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19-1245; Rev 0; 7/97
KIT ATION EVALU E AILABL AV
Adjustable-Output, Switch-Mode Current Sources with Synchronous Rectifier
____________________________Features
o 95% Efficiency o +5.5V to +26V Input Supply Range o 2V to 24V Adjustable-Output Voltage Range o 100% Maximum Duty Cycle (Low Dropout) o Up to 500kHz PWM Operation o Optional Synchronous Rectifier o 16-Pin QSOP Package o Current-Sense Accuracy: 2% (MAX1641) 5.3% (MAX1640)
_______________General Description
The MAX1640/MAX1641 CMOS, adjustable-output, switch-mode current sources operate from a +5.5V to +26V input, and are ideal for microprocessor-controlled battery chargers. Charging current, maximum output voltage, and pulse-trickle charge are programmed with external resistors. Programming the off-time modifies the switching frequency, suppressing undesirable harmonics in noise-sensitive circuits. The MAX1640's highside current sensing allows the load to connect directly to ground, eliminating ground-potential errors. The MAX1641 incorporates a low-side current sense. The MAX1640/MAX1641 step-down pulse-width-modulation (PWM) controllers use an external P-channel MOSFET switch and an optional, external N-channel MOSFET synchronous rectifier for increased efficiency. An internal low-dropout linear regulator provides power for the internal reference and circuitry as well as the gate drive for the N-channel synchronous rectifier. The MAX1640/MAX1641 are available in space-saving, 16-pin narrow QSOP packages.
MAX1640/MAX1641
______________Ordering Information
PART MAX1640C/D MAX1640EEE MAX1641C/D MAX1641EEE TEMP. RANGE 0C to +70C -40C to +85C 0C to +70C -40C to +85C PIN-PACKAGE Dice* 16 QSOP Dice* 16 QSOP
________________________Applications
Battery-Powered Equipment Laptop, Notebook, and Palmtop Computers Handy Terminals Portable Consumer Products Cordless Phones Cellular Phones PCS Phones Backup Battery Charger
*Dice are specified at TA = +25C, DC parameters only.
__________Typical Operating Circuit
VIN = +5.5V TO +26V IN D0 D1 TOFF RTOFF NDRV PGND CS+ SET CSOUT LDOH PDRV
P
__________________Pin Configuration
TOP VIEW
LDOL 1 TOFF 2 D1 3 D0 4 CC 5 REF 6 SET 7 TERM 8 16 IN 15 LDOH 14 PDRV
REF
MAX1640 MAX1641
13 NDRV 12 PGND 11 CS+ 10 CS9 GND
CC GND
MAX1640
TERM LDOL
QSOP ________________________________________________________________ Maxim Integrated Products 1
For free samples & the latest literature: http://www.maxim-ic.com, or phone 1-800-998-8800. For small orders, phone 408-737-7600 ext. 3468.
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier MAX1640/MAX1641
ABSOLUTE MAXIMUM RATINGS
IN to GND ...............................................................-0.3V to +28V LDOH to IN ...............................................................+0.3V to -6V LDOL to GND ...........................................................-0.3V to +6V PDRV to GND .............................. (VLDOH - 0.3V) to (VIN + 0.3V) NDRV to GND .........................................-0.3V to (VLDOL + 0.3V) TOFF, REF, SET, TERM, CC to GND ......-0.3V to (VLDOL + 0.3V) D0, D1 to GND .........................................................-0.3V to +6V CS+, CS- to GND ...................................................-0.3V to +28V PGND to GND.....................................................................0.3V Continuous Power Dissipation (TA = +70C) QSOP (derate 8.30mW/C above +70C) ................... 667mW Operating Temperature Range MAX164_EEE ...................................................-40C to +85C Storage Temperature Range .............................-65C to +150C Lead Temperature (soldering, 10sec) ............................ +300C
Stresses beyond those listed under "Absolute Maximum Ratings" may cause permanent damage to the device. These are stress ratings only, and functional operation of the device at these or any other conditions beyond those indicated in the operational sections of the specifications is not implied. Exposure to absolute maximum rating conditions for extended periods may affect device reliability.
ELECTRICAL CHARACTERISTICS
(VIN = +12V, VOUT = 6V, Circuit of Figure 2, TA = 0C to +85C, unless otherwise noted. Typical values are at TA = +25C.) PARAMETER Input Voltage Range Linear-Regulator Output Voltage, VIN Referenced Linear-Regulator Output Voltage, Ground Referenced Full-Scale Current-Sense Threshold Quarter-Scale Current-Sense Threshold Current-Sense Line Regulation Output Current Compliance SYMBOL VIN VLDOH VLDOL VIN = 5.5V to 26V, ILOAD = 0 to 20mA VIN = 5.5V to 26V, ILOAD = 0 to 20mA MAX1640 MAX1641 MAX1640 MAX1641 VIN = VOUT + 0.5V to 26V VOUT = 2V to 24V D0 or D1 = high D0 = D1 = low (off mode) D0 = D1 = low 4.05 VREF IREF = 0 to 50A PFET and NFET drive 1 RTOFF = 62k D0 = low, D1 = high, RTOFF = 100k D0 = low, D1 = high, RTOFF = 100k 1.7 27 2.2 33 12.5 1.96 4.20 2.00 4 MAX1640 MAX1641 CONDITIONS MIN 5.5 VIN 5.5 4.5 142 147 36 34 VIN 5.0 5.0 150 150 42 37.5 0.03 0.1 0.1 2 500 1 4.35 2.04 10 1 12 10 2.7 40 4 0.4 TYP MAX 26 VIN 4.5 5.5 158 153 48 41 UNITS V V V mV
mV %/V %/V mA A A V V mV A s s ms %
Quiescent VIN Supply Current Output Current in Off Mode VLDOL Undervoltage Lockout Reference Voltage Reference Load Regulation VSET Input Current FET Drive Output Resistance Off-Time Range Off-Time Accuracy Pulse-Trickle Mode Duty-Cycle Period Pulse-Trickle Mode Duty Cycle (Note 1)
Note 1: This ratio is generated by a 1:8 clock divider and is not an error source for current calculations. 2 _______________________________________________________________________________________
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier
ELECTRICAL CHARACTERISTICS (continued)
(VIN = +12V, VOUT = 6V, Circuit of Figure 2, TA = 0C to +85C, unless otherwise noted. Typical values are at TA = +25C.) PARAMETER PWM Maximum Duty Cycle Input Low Voltage Input High Voltage Input Leakage Current SYMBOL VIL VIH IIN D0, D1 D0, D1 D0, D1 CONDITIONS MIN 100 0.8 2.4
1
MAX1640/MAX1641
TYP
MAX
UNITS % V V A
ELECTRICAL CHARACTERISTICS
(VIN = +12V, VOUT = 6V, Circuit of Figure 2, TA = -40C to +85C, unless otherwise noted.) PARAMETER Input Voltage Range Linear-Regulator Output Voltage, VIN Referenced Linear-Regulator Output Voltage, Ground Referenced Full-Scale Current-Sense Threshold Quarter-Scale Current-Sense Threshold Output Current Compliance Quiescent VIN Supply Current Output Current in Off Mode VLDOL Undervoltage Lockout Reference Voltage Reference Load Regulation VSET Input Current FET Drive Output Resistance Off-Time Range Off-Time Accuracy Pulse-Trickle Mode Duty-Cycle Period PWM Maximum Duty Cycle Input Low Voltage Input High Voltage Input Leakage Current VIL VIH IIN D0, D1 D0, D1 D0, D1 2.4
1
SYMBOL VIN VLDOH VLDOL
CONDITIONS
MIN 5.5
TYP
MAX 26 VIN 4.5 5.5 159 154 48 42 0.4 4 1
UNITS V V V mV
VIN = 5.5V to 26V, ILOAD = 0 to 20mA VIN = 5.5V to 26V, ILOAD = 0 to 20mA MAX1640 MAX1641 MAX1640 MAX1641 VOUT = 2V to 24V (MAX1640) D0 or D1 = high D0 = D1 = low
VIN 5.5 4.5 141 146 34 33
mV %/V mA A V V mV A s s ms %
4.0 VREF IREF = 0 to 50A 1.94
4.4 2.06 10 1 12
1.5 RTOFF = 62k D0 = low, D1 = high, RTOFF = 50k 1.5 25 100
8 2.5 42
0.8
V V A
_______________________________________________________________________________________
3
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier MAX1640/MAX1641
__________________________________________Typical Operating Characteristics
(Circuit of Figure 2, TA = +25C, unless otherwise noted.)
MAX1640 OUTPUT CURRENT vs. INPUT VOLTAGE
MAX1640/41-TOC01
EFFICIENCY vs. OUTPUT VOLTAGE
100 90 EFFICIENCY (%) 80 70 60 50 40 2 4 6 8 10 12 14 16 18 20 22 24 OUTPUT VOLTAGE (V) VIN = 12V VIN = 18V VIN = 26V 1.510
MAX1640 OUTPUT CURRENT vs. OUTPUT VOLTAGE
MAX1640/41 TOC02 MAX1640/41-TOC03
1.510 1.500 OUTPUT CURRENT (A) 1.490 1.480 1.470 1.460 1.450 TA = +25C TA = -40C TA = +85C
(VOUT = 4V) 1.500 OUTPUT CURRENT (A) TA = -40C
1.490 TA = +85C TA = +25C 1.470
1.480
1.460 4 8 12 16 20 24 28 INPUT VOLTAGE (V)
2
4
6
8 10 12 14 16 18 20 22 24 OUTPUT VOLTAGE (V)
MAX1641 OUTPUT CURRENT vs. INPUT VOLTAGE
MAX1640/41 TOC04
MAX1641 OUTPUT CURRENT vs. OUTPUT VOLTAGE
MAX1640/41-TOC05
QUIESCENT CURRENT vs. INPUT VOLTAGE (NO-LOAD)
2.7 QUIESCENT CURRENT (mA) 2.5 2.3 2.1 1.9 1.7 1.5 TA = -40C TA = +25C TA = +85C
MAX1640/41-TOC06
1.550 (VOUT = 4V) OUTPUT CURRENT (A) 1.525 TA = -40C TA = +25C 1.500 TA = +85C 1.475
1.560 1.540 OUTPUT CURRENT (A) 1.520 TA = -40C 1.500 1.480 TA = +85C 1.460 1.440 TA = +25C
2.9
1.450 4 8 12 16 20 24 28 INPUT VOLTAGE (V)
1.420 2 4 6 8 10 12 14 16 18 20 22 24 VOUT (V)
4
8
12
16
20
24
28
INPUT VOLTAGE (V)
OFF-MODE SUPPLY CURRENT (NO-LOAD)
0.63 OFF-MODE SUPPLY CURRENT (mA) 0.61 0.59 0.57 0.55 0.53 0.51 0.49 0.47 0.45 4 8 12 16 20 24 28 INPUT VOLTAGE (V) 1 0 TA = +25C TA = -40C TA = +85C
MAX1640/41-TOC07
SWITCHING FREQUENCY vs. RTOFF
MAX1640/41 TOC 08
LINE-TRANSIENT RESPONSE
MAX1640/41 TOC 09
0.65
10,000
SWITCHING FREQUENCY (kHz)
1000
VOUT = +3V
A 0A
100
VOUT = +6V
10 B 0V 50 100 150 200 250 TOFF (k) 300 350 400 VLOAD = 3V 2ms/div A: OUTPUT CURRENT, D1 = D0 = 1 1A/div B: INPUT VOLTAGE, 10V/div
4
_______________________________________________________________________________________
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier
____________________________Typical Operating Characteristics (continued)
(Circuit of Figure 2, TA = +25C, unless otherwise noted.)
CURRENT-MODE CHANGE RESPONSE TIME
MAX1640/41 TOC 10
MAX1640/MAX1641
EXITING OFF MODE
MAX1640/41 TOC11
A 0A
A
0V B 2ms/div VIN = 12V, VSET = 1V, RLOAD = 4, NO OUTPUT CAPACITOR A: OUTPUT CURRENT, D0 = D1 = 0 1A/div B: LOAD VOLTAGE, AC coupled, 500mV/div VIN = 12V, RLOAD = 4 A: D0 = D1 = 1 2V/div B: OUTPUT CURRENT, 0.5A/div B 20s/div
______________________________________________________________Pin Description
PIN 1 NAME LDOL FUNCTION Internal, Ground-Referenced Low-Dropout Linear Regulator Output. Bypass with a 0.1F capacitor in parallel with a 4.7F capacitor to GND. Off-Time Select Input. A resistor (RTOFF) connected from this pin to GND programs the off-time for the hysteretic PWM step-down converter. This resistor also sets the period in duty-cycle mode. See Duty-Cycle Mode and Programming the Off-Time. Digital Inputs. Select mode of operation (Table 1). Constant-Current Loop Compensation Input. Bypass with a 0.01F capacitor to GND. Reference Voltage Output (VREF = 2V). Bypass with a 0.1F capacitor to GND. Current Select Input. Program the desired current level by applying a voltage at SET between 0V and VREF, (I = VSET / 13.3RSENSE). See Figure 3. Maximum Output Voltage Termination Input. When VTERM exceeds the reference voltage, the comparator resets the internal PWM latch, shutting off the external P-channel FET. Ground Negative Current-Sense Comparator Input Positive Current-Sense Comparator Input High-Current Ground Return for the output drivers Gate Drive for an optional N-channel FET synchronous rectifier Gate Drive for the P-channel FET Internal, Input-Referenced Low-Dropout Linear Regulator Output. Bypass with a 0.33F capacitor to IN. Power-Supply Input. Input of the internal, low-dropout linear regulators. _______________________________________________________________________________________ 5
2 3, 4 5 6 7 8 9 10 11 12 13 14 15 16
TOFF D1, D0 CC REF SET TERM GND CSCS+ PGND NDRV PDRV LDOH IN
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier MAX1640/MAX1641
IN
LDOL
LDOH
REG
A1 CS+
PDRV A2 CSGm MODE CONTROL SET B NDRV MUX PGND REF A SEL
MAX1640 MAX1641
TERM
D0, D1
CC
TOFF
Figure 1. MAX1640/MAX1641 Functional Diagram
6
_______________________________________________________________________________________
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier MAX1640/MAX1641
47F 0.33F 1/2 IR7309 P
47F
0.33F
IN LDOL 4.7F 0.1F
LDOH PDRV
IN LDOL 4.7F 0.1F
LDOH PDRV
1/2 IR7309 P
MAX1641
D0 D1 RTOFF TOFF NDRV REF PGND BATT R1 CS+ 0.1F R2 CSSET 100m R4 R3 1/2 IR7309 N 47H
D0 D1 RTOFF
MAX1640
TOFF NDRV
VOUT
1/2 IR7309 N 47H
REF
PGND
R1 0.1F R2 SET
CS+ 100m CSVOUT R3
TERM CC 0.01F GND
BATT TERM CC 0.01F GND R4
Figure 2a. Standard Application Circuit
Figure 2b. Standard Application Circuit
_______________Detailed Description
The MAX1640/MAX1641 switch-mode current sources utilize a hysteretic, current-mode, step-down pulsewidth-modulation (PWM) topology with constant offtime. Internal comparators control the switching mechanism. These comparators monitor the current through a sense resistor (RSENSE) and the voltage at TERM. When inductor current reaches the current limit [(VCS+ - VCS-) / RSENSE], the P-channel FET turns off and the N-channel FET synchronous rectifier turns on. Inductor energy is delivered to the load as the current ramps down. This ramp rate depends on RTOFF and inductor values. When off-time expires, the P-channel FET turns back on and the N-channel FET turns off. Two digital inputs, D0 and D1, select between four possible current levels (Table 1). In pulse-trickle mode, the
part operates for 12.5% of the period set by RTOFF, resulting in a lower current for pulse-trickle charging. Figure 1 is the MAX1640/MAX1641 functional diagram. Figure 2 shows the standard application circuits.
Charge Mode: Programming the Output Currents
The sense resistor, RSENSE, sets two charging current levels. Choose between these two levels by holding D0 high, and toggling D1 either high or low (Table 1). The fast-charge current level equals V CS / R SENSE where VCS is the full-scale current-sense voltage of 150mV. Alternatively, calculate this current by VREF / (13.3R SENSE ). The top-off current equals V SET / (13.3RSENSE). A resistor-divider from REF to GND programs the voltage at SET (Figure 3).
_______________________________________________________________________________________
7
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier MAX1640/MAX1641
The voltage at SET is given by: R1 = R2 (VREF / VSET -1 ); 10k < R2 < 300k where V REF = 2V and V SET is proportional to the desired output current level.
MAX1641
L
BATT
Table 1. Selecting Output Current Levels
D1 0 0 1 1 DO 0 1 0 1 MODE OFF Top-Off Pulse-Trickle Fast Charge OUTPUT CURRENT (A) 0 VSET / (13.3RSENSE) VSET / (13.3RSENSE) 12.5% duty cycle VSET / (13.3RSENSE)
CSCS+ RSENSE R4 R3
TERM
Figure 4b. Setting the Maximum Output Voltage Level
MAX1640 MAX1641
REF R1 SET R2
The MAX1640/MAX1641 are specified for V SET between 0V and VREF. For VSET > VREF, output current increases linearly (with reduced accuracy) until it clamps at VSET 4V.
Pulse-Trickle Mode: Selecting the Pulse-Trickle Current
Pulling D0 low and D1 high selects pulse-trickle mode. This current equals VSET / (13.3RSENSE) and remains on for 12.5% of the period set by RTOFF. Pulse-trickle current maintains full charge across the battery and can slowly charge a cold battery before fast charging commences.
Figure 3. Adjusting the Output Current Level
PERIOD = 3.2 x 10-7 x RTOFF (sec)
Off Mode: Turning Off the Output Current
L
MAX1640
CS+ RSENSE CSR3 TERM R4 BATT
Pulling D0 and D1 low turns off the P-channel FET and hence the output current flow. This mode also controls end of charge and protects the battery against excessive temperatures.
Setting the Maximum Output Voltage Level
The maximum output voltage should be programmed to a level higher than the output/battery voltage (ILOAD x RLOAD). An external resistor-divider between the output and ground (Figure 4) sets the voltage at TERM. Once the voltage at TERM exceeds the reference, the internal comparator turns off the P-channel FET, terminating current flow. Select R4 in the 10k to 500k range. R3 is given by: R3 = R4 (VOUT / VTERM) -1
Figure 4a. Setting the Maximum Output Voltage Level
8
_______________________________________________________________________________________
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier
where V TERM = 2V and V OUT is the desired output voltage. generating increased ripple at the output. Select CCC to optimize the ripple vs. loop response.
MAX1640/MAX1641
Programming the Off-Time
When programming the off-time, consider such factors as maximum inductor current ripple, maximum output voltage, inductor value, and inductor current rating. The output current ripple is less than the inductor current ripple and depends heavily on the output capacitor's size. Perform the following steps to program the off-time: 1) Select the maximum output current ripple. IR(A) 2) Select the maximum output voltage. VOUT(MAX)(V) 3) Calculate the inductor value range as follows: LMIN = (VOUTMAX x 1s) / IR LMAX = (VOUTMAX x 10s) / IR 4) Select an inductor value in this range. 5) Calculate tOFF as follows: t OFF = L x IR VOUTMAX
Capacitors
Synchronous Rectification
Synchronous rectification reduces conduction losses in the rectifier by shunting the Schottky diode with a lowresistance MOSFET switch. In turn, efficiency increases by about 3% to 5% at heavy loads. To prevent crossconduction or "shoot-through," the synchronous rectifier turns on shortly after the P-channel power MOSFET
Table 2. Component Manufacturers
COMPONENT Sumida Inductor Coilcraft Coiltronics MOSFETs Sense Resistor International Rectifier Siliconix Dale IRC AVX Sprague Motorola Nihon MANUFACTURER CDRH125 series D03316P series UP2 series IRF7309 S14539DY WSL-2010 series LR2010-01 series TPS series 595D series MBAR5340t3 IN5817-IN5822 NSQ03A04
6) Program tOFF by selecting RTOFF from:
Rectifier
RTOFF = (29.3 x 109) x tOFF 7) Calculate the switching frequency by: fs = 1 / (tON + tOFF) where tON = (IR x L) / (VIN - VOUT) and IR = (VOUT x tOFF) / L. L is the inductor value, VIN is the input voltage, VOUT is the output voltage, and IR is the output peak-to-peak current ripple. Note that RTOFF sets both the off-time and the pulsetrickle charge period.
turns off. The synchronous rectifier remains off for 90% of the off-time. In low-cost designs, the synchronous rectifier FET may be replaced by a Schottky diode.
Component Selection
External Switching Transistors The MAX1640/MAX1641 drive an enhancement-mode P-channel MOSFET and a synchronous-rectifier Nchannel MOSFET (Table 2). When selecting a P-channel FET, some important parameters to consider are on-resistance (rDS(ON)), maximum drain-to-source voltage (VDS max), maximum gate-to-source voltage (V GS max), and minimum threshold voltage (VTH min). In high-current applications, MOSFET package power dissipation often becomes a dominant design factor. I2R power losses are the greatest heat contributor for both high-side and low-side MOSFETs. Switching losses affect the upper MOSFET only (P-channel), since the Schottky rectifier or the N-FET body diode clamps the switching node before the synchronous rectifier turns on. Rectifier Diode If an N-channel MOSFET synchronous rectifier is not used, a Schottky rectifier is needed. The MAX1640/
9
Reference
The on-chip reference is laser trimmed for a precise 2V at REF. REF can source no more than 50A. Bypass REF with a 0.1F capacitor to ground.
Constant-Current Loop: AC Loop Compensation
The constant-current loop's output is brought out at CC. To reduce noise due to variations in switching currents, bypass CC with a 1nF to 100nF capacitor to ground. A large capacitor value maintains a constant average output current but slows the loop response to changes in switching current. A small capacitor value speeds up the loop response to changes in switching current,
_______________________________________________________________________________________
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier MAX1640/MAX1641
DC IN
PDRV
P
I/0 I/0
D0 D1
MAX1640
NDRV PGND CS+
N LOW-SIDE IS SHORTED
RSENSE CH0 CSCH1 R3 T TERM GND R4 BATT
Figure 5. Microcontroller Battery Charger
MAX1641's high switching frequency demands a highspeed rectifier (Table 2). Schottky diodes such as the 1N5817-1N5822 are recommended. Make sure the Schottky diode's average current rating exceeds the peak current limit and that its breakdown voltage exceeds the output voltage (VOUT). For high-temperature applications, Schottky diodes may be inadequate due to their high leakage current; high-speed silicon diodes such as the MUR105 or EC11FS1 can be used instead. At heavy loads and high temperatures, the benefits of a Schottky diode's low forward voltage may outweigh the disadvantage of high leakage current. If the application uses an N-channel MOSFET synchronous rectifier, a parallel Schottky diode is usually unnecessary except with very high charge current (> 3 amps). Best efficiency is achieved with both an N-channel MOSFET and a Schottky diode.
inductor value, off-time, output current ripple, and switching frequency.
__________Applications Information
All-Purpose Microcontroller Battery Charger: NiCd, NiMH
In applications where a microcontroller is available, the MAX1640/MAX1641 can be used as a low-cost battery charger (Figure 5). The controller takes over fast charge, pulse-trickle charge, charge termination, and other smart functions. By monitoring the output voltage at VOUT, the controller initiates fast charge (set D0 and D1 high), terminates fast charge and initiates top-off (set D0 high and D1 low), enters trickle charge (set D0 low and D1 high), or shuts off and terminates current flow (set D0 and D1 low).
Inductor Value Refer to the section Programming the Off-Time to select the proper inductor value. There is a trade-off between
Layout and Grounding
Due to high current levels and fast switching waveforms, proper PC board layout is essential. High-current ground paths should be connected in a star
10
______________________________________________________________________________________
Adjustable-Output, Switch-Mode Current Source with Synchronous Rectifier
configuration to PGND. These traces should be wide to reduce resistance and as short as possible to reduce stray inductance. All low-current ground paths should be connected to GND. Place the input bypass capacitor as close as possible to the IN pin. See MAX1640 EV kit for layout example.
___________________Chip Information
TRANSISTOR COUNT: 1233
MAX1640/MAX1641
________________________________________________________Package Information
QSOP.EPS
______________________________________________________________________________________
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