 Murata/TDK 4 C1 Electrolytic capacitor, 100uF/35V, 5x7mm 1 Koshin 5 C2 Ceramic capacitor, 10uF/35V, X7R, 0805 1 Murata/TDK 6 C3 Ceramic capacitor, 2.2nF/16V, X7R, 0603 1 Murata/TDK 7 C4 Ceramic capacitor, 47pF/16V, X7R, 0603 (Optional) 1 Murata/TDK 8 C5 Ceramic capacitor, 22nF/25V, X7R, 0603 1 Murata/TDK 9 C6 Ceramic capacitor, 1nF/25V, X7R, 0603(Optional) 1 Murata/TDK 10 C7 Electrolytic capacitor, 220uF/16V 1 Murata/TDK 11 C8 Ceramic capacitor, 10uF/25V, X7R, 0805 1 Murata/TDK 12 C9 Ceramic capacitor, 1nF/16V, X7R, 0603 1 Murata/TDK 13 C10 Ceramic capacitor, 220nF/25V, X7R, 0603 1 Murata/TDK 14 C11 Ceramic capacitor, 10uF/16V, X7R, 0603 1 Koshin 15 F1 Fuse,3A,1206 (Replaced by 0Ω 1206 chip resistor) 1 Murata/TDK 16 R1 Chip Resistor, 7.87KΩ, 1/10W, 1%, 0603 1 Murata/TDK 17 R2 Chip Resistor, 10KΩ, 1/10W, 5%, 0603 1 Murata/TDK 18 R3 Chip Resistor, 100KΩ, 1/10W, 1%, 0603(Optional OVP) 1 Murata/TDK 19 R4 Chip Resistor, 6.04KΩ, 1/10W, 1%, 0603(Optional OVP) 1 Murata/TDK 20 R5 Chip Resistor, 9.76KΩ, 1/10W, 1%, 0603 1 Murata/TDK 21 R6 Chip Resistor, 5.1 Ω, 1/10W, 1%, 0603 1 Murata/TDK 22 R7 Chip Resistor, 10.2kΩ, 1/10W, 1%, 0603 1 Murata/TDK 23 R8 Chip Resistor, 14KΩ, 1/10W, 1%, 0603 1 Murata/TDK 24 R9 Chip Resistor, 51.1 KΩ, 1/10W, 5%, 0603 1 Murata/TDK 25 R10,R11 Chip Resistor, 100 KΩ, 1/10W, 1%, 0603 (R10, Optional) 2 Murata/TDK 26 R12 Chip Resistor, 4.53KΩ, 1/10W, 1%,0603 1 Murata/TDK 27 R13 Chip Resistor, 127KΩ, 1/10W, 5%, 0603 1 Murata/TDK 28 R14 Chip Resistor, 390KΩ, 1/10W, 1%, 0603 1 Murata/TDK 29 U1 IC, ACT4533C, SOP-8-EP 1 ACT 30 U2 IC, CHY100, SO-8 1 PI 31 USB USB Rev:A 1 Active-Semi, Inc. Description -5- Active-Semi. Confidential-Do Not Copy or Distribute QTY Manuf. www.active-semi.com 5V/2.1A&9V/1.5A Solution 5. FUNCTIONAL TEST 5.1. Output Regulation Output Voltage Output Voltage at Max. load (V) at No load (V) 12V 5.07 5.04 0.6% 16V 5.07 5.04 0.6% 24V 5.07 5.04 0.6% Output Voltage Output Voltage at Max. load (V) at No load (V) 12V 9.04 9.02 0.22% 16V 9.04 9.02 0.22% 24V 5.04 9.02 0.22% VIN VIN Load regulation Iload(max) 2.4A Load regulation Iload(max) 1.5A 5.2. Efficiency (Ta=25C) Efficiency (%) VIN Vout=5V Io=100mA Io=500mA Io=1000mA Io=2000mA Io=2100mA 12V 84.8 94.2 91.6 88.8 88.9 16V 82.5 90.4 90.3 88.4 88.3 24V 72.5 87.8 88.9 87.9 87.6 Active-Semi, Inc. -6- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Efficiency (%) VIN Vout=9V Io=100mA Io=300mA Io=500mA Io=1000mA Io=1500mA 12V 91.1 95.5 95.9 96 95 16V 87.3 93.5 94.3 94.99 94 24V 81.7 90.1 91.92 93.1 92.8 5.3. Constant Current and Constant Voltage (Ta=25C) Vin=12V Vin=16V Vin=24V Vout(V) Iout(mA) Vout(V) Iout(mA) Vout (V) Iout(mA) CC Load CV Load Active-Semi, Inc. 5.04 0 5.04 0 5.04 0 5.04 200 5.04 200 5.04 200 5.05 1000 5.05 1000 5.04 1000 5.07 2000 5.06 2000 5.05 2000 5.08 2400 5.07 2400 5.06 2400 5.08 2600 5.08 2600 5.07 2600 5 2714 5 2723 5 2736 4.9 2712 4.9 2721 4.9 2735 4.7 2711 4.7 2720 4.7 2735 4.5 2711 4.5 2719 4.5 2735 4 2713 4 2715 4 2736 3 2712 3 2719 3 2717 2 2715 2 2720 2 2715 1 2713 1 2703 1 2711 0.8 2710 0.8 2709 0.8 2723 0 2704 0 2705 0 2712 -7- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Vin=12V Vin=16V Vin=24V Vout(V) Iout(mA) Vout(V) Iout(mA) Vout (V) Iout(mA) CC Load CV Load Active-Semi, Inc. 9.02 0 9.02 0 9.03 200 9.03 200 9.03 200 9.03 1000 9.03 1000 9.03 1000 9.04 2000 9.04 2000 9.03 2000 9.04 2400 9.05 2400 9.05 2400 9.05 2600 9.06 2600 9.05 2600 9 2686 9 2711 9 2739 8 2679 8 2714 8 2737 7 2704 7 2717 7 2737 6 2706 6 2718 6 2733 5 2711 5 2724 5 2728 4 2715 4 2717 4 2731 3 2713 3 2721 3 2716 2 2716 2 2724 2 2714 1 2710 1 2710 1 2714 0.8 2710 0.8 2712 0.8 2722 0 2705 0 2708 0 2711 0 -8- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 5.4. Current Limit vs. Input Voltage No Wind ( Test Condition : CV load 4.7V, Ta=25C) Vin (V) 10 11 12 13 14 15 16 18 20 24 28 30 31 Iout (mA) 2718 2722 2726 2730 2726 2731 2734 2741 2741 2748 2758 2760 2758 Active-Semi, Inc. -9- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution No Wind ( Test Condition : CV load 7V, Ta=25C) Vin (V) 10.5 11 12 13 14 15 16 18 20 24 28 30 31 Iout (mA) 2700 2712 2716 2723 2723 2726 2730 2740 2744 2755 2764 2766 2766 5.5. Power Loss Power loss (W) Vout=5V Vin Io=0mA Io=100mA Io=500mA Io=1000mA Io=2000mA Io=2100mA Vin=12V 0.04 0.09 0.16 0.46 1.28 1.32 Vin=16V 0.06 0.11 0.27 0.54 1.33 1.41 Vin=24V 0.06 0.17 0.35 0.63 1.40 1.50 Active-Semi, Inc. - 10 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Power loss (W) Vout=9V Vin Io=0mA Io=100mA Io=500mA Io=1000mA Io=1500mA Vin=12V 0.07 0.09 0.19 0.37 0.71 Vin=16V 0.09 0.13 0.27 0.48 0.86 Vin=24V 0.13 0.21 0.40 0.67 1.05 5.6. Standby Input Current Test Conditions(Vout=5V) Input Current（mA） Power Loss at No Load (W) Vin=12V 3.65 0.04 Vin=16V 3.53 0.06 Vin=24V 2.41 0.06 Test Conditions(Vout=9V) Active-Semi, Inc. Input Current （mA） Power Loss at No Load (W) Vin=12V 5.89 0.07 Vin=16V 5.42 0.09 Vin=24V 5.55 0.13 - 11 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 5.7. Ripple and Noise (Note: CH1: Input Voltage CH2:SW Vin=12V 5V/1A output load (30.4mV) CH3:Output voltage CH4:Output Current) Vin=12V 5V/2.4A output load (50mV) Vin=24V 5V/1A output load (37mV) Vin=24V 5V/2.4A output load(54mV) Vin=12V 9V/1A output load (24.4mV) Vin=12V 9V/1.5A output load(28.4mV) Vin=24V 9V/1A output load (48mV) Active-Semi, Inc. Vin=24V 9V/1.5A output load(55mV) - 12 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Test Conditions Output Ripple at 5V/1A Load (mV) Output Ripple at 5V/2.4A Load (mV) Vin=12V 30.4 50.0 Vin=24V 37.0 54.0 Test Conditions Output Ripple at 9V/1A Load (mV) Output Ripple at 9V/1.5A Load (mV) Vin=12V 24.4 28.4 Vin=24V 48.0 55.0 5.8. Load Dynamic Response (Note: CH1:Output Voltage(DC) CH2: Output Voltage( AC) CH3: Output Current) Vin=12V Vout=5V load step 80mA-1A -80mA Vin=12V Vout=5V load step 1A-2.4A-1A Vin=24V Vout=5V load step 80mA-1A -80mA Vin=24V Vout=5V load step 1A-2.4A-1A Active-Semi, Inc. - 13 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Vin=12V Vout=9V load step 80mA-1A -80mA Vin=24V Vout=9V load step 80mA-1A -80mA Vin=12V Vout=9V load step 1A-1.5A-1A Vin=24V Vout=9V load step 1A-1.5A -1A 5.9. Turn-on Delay Time (Note:CH1:Input Voltage CH2:Output Voltage CH3: SW) No load Input:12V, Output: 5V T= 2ms Full load(2.4A) Input:12V, Output: 5V T= 2ms Active-Semi, Inc. - 14 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution No load Input:24V, Output: 5V T= 600us Full load(2.4A) Input:24V, Output: 5V T= 800us 5.10. Output Voltage Transition (Note: CH1: Input Voltage CH2: Output Voltage CH3: SW) 5V-9V No Load Tr=380us 9V-5V No Load Tr=248ms 5.11. Key Components Temperature Test (Ta=40C, burning for 2 hours) Active-Semi, Inc. Vout=5V Vin/Iout 12V/2.4A 16V/2.4A 24V/2.4A IC 80.3 ºC 80.7 ºC 88.8 ºC Diode 83.6 ºC 84.2 ºC 93.7 ºC Inductor 72.3 ºC 72.6 ºC 77.1 ºC Vout=9V Vin/Iout 12V/1.5A 16V/1.5A 24V/1.5A IC 63.3 ºC 65.3 ºC 67.5 ºC Diode 61.9 ºC 65.9 ºC 71.1 ºC Inductor 58.2 ºC 59.8 ºC 61.5 ºC - 15 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 6. EMI TEST (RADIATED) 6.1. Input 12V Output 5V/2.1A Active-Semi, Inc. - 16 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Active-Semi, Inc. - 17 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 6.2. Input 24V Output 5V/2.1A Active-Semi, Inc. - 18 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Active-Semi, Inc. - 19 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 6.3. Active-Semi, Inc. Input 12V Output 9V/1.5A - 20 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Active-Semi, Inc. - 21 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution 6.4. Input 24V Output 9V/1.5A Active-Semi, Inc. - 22 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com 5V/2.1A&9V/1.5A Solution Active-Semi, Inc. - 23 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com