EA4501SH

ACT4501 High Performance 5V/1A Car Charger Single layer Application Report High Performance Car Charger with EMI Solution FEATURES         Wide input voltage range from 10V to 24V 5% output voltage accuracy No load standby input current 5mA 7.5% constant current accuracy Thermal shutdown protection Cycle-by-cycle current limit Cord compensation Over current protection with frequency fold back SPECIFICATION DESCRIPTION CONDITION MIN Input Voltage 10 Switching Frequency No-load Standby Input current TYP MAX UNITS 24 V 110 kHz Vin=12V no Load 5 mA Vin=24V no Load 4 mA Output Voltage 4.75 5 Output Current 5.25 V 1000 mA Ripple Voltage Vin=12V Io=1A 46 mVpp Efficiency at full load Vin=12V Io=1A 87.9 % Contact 4 kV Through air 8 kV ENVIRONMENTAL ESD Ambient Temperature Active-Semi, Inc. Free convection 0 -1- Active-Semi. Confidential-Do Not Copy or Distribute 50 ºC www.active-semi.com ACT4501 5V/1A TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. Demo Board Photo ............................................................................................................................3 Schematics........................................................................................................................................3 PCB Layout .......................................................................................................................................3 Bill of Materials ..................................................................................................................................4 Functional Test ..................................................................................................................................5 5.1. Output Regulation ....................................................................................................................5 5.2. Efficiency .................................................................................................................................5 5.3. Constant Current and Contant Voltage.....................................................................................6 5.4. Power Loss ..............................................................................................................................7 5.5. Standby Power Loss ................................................................................................................7 5.6. Switching Frequency, Ripple and Noise ...................................................................................8 5.7. Key Components Temperature Test .........................................................................................8 EMC TEST ........................................................................................................................................9 6.1. Radiated EMI Test .......................................................................................................................7 6.2. ESD Test................................................................................................................................10 Active-Semi, Inc. -2- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A 1. DEMO BOARD PHOTO 2. SCHEMATICS 3. PCB LAYOUT Bottom layer Active-Semi, Inc. Top overlay -3- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A 4. BILL OF MATERIALS Item Reference Description QTY Manufacturer Haining 1 L1 Choke Coil, ring core:8*4*5mm,Pi=0.35mm,L=82uH, Electronic-Mag dip 1 netics 2 D1 Schottky Diode, B240A,2A/40V, SMA 1 Diodes 3 C1 Capacitor,Electrolytic,100uF/35V,Ö7x8mm,Dip 1 KSC 4 C2 Ceramic capacitor,10uF/16V,X7R,0805 1 Murata/TDK 5 C4 Ceramic capacitor, 10nF/25V, X7R, 0603 1 Murata/TDK 6 C5 Ceramic capacitor, 2200pF/25V, X7R, 0603 1 Murata/TDK 7 C6 Ceramic capacitor, 100pF/25V, X7R, 0603 1 Murata/TDK 8 C7 Ceramic capacitor, 10uF/25V, X7R, 0805 1 Murata/TDK 9 C8 Ceramic Electrolytic, 220F/10V, Ö6.3x7mm,Dip 1 Murata/TDK 10 C9 open 11 R1 Chip Resistor, 1KÙ, 1/16W, 5%, 0603 1 Murata/TDK 12 R2 Chip Resistor, 20KÙ, 1/16W, 1%, 0603 1 Murata/TDK 13 R3 Chip Resistor, 25KÙ, 1/16W, 5%, 0603 1 Murata/TDK 14 R4 Chip Resistor, 0Ù, 1/16W, 5%, 0603 1 Murata/TDK 15 R5 Chip Resistor, 51.1KÙ, 1/16W, 1%, 0603 1 Murata/TDK 16 R6 Chip Resistor, 9.76KÙ, 1/16W ,1%, 0603 1 Murata/TDK 17 R7 open 18 R8 Chip Resistor, 5KÙ, 1/16W, 5%,0805 1 Murata/TDK 19 RB/RD Chip Resistor, 49.9KÙ, 1/16W, 1%,0603 2 Murata/TDK 20 RA Chip Resistor, 43.2KÙ, 1/16W, 1%,0603 1 Murata/TDK 21 RC Chip Resistor, 75KÙ, 1/16W, 1%,0603 1 Murata/TDK 22 U1 IC, ACT4501 SOP-8 1 Active semi 23 USB 15mm*10mm*8mm 1 USB Manu Active-Semi, Inc. -4- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A 5. FUNCTIONAL TEST 5.1. Output Regulation Output Voltage at Load Voltage Output Voltage at Max. load Min. load regulation Iload(max) Vin=24V 5.08 4.97 -2.2% 1.2A Vin=12V 5.09 4.98 -2.2% 5.2. Efficiency Efficiency (%) Iout Io=0mA Io=100mA Io=200mA Io=300mA Io=500mA Io=750mA Io=1000mA Vin=24V 0.00 76.41 83.50 85.15 85.86 85.44 84.62 Vin=12V 0.00 84.11 89.09 90.03 90.14 89.15 87.94 Efficiency(%) Efficiency 100 90 80 70 60 50 40 30 20 10 0 Vin=12V Vin=24V 10 Active-Semi, Inc. 100 Iout(mA) -5- Active-Semi. Confidential-Do Not Copy or Distribute 1000 www.active-semi.com ACT4501 5V/1A 5.3. Constant Current and Contant Voltage CC load CV load Vin124V Vin=12V Vin=16V Vin=16V Vin=24V Vin=24V Vout Iout (mA) Vout Iout (mA) Vout Iout (mA) 5 0 5 0 5 0 5 200 5 200 5 200 5 400 5 400 5 400 5 600 5 600 5 600 5 800 5 800 5 800 5 1000 5 1000 5 1000 5 1270 5 1240 5 1200 4.9 1206 4.9 1290 4.9 1328 4.75 1219 4.75 1291 4.75 1327 4.7 1224 4.7 1292 4.7 1327 4.5 1270 4.5 1293 4.5 1326 4 1274 4 1295 4 1326 3.5 1278 3.5 1297 3.5 1322 3 1282 3 1301 3 1318 2.5 1286 2.5 1302 2.5 1315 2 1290 2 1306 2 1319 1 1106 1 1187 1 1356 0 1293 0 1313 0 1344 CC CV Curve 6 Output Voltage(V) 5 4 3 2 Vin=12V Vin=16V 1 Vin=24V 0 0 200 400 600 800 1000 1200 1400 1600 Load current(mA) Active-Semi, Inc. -6- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A 5.4. Power Loss Power Loss(W) VIN Io=0mA Io=100mA Io=200mA Io=300mA Io=500mA Io=750mA Io=1000mA Vin=24V 0.082 0.157 0.201 0.265 0.417 0.645 0.915 Vin=12V 0.056 0.096 0.124 0.169 0.277 0.461 0.691 Power Loss(W) Power Loss 1.000 0.900 0.800 0.700 0.600 0.500 0.400 0.300 0.200 0.100 0.000 Vin=12V Vin=24V 0 200 400 600 800 1000 Iout(mA) 5.5. Standby Power Loss Test Conditions Iin at No Load Power Loss at No Load Vin=24V 4mA 92mW Max Load: 1A Vin=12V 5mA 70mW No Load: 0A Active-Semi, Inc. -7- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A 5.6. Switching Frequency, Ripple and Noise Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Test Conditions Max load (mV) Mini Load(mV) Vin=24V 50 25 Max Load: 1A Vin=12V 46 20 Mini Load: 0mA Vin=12V Io=1A Vin=24V Io=1A 5.7. Dynamic Response Vin=12V load step from 80mA-1A-80mA 5.8. Vin=24V load step from 80mA-1A-80mA Temperature Test Test condition: Ambient Temp: 55 ℃; full load Io=1000mA Test on IC ,Burning for 2 hours Active-Semi, Inc. Test Conditions Vin=12V Vin=24V IC Top (℃) 97.2℃ 109.5℃ -8- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A 6. EMC TES 6.1. Radiated EMI Test Vin=12V Io=1A Horizontal Active-Semi, Inc. -9- Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com ACT4501 5V/1A Vin=12V Io=1A Vertical 6.2. ESD Test Test Condition Vin=24V Io=1A Vin=12V Io=1A 4KV contact 30 times pass 30 times pass 8KV air 30 times pass 30 times pass Active-Semi, Inc. - 10 - Active-Semi. Confidential-Do Not Copy or Distribute www.active-semi.com