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Design Example Report
Title Specification Application Author Document Number Date Revision 3W Power Supply using LNK501P Input: 90 - 265 VAC Output: 12V / 250mA Industrial Power Integrations Applications Department DER-57 April 20, 2005 1.0
Summary and Features This document is an engineering prototype report for a universal input, power factor corrected power supply unit providing 12V at 250mA.
* * * * Very low cost, low component count isolated power supply Extremely simple circuit configuration designed for high volume low cost manufacture High input power factor Small EE16 transformer allows compact size No Optocoupler or sense resistors required Efficiency greater than 65%
* *
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com.
Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-57
Industrial - LNK501P
April 20, 2005
Table Of Contents
Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input Stage.......................................................................................................... 6 4.2 LinkSwitch Operation...................................................................................... 6 4.3 Transformer......................................................................................................... 7 4.4 Clamp and Feedback Components ..................................................................... 7 4.5 Output Stage ....................................................................................................... 8 5 PCB Layout ................................................................................................................ 9 6 Bill Of Materials ........................................................................................................ 10 7 Transformer Specification......................................................................................... 11 7.1 Transformer Winding......................................................................................... 13 7.2 Electrical Specifications..................................................................................... 13 7.3 Materials............................................................................................................ 13 7.4 Transformer Build Diagram ............................................................................... 14 7.5 Transformer Construction.................................................................................. 14 8 Performance Data .................................................................................................... 15 8.1 Line and Load Regulation ................................................................................. 15 8.2 Input Current ..................................................................................................... 16 8.3 Efficiency........................................................................................................... 16 8.4 Power Factor..................................................................................................... 17 8.5 Standby Power.................................................................................................. 18 9 Waveforms ............................................................................................................... 19 9.1 Output Voltage Start-up Profile ......................................................................... 19 9.2 Input Current Profile .......................................................................................... 20 9.3 Bulk Capacitor Voltage Profile........................................................................... 20 10 Output Ripple Measurements ............................................................................... 21 10.1.1 Ripple Measurement Technique ................................................................ 21 10.1.2 Measurement Results ................................................................................ 22 11 Conducted EMI ..................................................................................................... 23 12 Revision History.................................................................................................... 25 1 2 3 4
Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
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DER-57
Industrial - LNK501P
April 20, 2005
1 Introduction
This document is an engineering prototype report for a universal input, power factor corrected power supply unit providing 12V at 250mA. This power supply uses LinkSwitch - an integrated IC combining a 700 V high voltage MOSFET, PWM controller, start-up, thermal shut down and fault protection circuitry. This power supply is designed to provide a cost effective replacement for linear transformer based Auxiliary power supplies while providing the additional benefits of universal input range and high-energy efficiency. This document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit board layout, and performance data.
Figure 1 - Prototype Circuit Board Picture
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DER-57
Industrial - LNK501P
April 20, 2005
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (265 VAC) Output Output Voltage Output Ripple Voltage Output Current Input Power Factor Continuous Output Power Efficiency Environmental Ambient Temperature Conducted EMI Safety TAMB 0 60
o
Symbol VIN fLINE
Min 90 47
Typ
Max 265 64 0.3 15 500 250
Units VAC Hz W V mV mA
Comment
2 Wire - no Protective Ground
50/60
VOUT VRIPPLE R IOUT % POUT
8 50 65
12
0.25A Load / 120VAC / 220VAC
3 70
W %
Measured at output peak power point, 25 oC
C
Meets CISPR22B / EN55022B & FCC B with artificial hand connected to output return Designed to meet IEC950, UL1950 Class II
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DER-57
Industrial - LNK501P
April 20, 2005
3 Schematic
Figure 2 - Schematic
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DER-57
Industrial - LNK501P
April 20, 2005
4 Circuit Description
The schematic shown in Figure 2 provides two isolated outputs from a universal input voltage range of 90 VAC to 265 VAC. 4.1 Input Stage The incoming AC is rectified and filtered by D1, D2, D3, D5, D6, D7, D8, R4, C2, and C8 with a high power factor. Resistor R1 is a flameproof fusible type to protect against fault conditions and is a requirement to meet safety agency fault testing. Please consult with a safety engineer or local safety agency. L1 and L2 provide differential mode filtering of switching frequency noise generated by the LNK500 power stage. C6 provides local energy storage for the Flyback stage. C5 is a safety X1 capacitor that helps filter switching noise of the bridge rectifier and maintains compliance to the conducted EMI requirements of EN55022 Class B in conjunction with safety Y1 capacitor C9. 4.2 LinkSwitch Operation When power is applied to the supply, high voltage DC appears at the DRAIN pin of LinkSwitch (U1). The CONTROL pin capacitor C1 is then charged through a switched high voltage current source connected internally between the DRAIN and CONTROL pins. When the CONTROL pin voltage reaches approximately 5.7 V relative to the SOURCE pin, the internal current source is turned off. The internal control circuitry is activated and the high voltage internal MOSFET starts to switch, using the energy in C1 to power the IC. As the current ramps in the primary of Flyback transformer T1, energy is stored. This energy is delivered to the output when the MOSFET turns off each cycle. The secondary of the transformer is rectified and filtered by D4 and C7 to provide the DC output to the load. Control of the output characteristic is entirely sensed from the primary-side by monitoring the primary-side VOR (reflected output voltage). While the output diode is conducting, the voltage across the transformer primary is equal to the output voltage plus diode drop multiplied by the turn's ratio of the transformer. Since the LinkSwitch is connected on the high side of the transformer, the VOR can be sensed directly. Diode D9 and capacitor C3 form the primary clamp network. The voltage held across C3 is essentially the VOR with a small error due to the parasitic leakage inductance. The LinkSwitch has three operating modes determined by the current flowing into the CONTROL pin.
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DER-57
Industrial - LNK501P
April 20, 2005
During start-up, as the output voltage, and therefore the reflected voltage and voltage across C3 increases, the feedback current increases from 0 to approximately 2mA through R3 into the CONTROL pin. The internal current limit is increased during this period until reaching 100%, providing an approximately constant output current. Once the output voltage reaches the regulated value, the output voltage is regulated through control of the duty cycle. As the current into the CONTROL pin exceeds approximately 2mA, the duty cycle begins to reduce, reaching 30% at a CONTROL pin current of 2.3mA. If the duty cycle reaches a 3% threshold, the switching frequency is reduced, which reduces energy consumption under light or no load conditions. As the output load increases beyond the peak power point (defined by 1/2*L*I*f) and the output voltage and VOR falls, the reduced CONTROL pin current will lower the internal current providing an approximately constant current output characteristic. If the output load is further increased and the output voltage falls further to below a CONTROL pin current of 1mA, the CONTROL pin capacitor C1 will discharge and the supply will enter auto-restart. 4.3 Transformer The transformer is designed to always be discontinuous; all the energy is transferred to the load during the MOSFET off time. The energy stored in the transformer during discontinuous mode operation is 1/2*L*I*f where L is the primary inductance, I is the peak primary current squared and f is the switching frequency. Since the value of LinkSwitch current limit and frequency directly determines the peak power, the parameter of current squared times frequency is defined in the datasheet. This parameter, together with the output power, is used to specify the transformer primary inductance. As LinkSwitch is powered by the energy stored in the leakage inductance of the transformer, only a low cost two winding transformer is required. Leakage inductance should be kept low, ideally at less than 2% of the primary inductance. High leakage inductance will cause the output current limit characteristic to walk out as the output voltage decreases and increases the no-load consumption of the supply. 4.4 Clamp and Feedback Components Diode D9 should either be a fast (trr <250 ns) or ultra-fast type to prevent the voltage across LinkSwitch from reversing and ringing below ground. A fast diode is preferred, being lower cost. Capacitor C3 is typically fixed at 0.1 F and should be rated above the VOR and be stable with both temperature and applied voltage. Low-cost, Metalized plastic film capacitors are ideal; high value, low-cost ceramic capacitors are not recommended. Dielectrics
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Page 7 of 26
DER-57
Industrial - LNK501P
April 20, 2005
used for these capacitors such as Z5U and Y5U are not stable and can cause output instability as their value changes with voltage and temperature. Stable dielectrics such as COG/NPO are acceptable but are costly when compared to a Metalized plastic film capacitor. R3 was selected to program the peak power point to be 250mA when a transformer with a nominal LP value was used. The expression used to size R3 is from Power Integrations Application note, AN-35. C1 sets the auto-restart period and also the time the output has to reach regulation before entering auto-restart from start-up. 4.5 Output Stage Diode D4 should be rated for 80% of applied reverse voltage and thermally for average current multiplied by forward voltage at maximum ambient. Here a 1 A, 100 V Schottky diode was used to reduce the losses and improve efficiency. R2 and C4 from a snubber network to reduce ringing on D4. Capacitor C7 should be rated for output voltage and ripple current.
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DER-57
Industrial - LNK501P
April 20, 2005
5 PCB Layout
Figure 3 - Printed Circuit Layout
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DER-57
Industrial - LNK501P
April 20, 2005
6 Bill Of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Quantity 2 1 1 1 1 1 1 1 7 1 1 1 1 1 1 1 1 1 1 1 Reference C2, C8 C1 C3 C4 C5 C6 C7 C9 D1, D2, D3, D5, D6, D7, D8 D9 D4 L1 L2 R1 R2 R5 R4 R3 T1 U1 Part Description Capacitor, 10 F, 400 V Capacitor, 10 F, 16 V, General Purpose Capacitor, 0.1 F, 5%, 100 V, Metallized Film - Capacitor, Panasonic, part # ECQ-V1104JM Capacitor, Ceramic, 470 pF, 100 V Capacitor, X-cap, 0.1 F Capacitor, Film, 100 nF, 630V Capacitor, 470 F, 25 V, Low ESR Panasonic FC Series Capacitor, Y-cap, 2200 pF Diode, 1N4005, 1 A, 600 V Diode, 1N4937, 1 A, 600 V, Fast Rectifier Diode, SB1100, 1 A, 100 V, Schottky Inductor, 2.2 mH Ferrite Bead 10 , 1 W, Fusible 51 , 5%, 1/4 W 220 , 5%, 1/2 W 1 k, 5%, 1/2 W 30.9 k, 1%, 1/4 W Custom EE16 LNK501P - Power Integrations, Inc
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DER-57
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April 20, 2005
7 Transformer Specification
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April 20, 2005
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DER-57 7.1 Transformer Winding
Industrial - LNK501P
April 20, 2005
3 WDG # 2 Shield 2 X 18 T # 30 AWG 4 4
5 WDG # 1 22 T # 32 T.I.W 6
WDG # 3 Primary 99 T # 36 AWG 1
Figure 4 - Transformer Winding Diagram
7.2
Electrical Specifications 60Hz 1 minute, from Pins 1-4 to Pins 5-8 All windings open All windings open L13 with pins 5-6 shorted 3 kV for 1 minute 2.3mH -0%, +20% 300 kHz min. 50H max.
Electrical Strength Primary Inductance Resonant Frequency Leakage Inductance 7.3 Materials
Item [1] [2] [3] [4] [5] [6] [7]
Description Core: EE16, Gapped for AL = Nominal - 200 nH/T2 Bobbin: Vertical 10 pins Magnet Wire: # 30 AWG Magnet Wire: # 36 AWG Magnet Wire: # 32 AWG Triple-Insulated Tape: 3M 1298 Polyester Film (white) Varnish
Design Notes: Power Integrations Device Frequency of Operation Mode Primary Current Reflected Voltage (Secondary to Primary) Maximum DC Input Voltage Minimum DC Input Voltage
42 kHz Discontinuous 0.075 Arms 60 V 200 V 111 V
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DER-57 7.4
Industrial - LNK501P
April 20, 2005
Transformer Build Diagram
Finish - pin 1 W3 Start - pin 4
Finish - pin 4 Start - pin 3 W1 Finish - pin 6 Start - pin 5
W2
Figure 5 - Transformer Build Diagram
7.5 Transformer Construction All windings should be wound in the forward direction. Place the bobbin on the winding machine with pins 1-4 on the Bobbin orientation right side and pins 5-8 on the left side. W1 (Secondary Wind 22 turns from right to left with # 32 triple-insulated Winding) magnet wire starting from pin 5 and finishing to pin 6. Insulation One layer of tape for insulation. W2 (Primary) Wind 18 turns from right to left with 2 x # 30 bifilar magnet wires starting from pin 3 and finishing to pin 4. Insulation Three layer of tape for insulation. W3 (Primary) Wind 99 turns from right to left with # 36 magnet wire starting from pin 3 and finishing to pin 1. Outer Insulation 3 layers of tape for insulation. Core Assembly Assemble and secure core halves. Final Assembly Vanish transformer - Do not impregnate.
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DER-57
Industrial - LNK501P
April 20, 2005
8 Performance Data
All measurements were performed at room temperature, 60 Hz input frequency unless otherwise specified. 8.1 Line and Load Regulation
Output Regulation
20 18 Output Voltage (V) 16 14 12 10 0 0.05 0.1 0.15 0.2 0.25 Output Current (Amps) 90VAC 115VAC 135VAC 220VAC 265VAC
Figure 6 - Output Load Regulation at Selected Input Voltages
Note: a small preload can be used to reduce the peak voltage under no load conditions if so desired.
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DER-57 8.2 Input Current
Industrial - LNK501P
April 20, 2005
Input Current
50 40 30 20 10 0 0 0.05 0.1 0.15 0.2 0.25 Output Current (Amps) 90VAC 115VAC 135VAC 220VAC 265VAC
Input Current (mArms)
Figure 7 - Input Current
8.3
Efficiency
Efficiency
90% 88% 85% 83% 80% 78% 75% 73% 70% 68% 65% 63% 60% 0
Efficiency (%)
90VAC 115VAC 135VAC 220VAC 265VAC
0.05
0.1
0.15
0.2
0.25
Output Current (Amps)
Figure 8 - Efficiency
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DER-57
Industrial - LNK501P
April 20, 2005
8.4
Power Factor
Power Factor
100% 90% 80% Power Factor (%) 70% 60% 50% 40% 30% 20% 10% 0% 0 0.05 0.1 0.15 0.2 0.25 Output Current (Amps) 90VAC 115VAC 135VAC 220VAC 265VAC
Power Factor
100.0% 95.0% 90.0% Power Factor (%) 85.0% 80.0% 75.0% 70.0% 65.0% 60.0% 55.0% 50.0% 90 115 140 165 190 215 240 265 290 Input Voltage (RMS) 0.25A load
Figure 9 - Power Factor
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DER-57
Industrial - LNK501P
April 20, 2005
8.5
Standby Power
Standby Power
0.3
Standby Power (W)
0.275
0.25
0.225
0.2 90 115 140 165 190 215 240 265 290 Input Voltage (RMS)
Figure 10 - Standby Power
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DER-57
Industrial - LNK501P
April 20, 2005
9 Waveforms
9.1 Output Voltage Start-up Profile
Figure 11 - Start-up Profile, 90VAC, 0.2A Load 5 V, 100 ms / div.
Figure 12 - Start-up Profile, 265 VAC, 0.2A Load 5 V, 100 ms / div.
Figure 13 - Start-up Profile, 90VAC, No Load 5 V, 100 ms / div.
Figure 14 - Start-up Profile, 265 VAC, No Load 5 V, 100 ms / div.
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DER-57 9.2 Input Current Profile
Industrial - LNK501P
April 20, 2005
Figure 15 - Input Current Profile, 90VAC, 0.25A Load 50 mA/DIV, 5 ms / div.
Figure 16 - Input Current Profile, 265VAC, 0.25A Load 50 mA/DIV, 5 ms / div.
9.3
Bulk Capacitor Voltage Profile
Figure 17 - Bulk Cap Voltage, 90VAC, 0.25A Load 50 V/DIV, 5 ms / div.
Figure 18 - Bulk Cap Voltage, 265VAC, 0.25A Load 100 V/DIV, 5 ms / div.
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DER-57
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10 Output Ripple Measurements
10.1.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 19 and Figure 20. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 19 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 20 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
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DER-57
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April 20, 2005
10.1.2 Measurement Results
Figure 21 - Ripple Profile, 90VAC, 0.25A Load 100 mV/DIV, 2 ms / div.
Figure 22 - Ripple Profile, 265VAC, 0.25A Load 100 mV/DIV, 2 ms / div.
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DER-57
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April 20, 2005
11 Conducted EMI
Figure 23 - Conducted EMI, VIN = 120 VAC, 60 Hz Line, 250mA Load
Figure 24 - Conducted EMI, VIN = 120 VAC, 60 Hz Neutral, 250mA Load
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DER-57
Industrial - LNK501P
April 20, 2005
Figure 25 - Conducted EMI, VIN = 230 VAC, 60 Hz Line, 250mA Load
Figure 26 - Conducted EMI, VIN = 230 VAC, 60 Hz Line, 250mA Load
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DER-57
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April 20, 2005
12 Revision History
Date April 20, 2005 Author RSP/EC Revision 1.0 Description & changes Initial release Reviewed KM / AM
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DER-57
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April 20, 2005
For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
Power Integrations Worldwide Sales Support Locations
WORLD HEADQUARTERS 5245 Hellyer Avenue, San Jose, CA 95138, USA Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: usasales@powerint.com CHINA (SHANGHAI) Rm 807, Pacheer, Commercial Centre, 555 Nanjing West Road, Shanghai, 200041, China Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: chinasales@powerint.com CHINA (SHENZHEN) Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu, Shenzhen, Guangdong, 518031, China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 GERMANY Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: eurosales@powerint.com JAPAN Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com KOREA 8th Floor, DongSung Bldg. 17-8 Yoido-dong, Youngdeungpo-gu, Seoul, 150-874, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 e-mail: koreasales@powerint.com SINGAPORE 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.co m TAIWAN 17F-3, No. 510, Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com
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