Test Report: GC160A12 160W Single Output Battery Charger DESIGN VERIFY TEST Output Function Test Input Function Test Protection Function Test Component Stress Test SAFETY & E.M.C. TEST Safety Test E.M.C. Test RELIABILITY TEST ENVIRONMENT TEST GC160A series DESIGN VERIFY TEST OUTPUT FUNCTION TEST NO 1 TEST ITEM SPECIFICATION TEST CONDITION DC VOLTAGE (Typ.) 13.6V I/P： 230 VAC RESULT 13.301 V /230V VERDICT I/P： 115 VAC 13.301 V /115V P O/P：FULL LOAD Ta：25℃ 2 CONTINUOS OUTPUT 10A CURRENT (Typ.) I/P： 230 VAC 10.3 A /230V I/P： 115 VAC 10.3 A /115V P O/P：CV=12V Ta：25℃ 3 LED INDICATOR Charging(CC) : RED I/P： 230 VAC > 0.8943 A,LED :RED Floating charging(CC) : GREEN O/P：setting < 0.8643 A,LED :GREEN P Ta：25℃ INPUT FUNCTION TEST NO 1 TEST ITEM SPECIFICATION INPUT VOLTAGE RANGE TEST CONDITION 90VAC~264 VAC RESULT I/P：TESTING VERDICT 60 V~264V O/P：FULL LOAD Ta：25℃ I/P： TEST： OK LOW-LINE-3V= 87 V P HIGH-LINE+15%=300 V O/P：FULL/MIN LOAD ON： 30 Sec . OFF： 30 Sec 10MIN ( AC POWER ON/OFF NO DAMAGE ) 2 47HZ ~63 HZ I/P：90 VAC ~ 264 VAC NO DAMAGE OSC O/P：FULL~MIN LOAD INPUT FREQUENCY RANGE TEST： OK P Ta：25℃ 3 POWER FACTOR 0.95 / 230 VAC(TYP) 0.98 / 115 VAC(TYP) I/P： 230 VAC I/P： 115 VAC O/P：FULL LOAD PF= 0.9557 / 230 VAC PF= 0.9948 / 115 VAC P Ta：25℃ 4 EFFICIENCY I/P： 230 VAC 89 % (TYP) 90.2 % P O/P：FULL LOAD Ta：25℃ 5 INPUT CURRENT 230V/ 1 A (TYP) I/P： 230 VAC I= 0.668 A/ 230 VAC 115V/ 1.85 A (TYP) I/P： 115 VAC I= 1.3027 A/ 115 VAC I= 105 A/ 230 VAC O/P：FULL LOAD P Ta：25℃ 6 INRUSH CURRENT 230V/ 120 A (TYP) I/P： 230 VAC O/P：FULL LOAD 7 LEAKAGE CURRENT < 0.75 P Ta：25℃ COLD START mA / 240 VAC I/P： 264 VAC L-FG： 0.2 mA O/P：Min LOAD N-FG： 0.2 mA I/P： 230 VAC <0.57 W/230V I/P： 115VAC <0.773 W/115V P Ta：25℃ 8 No load consumption < 1 W O/P：MIN P LOAD Ta：25℃ Model: GC160A12 Test Report 2 / 6 GC160A series PROTECTION FUNCTION TEST NO 1 TEST ITEM SPECIFICATION OVER LOAD PROTECTION 90 %~ 110 % TEST CONDITION RESULT I/P： 230 VAC I/P： 115 VAC VERDICT 105.33 %/ 230 VAC 105.33 %/ 115 VAC O/P：TESTING Constant current limiting recovers Ta：25℃ automatically after fault condition P is removed 2 3 OVER VOLTAGE PROTECTION OVER TEMPERATURE PROTECTION CH1： 14.28 V~ 18.36 V SPEC： I/P： 230 VAC 16.66V/ 230 VAC I/P： 115 VAC 16.54V/ 115 VAC O/P：MIN LOAD Shut down o/p voltage, re-power Ta：25℃ on to recover I/P： 230 VAC RTH2： 90 + 10℃ O.T.P. O/P：FULL LOAD NO DAMAGE 4 SHORT PROTECTION P O.T.P. Active Shut down o/p voltage, re-power P on to recover SHORT EVERY OUTPUT I/P： 264 VAC NO DAMAGE 1 HOUR NO DAMAGE O/P：FULL LOAD Hiccup mode P Ta：25℃ COMPONENT STRESS TEST NO 1 TEST ITEM SPECIFICATION TEST CONDITION RESULT Power Transistor Q6 I/P：High-Line +3V = 267 V (1) 450 V ( D to S) or (C to E) Peak Voltage STF13NM50N 12A/500V O/P： (1)Full Load Turn on (2) 438 V (3) 402 V Rated： (2) Output Short VERDICT P (3)Fulll load continue Ta：25℃ 2 Diode Peak Voltage D101 Rated： I/P：High-Line +3V = 267 V (1) 31.2 V PFR40L45CT 40A/45V O/P： (1)Full Load Turn on (2) 13.6 V (3) 30.6 V I/P：High-Line +3V = 267 V (1) 383.1 V O/P： (1)Full Load Turn on /Off (2) 397.1 V (2) Min load Turn on /Off (3) 396.2 V (2)Output Short P (3)Fulll load continue Ta：25℃ 3 Input Capacitor Voltage C 5 Rated： 150u/420V 105℃ KMG P (3)Full Load /Min load Change Ta：25℃ 4 Control IC Voltage Test U 1 Rated： I/P：High-Line +3V = 267 V (1) 13.713 V NCP1605DR2G 10V~20V O/P： (1)Full Load Turn on /Off (2) 13.662 V (2) Min load Turn on /Off (3) 13.662 V P (3)Full Load /Min load Change Ta：25℃ 5 Power Transistor Q1 Rated： I/P：High-Line +3V = 267 V (1) 504 V ( D to S) or (C to E) Peak Voltage STF21NM60N 17A/600V O/P： (1)Full Load Turn on (2) 438 V (3) 438 V (2) Output Short P (3)Fulll load continue Ta：25℃ Model: GC160A12 Test Report 3 / 6 GC160A series SAFETY & E.M.C. TEST SAFETY TEST NO 1 2 TEST ITEM SPECIFICATION TEST CONDITION RESULT WITHSTAND VOLTAGE I/P-O/P： 3 KVAC/min I/P-O/P： 3.6 KVAC/min I/P-O/P： Ta：25℃ NO DAMAGE ISOLATION RESISTANCE I/P-O/P：500VDC>100MΩ I/P-O/P： 500 VDC Ta：25℃/70%RH 3 GROUNDING CONTINUITY 4 APPROVAL VERDICT I/P-O/P： 4.06 mA 18.1 GΩ P P NO DAMAGE FG(PE) TO CHASSIS 40 A / 2min Ta：25℃ / 70%RH OR TRACE < 100 mΩ TUV： Certificate NO ：S50178235 9 mΩ P N UL： File NO ： E.M.C TEST NO 1 2 TEST ITEM HARMONIC CONDUCTION SPECIFICATION TEST CONDITION RESULT EN61000-3-2,-3 I/P：220 /230/240VAC/50HZ PASS CLASS A O/P：FULL LOAD CLASS D Ta：25℃ EN55022 I/P： 230 VAC (50HZ) PASS CLASS B O/P：FULL/50% LOAD Test by certified Lab VERDICT P P Ta：25℃ 3 RADIATION EN55022 I/P： 230 VAC (50HZ) PASS CLASS B O/P：FULL LOAD Test by certified Lab P Ta：25℃ 4 5 6 7 E.S.D E.F.T SURGE EN61000-4-2 I/P： 230 VAC/50HZ LIGHT INDUSTRY AIR：8KV / Contact：4KV O/P：FULL LOAD EN61000-4-4 I/P： 230 VAC/50HZ LIGHT INDUSTRY INPUT： 1KV O/P：FULL LOAD IEC61000-4-5 I/P： 230 VAC/50HZ LIGHT INDUSTRY L-N ：1KV O/P：FULL LOAD CRITERIA A P Ta：25℃ CRITERIA A P Ta：25℃ CRITERIA A P Ta：25℃ Test by certified Lab ＆ Test Report Prepare Model: GC160A12 Test Report 4 / 6 GC160A series RELIABILITY TEST ENVIRONMENT TEST NO 1. TEST ITEM SPECIFICATION THERMO TRACER TEST MODEL:GC160A-12 ( ROOM AMBIENT) 2 TEMPERATURE RISE TEST TEST CONDITION RESULT VERDICT TEST CONDITION: 100VAC FULL LOAD ROOM AMBIENT = 26℃ Position P/N Temp VERDICT US6KB80R 61.5 P1 BD1 PASS P2 LF2 P3 L2 TR-827 61.2 PASS TR-892 61.8 PASS P4 L1 P5 Q1 TF-2101 60.1 PASS STP16NM50N 60.8 PASS P6 D2 P7 Q6 BYV29X-600 61.1 PASS STP13NM50N 61.4 PASS P8 Q5 P9 LF1 STP13NM50N 61.4 PASS TR-889 PASS P10 D102 PFR40L45CT 65.7 64 P PASS MODEL：GC160A12 1. ROOM AMBIENT BURN-IN：13.5 HRS I/P： 230VAC O/P： FULL LOAD Ta= 27.1 ℃ 2. HIGH AMBIENT BURN-IN： 96HRS I/P： 230VAC O/P： FULL LOAD Ta= 57.3℃ NO OVER LOAD BURN-IN TEST P/N ROOM AMBIENT HIGH AMBIENT Ta= 27.1℃ Ta= 57.3℃ 66.2℃ 91.1℃ 1 L2 TR949 2 BD1 67.0℃ 92.0℃ 3 Q1 6A/800V SILICON GBU608 STF21NM60N 17A/600V TO220FP BYV29X-600 7A/600V TO220F STF13NM50N 12A/500V TO220F TF2101 67.8℃ 93.1℃ 68.0℃ 93.5℃ 67.9℃ 93.1℃ 66.8℃ 91.8℃ 70.1℃ 94.4℃ 68.8℃ 93.8℃ 79.3℃ 104.1℃ 4 D2 5 Q5 6 L1 7 C902 8 RTH2 9 C101 10 C102 220u/25V UL7Kh 8*11.5 KY NTC 330KΩ 3Φ TTC3A334F4573EY 1% 2200u/16V UL10Kh 12.5*20 ZLH 1500u/16V UL10Kh 10*20 ZLH 79.0℃ 104.1℃ 11 T1 TF2134 83.0℃ 107.8℃ 12 D101 PFR40L45CT 40A/45V TO220 80.8℃ 106.4℃ 13 U900 L6599AD SO-16N 65.9℃ 90.6℃ C11 474/450V 10% P=10 MEX 66.7℃ 91.4℃ 15 C216 220u/35V UL8Kh 8*11.5 ZLH 72.8℃ 98.0℃ 16 CASE CASE 56.4℃ 83.0℃ 14 3 Position NO DAMAGE I/P： 230 VAC 1 HOUR ( MIN ) O/P：O/P SHORT TEST P TEST：OK P Ta：25℃ Model: GC160A12 Test Report 5 / 6 GC160A series 4 LOW TEMPERATURE TURN ON AFTER I/P： 264VAC/100VAC 2 HOUR TEST：OK O/P：CV=12V TURN ON TEST P Ta= -30 ℃ 5 6 HIGH HUMIDITY AFTER 12 HOURS I/P： 272 VAC HIGH TEMPERATURE O/P：CV=12V HIGH VOLTAGE IN CHAMBER ON CONTROL 50 ℃ TURN ON TEST NO DAMAGE HUMIDITY= 95 %R.H I/P： 230 VAC + 0.01 %(0~50℃) O/P：FULL LOAD COEFFICIENT 7 P Ta= 50 ℃ + 0.03 %(0~50℃) TEMPERATURE TEST：OK STORAGE TEMPERATURE TEST P 1. Thermal shock Temperature： -45℃~ +90℃ OK 2. Temperature change rate ：25℃ / MIN 3. Dwell time low and high temperature ： 30 MIN/EACH P 4. Total test cycle：5 CYCLE 5. Input/Output condition： STATIC 8. THERMAL SHOCK TEST 1. Thermal shock Temperature： -30℃~ +55℃ OK 2. Temperature change rate ：25℃ / MIN 3. Dwell time low and high temperature ： 30 MIN/EACH P 4. Total test cycle：10 CYCLE 5. Input/Output condition： 230VAC/Full Load turn on 58 sec；turn off 2 sec 9 VIBRATION TEST TEST：OK 1 Carton & 1 Set (1) Waveform： Sine Wave (2) Frequency：10~500Hz (3) Sweep Time：10min/sweep cycle P (4) Acceleration：2G (5) Test Time：60min in each axis (X.Y.Z) (6) Ta：25℃ 10 CAPACITOR LIFE CYCLE 11 MTBF DATE GC160A12: SUPPOSE C101 IS THE MOST CRITICAL COMPONENT (1) I/P： 230VAC O/P：FULL LOAD Ta=25℃ LIFE TIME (1) 81753 HRS (2) I/P： 230VAC (2) 21063 HRS O/P：FULL LOAD Ta=50℃ LIFE TIME P MIL-HDBK-217F NOTICES2 PARTS COUNT TOTAL FAILURE RATE： 274.1K HRS P SAMPLE TEST RESULT TESTER APPROVAL 2010/3/11 RD SAMPLE PASS SANFORD SU VINCENT TSENG 2010/4/2 PRODUCT SAMPLE PASS SANFORD SU VINCENT TSENG 2010/5/5 PRODUCT SAMPLE W1004A24 PASS SANFORD SU VINCENT TSENG 2003/12/12 Model: GC160A12 A50-F023 Test Report 6 / 6