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

2. Contents From 4 to 9 can be different for different part families
Specification
Schematic and PCB
2.1 Schematic
2.2 PCB and photograph
Performance Data
3.1 Test Setup
Test Equipment
3.2 Efficiency
Efficiency
No Load power consumption
3.3 Input
Input voltage and current
3.4 Output
Line Regulation
Output Voltage Ripple
Start up
Shut down
Dynamic response
Protection
Short Circuit Protection
3.6 EMC and Safety
PF and THD
Conducted Emission
Inductor and Transformer Specification
Boost Inductor
LLC Resonant Inductor
LLC Power Transformer
From 4 to 9 can be different for different part families

3. 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 IEC 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.

4. 2. Schematic and PCB
Schematic

5. 2. Schematic and PCB
PCB and photograph
Top View

6. 2. Schematic and PCB
PCB and photograph
Bottom View

7. 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
… …

8. 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

9. Performance Data
…Continued
PFC Diode: C3D0806A+PQ3535 XFMR

10. 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

11. 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

12. 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

13. 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.

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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

25. 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

26. 3. Performance Data
Protection 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

27. 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

28. 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

29. 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

30. 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

31. 3. Performance Data 3.6 EMC and Safety
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

32. Performance Data
…Continued
With Compensation

33. Performance Data
…Continued
Harmonics current

34. 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

35. 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

36. 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

37. 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