HR1200 Demo Board TEST REPORT 90V-264V 12V/20A 2015-4

Contents From 4 to 9 can be different for different part families Specification Schematic and PCB 2.1 Schematic 2.2 PCB and photograph 3. Performance Data 3.1 Test Setup 3.1.1 Test Equipment 3.2 Efficiency 3.2.1 Efficiency 3.2.2 No Load power consumption 3.3 Input 3.2.1 Input voltage and current 3.4 Output 3.4.1 Line Regulation 3.4.2 Output Voltage Ripple 3.4.3 Start up 3.4.4 Shut down 3.4.5 Dynamic response 3.5 Protection 3.5.1 Short Circuit Protection 3.6 EMC and Safety 3.6.1 PF and THD 3.6.2 Conducted Emission Inductor and Transformer Specification 4.1 Boost Inductor 4.2 LLC Resonant Inductor 4.3 LLC Power Transformer From 4 to 9 can be different for different part families

1. Specification Parameter Symbol Condition Min Typ Max Units Input Supply Voltage VAC 2 Wire or 3Wire Full load range: 90VAC -264VAC 90 264 V AC Line Frequency fLINE 47 50/60 63 Hz Output Voltage VO 12 Output Current IO 20 A Output Voltage Ripple VO_ripple VAC=220V, full load 360 mV Continuous Output Power PO 240 W Efficiency η 92 % Startup time tST 1.5 s Power Factor VAC=90V to 264V, full load 0.9 THD 10% Conducted EMI Meets EN55022 Class B Harmonics Meets IEC61000-3-2 Class C SCP Auto-restart OVP Latch Operation Temperature TAMB Free convection, sea level -40 70 ℃ …… This page is from PE, it is not a must but if you have please paste it here.

2. Schematic and PCB 2.1 Schematic

2. Schematic and PCB 2.2 PCB and photograph Top View

2. Schematic and PCB 2.2 PCB and photograph Bottom View

3. Performance Data 3.1 Test Setup 3.1.1 Test Equipment AC Source: Chroma, Model 61602 Power Meter: Yokogawa, Model WT210 Oscilloscope: Tektronix, Model TDS3014C Current Probe/Amplifier: Tektronix, Model TCP305/TCPA300 EMC Receiver: Rohde & Schwarz, Model ESPI3+ESPI-B2 … …

3. Performance Data 3.2 Efficiency 3.2.1 Efficiency Test Conditions: The unit was set to required load and well pre-heated until temperature stabilization was achieved. Temperature stabilization was established for every load step before recording any measurements. PFC Diode: STTH806+PQ3230 XFMR

Performance Data …Continued PFC Diode: C3D0806A+PQ3535 XFMR

Performance Data 3.2.2 No-load Power Consumption Test Conditions: The unit was set to maximum load and well pre-heated. After 5 minutes the load was removed. The no-load input power measurements were recorded after stabilization of the input power reading. VAC/Hz 90/60 120/60 180/60 220/50 240/50 264/50 PIN(mW) 122.66 121.42 129.52 140.00 147.36 150.76 With 250mW output load, record the input power consumption . VAC/Hz 90/60 120/60 180/60 220/50 240/50 264/50 PIN(mW) 441.37 439.92 443.33 446.90 446.44 451.32

3. Performance Data 3.3 Input 3.3.1 Input voltage and current Test Conditions: The AC line input voltage and current are measured at output terminal with full load. 90V Input 120V Input AC input AC input Iin Iin

3. Performance Data 3.3 Input 3.3.1 Input voltage and current Test Conditions: The AC line input voltage and current are measured at output terminal with full load. 220V Input 264V Input AC input AC input Iin Iin

3. Performance Data 3.4 Output 3.4.1 Line Regulation Test Conditions: The output voltage deviation was measured while the input was increased from 90V to 264V at 100%/50%/25%/20%/10% load condition.

3. Performance Data 3.4.2 Output Ripple Test Conditions: The output ripple and noise are measured at output terminal with full load at 90VAC/120VAC input. 90VACInput 120VAC Input VP-P: 352mV Vo/AC Vo/AC IL_PFC IL_PFC I_Lr I_Lr

3. Performance Data 3.4.2 Output Ripple Test Conditions: The output ripple and noise are measured at output terminal with full load at 220VAC/264VAC input. 220VACInput 264VAC Input VP-P: 336mV VP-P: 328mV Vo/AC Vo/AC IL_PFC IL_PFC I_Lr I_Lr

3. Performance Data 3.4.3 Start up Test Conditions: The unit starts up with full load. The start-up time is measured from the time when line voltage is applied to the time when the output current ramps to 90% of the rating current. 90VAC Input 120VAC Input Vo Vo Vbus Vbus IL_PFC IL_PFC I_Lr I_Lr Startup Time: 1.24s Startup Time: 1.21s

3. Performance Data 3.4.3 Start up Test Conditions: The unit starts up with full load. The start-up time is measured from the time when line voltage is applied to the time when the output current ramps to 90% of the rating current. 220VAC Input 264VAC Input Vo Vo Vbus Vbus IL_PFC IL_PFC I_Lr I_Lr Startup Time: 1.18s Startup Time: 1.19s

3. Performance Data 3.4.3 Start up Test Conditions: The unit starts up with no load. The start-up time is measured from the time when line voltage is applied to the time when the output current ramps to 90% of the rating current. 90VAC Input 120VAC Input Vo Vo Vbus Vbus IL_PFC IL_PFC I_Lr I_Lr Startup Time: 1.25s Startup Time: 1.20s

3. Performance Data 3.4.3 Start up Test Conditions: The unit starts up with no load. The start-up time is measured from the time when line voltage is applied to the time when the output current ramps to 90% of the rating current. 220VAC Input 264VAC Input Vo Vo Vbus Vbus IL_PFC IL_PFC I_Lr I_Lr Startup Time: 1.16s Startup Time: 1.17s

3. Performance Data 3.4.4 Shut down Test Conditions: The unit shut down with full load. 90VAC Input 120VAC Input Vo Vo Vbus Vbus IL_PFC IL_PFC I_Lr I_Lr Hold up Time: 17.1ms Hold up Time: 17.3ms

3. Performance Data 3.4.4 Shut down Test Conditions: The unit shut down with full load. 220VAC Input 264VAC Input Vo Vo Vbus Vbus IL_PFC IL_PFC I_Lr I_Lr Hold up Time: 20.2ms Hold up Time: 20.5ms

Performance Data 3.4.5 Dynamic Response Test Conditions: The load of the unit changed from 0 to full, ½ to full, A at a slew rate of 2.5A/usec. CCHD: 100ms/100ms The frequency of change was set to give the best readability of the deviation and setting time. 90VAC 50%-100% load 90VAC 0-100% load Vo/AC Vo/AC Io Io I_Lr I_Lr VP-P: 368mV VP-P: 5.00V

Performance Data 3.4.5 Dynamic Response Test Conditions: The load of the unit changed from 0 to full, ½ to full, A at a slew rate of 2.5A/usec. CCHD: 100ms/100ms The frequency of change was set to give the best readability of the deviation and setting time. 120VAC 50%-100% load 120VAC 0-100% load Vo/AC Vo/AC Io Io I_Lr I_Lr VP-P: 360mV VP-P: 5.00V

Performance Data 3.4.5 Dynamic Response Test Conditions: The load of the unit changed from 0 to full, ½ to full, A at a slew rate of 2.5A/usec. CCHD: 100ms/100ms The frequency of change was set to give the best readability of the deviation and setting time. 220VAC 50%-100% load 220VAC 0-100% load Vo/AC Vo/AC Io Io I_Lr I_Lr VP-P: 328mV VP-P: 4.80V

Performance Data 3.4.5 Dynamic Response Test Conditions: The load of the unit changed from 0 to full, ½ to full, A at a slew rate of 2.5A/usec. CCHD: 100ms/100ms The frequency of change was set to give the best readability of the deviation and setting time. 264VAC 50%-100% load 264VAC 0-100% load Vo/AC Vo/AC Io Io I_Lr I_Lr VP-P: 368mV VP-P: 5.00V

3. Performance Data 3.5 Protection 3.5.1 Short Circuit Protection (SCP) Test Conditions: The unit was switched on with any load on the output. A short circuit was applied manually to the output at the end of the cable. The unit shall be capable of withstanding a continuous short-circuit at the output without damage or overstress of the unit under any input conditions. When short circuit occurs, the output of unit will enter a hiccup mode and auto-recovery. VAC/Hz 90/60 120/60 220/50 264/50 SCP OK

3. Performance Data Test Condition: VAC=90V/60Hz, Vo=12V, Io=20A SCP entry During SCP SCP recovery Vo Vo Vbus Vbus Vbus Vo IL_PFC IL_PFC IL_PFC I_Lr I_Lr I_Lr

3. Performance Data Test Condition: VAC=120V/60Hz, Vo=12V, Io=20A SCP entry During SCP SCP recovery Vo Vbus Vbus Vbus Vo Vo IL_PFC IL_PFC IL_PFC I_Lr I_Lr I_Lr

3. Performance Data Test Condition: VAC=220V/50Hz, Vo=12V, Io=20A SCP entry During SCP SCP recovery Vo Vbus Vbus Vbus Vo Vo IL_PFC IL_PFC IL_PFC I_Lr I_Lr I_Lr

3. Performance Data Test Condition: VAC=264V/50Hz, Vo=12V, Io=20A SCP entry During SCP SCP recovery Vo Vo Vbus Vbus Vbus Vo IL_PFC IL_PFC IL_PFC I_Lr I_Lr I_Lr

3. Performance Data 3.6 EMC and Safety 3.6.1 Harmonics current and PF test Test Conditions: The harmonic components were compared with the limits set for Class C. requirement with Everfine, Model PF9811. Without Compensation Vin/V 90 120 180 220 240 264 THD(%) 3.1 4.2 4.3 3.6 4.0 6.4 PF 0.999 0.998 0.994 0.992 0.990 0.985 With half load condition Vin/V 90 120 180 220 240 264 THD(%) 5.3 5.8 4.3 5.5 8.5 18.4 PF 0.996 0.994 0.984 0.975 0.965 0.943

Performance Data …Continued With Compensation

Performance Data …Continued Harmonics current

3. Performance Data 3.6.2 Conducted Emission Test Conditions: The unit was subjected to 120VAC/60Hz & 220VAC/50Hz input and with maximum load. 120Vac full load 220Vac full load

4. Inductor and Transformer Specification 4.1 Boost Inductor Electrical Diagram Electric Characteristic Parameter Condition Value Primary Inductance L (8,9-10,11) 260uH±5% Core/Bobbin PQ3230 Core material DMR40 or equivalent Turns N1 30 Winding Diagram Pin Definition of Bobbin Winding Specification Tape Layer Number Winding No. Start & End Turns Wire Diameter (mm) 1 N1 8,9 to 10,11 30 0.1×90

4. Inductor and Transformer Specification 4.2 LLC Resonant Inductor Electrical Diagram Electric Characteristic Parameter Condition Value Primary Inductance L (2-3) 80uH±5% Core/Bobbin EE20/10/6 Core material DMR40 or equivalent Turns N1 40 Winding Diagram Pin Definition of Bobbin Winding Specification Tape Layer Number Winding No. Start & End Turns Wire Diameter (mm) 1 N1 2 to 3 40 0.1×30

4. Inductor and Transformer Specification 4.3 LLC Power Transformer Electrical Diagram Electric Characteristic Parameter Condition Value Primary Inductance L (4-6) 0.65mH±5% Core/Bobbin PQ3230 Core material DMR40 or equivalent Turn Ratio N1:N2:N3:N4:N5 48:5:5:3:3 Winding Diagram Pin Definition of Bobbin Winding Specification Tape Layer Number Winding No. Start & End Turns Wire Diameter (mm) 1 N1 4 to 6 48 0.1×30 N2 3 to 2 5 0.2×1 3 N3 2 to 1 N4 10 to 9 0.1*100 N5 8 to floating