HFC0500+MP6902 Customer Support Test Report AE John Liu Manager En Li Date 2014-07-10 1 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Contents 1. Specification 6.4.2 Over Current Protection 2. Schematic 6.4.3 Output Over Voltage Protection 3. Circuit Board 6.5 Output and Timing 3.1 PCB Layout 6.5.1 Load Regulation 4. Bill of Materials 6.5.2 Output Ripple 5. Transformer Information 6.5.3 Transient Response 5.1 Winding Spec 6.5.4 Turn-on Delay and Output Rise Time 5.2 Winding Details 6.6 Thermal 6.6.1 Parts Thermal 6. Performance Data 6.1 Test Setup 6.7 EMC and Safety 6.1.1 Test Equipment 6.7.1 Conducted Emission 6.2 Efficiency 6.2.1 Active Mode Efficiency 6.2.2 No-load Power Consumption 6.3 Stress 6.3.1 Mosfet VDS 6.3.2 Output Mosfet Vds 6.4 Protection 6.4.1 Short Circuit Protection 2 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Specification 1. Specification Description Parameter Units Input voltage 90~264 VAC Input frequency 47~53 Hz Output voltage 12 V Output current 5 A Comment 3 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Schematic 2. Schematic C9 R13 20/1206 CY1 2.2nF/4kV R14 20/1206 1nF/250V D10 Vg C2 D9 R2 100k/2W 2.2nF SMAJ190 F1 6.3A/250V C18 NC BD1 KBP206 600V/4A F2 3.15A/250V C1 120uF 400V CN1 LX1 CX1 90Vac~264Vac TVR10431 330nF 600uH RT1 C17 R27 NC NC VCC LED1 LX3 C12 100nF 7,8,9 2 10 12V/5A GND Vaux R18 10 R15 560 Np_Aux Ns_Aux 5T 11 U2 47uF R19 43k 1% R16 2k TIMER HV C4 0.1uF 8 2 S8050 C7 47nF C6 4.7nF HFC0500 CS C5 68pF 3 4 C13 100nF FB CS GND VCC DRV D8 NC U3 CJ431 2.5V 6 5 R6 0/0805 CS R7 2 NC 6 R17 20k FB C8 NC C11 1500uF 16V EL817B 1 Q1 RT2 C10 1500uF 16V VCC 1 3 NC D5 BZT52C15 R26 VOUT FB R1 20k/1206 U1 5T Q3 AP85T10GP 100V/125A PQ2620 Lm=750uH C3 R5 1k 42T 3 D2 S1ML 1kV1A D1 S1ML 1kV1A Ns 5T R4 0/1206 2/DIP Np D4 IN4007 1kV1A R3 0 1206 18mH Vd Vs 11 450uH D3 IN4007 1kV1A LX2 RV1 T1 5 R25 20k 1206 1N5375B 10/0805 R8 20k/1206 D6 1N4148 R9 2.7k R10 3.3 1206 1% R11 1.1 1206 1% R12 1 1206 1% U4 MP6902 R22 3k 1 Vd 2 3 R21 30k Vs MPS Confidential- Power Factory Use Only R20 11.3k 1% Q2 IPP65R280E6 650V/39A C14 1nF 4 PGND VG EN NC LL VDD VD VSS R24 0 8 7 R23 0 6 5 C15 C16 1uF 0805 100nF Vg 200V/0.2A BAV21W 2 1 Vaux D7 4 The Future of Analog IC Technology® Circuit Board 3. Circuit Board 3.1 PCB Layout TOP & TSK BOT & BSK 5 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Bill of Materials 4. Bill of Materials (Main Board) Qty RefDes Value Description Package Manufacturer Manufacturer_PN 1 BD1 KBP206 Diode;600V;2A DIP Bangdayuan KBP206 1 C1 120uF Electrolytic Capacitor;400V; DIP Jianghai CD267-400V120 1 C2 2.2nF Ceramic Capacitor;630V 1206 muRata GRM31BR72J222KW01L 1 C3 47uF Electrolytic Capacitor;25V; DIP Jianghai CD286-25V47 3 C4,C13,C16 100nF Ceramic Capacitor;50V;X7R; 0603 muRata GRM188R71H104KA93D 1 C5 68pF Ceramic Capacitor;50V;C0G; 0603 TDK C1608COG1H680J 1 C6 4.7nF Ceramic Capacitor;50V;X7R; 0603 TDK C1608X7R1H471K 1 C7 47nF Ceramic Capacitor;50V;X7R; 0603 muRata GRM188R71H473KA61D 0 C8,C17,C18 NC 1 C9 1nF Capacitor;250V;X7R; 0805 TDK C2012X7R2E102K 2 C10,C11 1500uF Electrolytic Capacitor;16V DIP Any Any 1 C12 100nF Ceramic Capacitor;25V;X7R; 0805 muRata GRM21BR71E104KA01L 1 C14 1nF Ceramic Capacitor;25V;C0G; 0603 muRata GRM1885C1E102JA01D 1 C15 1uF Ceramic Capacitor;50V;X7R; 0805 muRata GRM21BR71H105KA12L 1 CN1 Connector DIP Any Any 1 CX1 330nF Capacitor;275V;10% DIP Carli PX334K3ID49L270D9R 1 CY1 2.2nF Capacitor;4kV;20% DIP Hongke JN12E222MY02N 2 D1,D2 S1ML Diode;1000V;1A SMA Taiwan Semiconductor S1ML 2 D3,D4 1N4007 Diode;1000V;1A DO-41 Diodes 1N4007 1 D5 BZT52C16 Zener Diode;16V;5mA/500mW; SOD-123 Diodes BZT52C16 6 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Bill of Materials …Continued Qty RefDes Value Description Package Manufacturer Manufacturer_PN 1 D6 1N4148 Schottky Diode;40V;0.5A SOD-123 Diodes B0540W 1 D7 BAV21W Diode;200V;0.2A; SOD-123 Diodes BAV21W-7-F 1 D8 NC 1 D9 SMAJ190A Diode;190V;1mA DO-214AC Brightking SMAJ190A 1 D10 1N5375B Zener Diode;82V;0.015A DIP Bangdayuan 1N5375B 1 F1 Fuse;250V;6.3A DIP Any Any 1 F2 SS-5-3.15A Fuse;250V;3.15A DIP Cooper Bussmann SS-5-3.15A 1 LED1 F3D02R-4A LED;Red DIP Any F3D02R-4A 1 LX1 600uH 600uH/2A DIP Any Any 1 LX2 18mH 18mH/2A DIP Any Any 1 LX3 450uH 450uH/6A DIP Any Any 1 Q1 S8050 Transistor;25V;0.5A; SOT-23 Changdian S8050 1 Q2 IPP65R280E6 Mosfet;650V;0.28ohm/10V; TO220 infineon IPP65R280E6 1 Q3 AP85T10GP N-Channel Mosfet;100V;8mohm; TO-220 APEC AP85T10GP 3 R1,R8,R25 20kΩ Film Resistor;5%; 1206 Yageo RC1206JR-0720KL 1 R2 100kΩ Resistor;5%;2W DIP Any Any 2 R3,R4 0Ω Film Resistor;5% 1206 Yageo RC1206JR-070RL 1 R5 1kΩ Film Resistor;1% 0603 Yageo RC0603FR-071KL 3 R6,R23,R24 0Ω Film Resistor;5%; 0805 Yageo RC0805JR-070RL 1 R7 10Ω Film Resistor;1%; 0805 Yageo RC0805FR-0710RL 1 R9 2.7kΩ Film Resistor;1% 0603 Yageo RC0603FR-072K7L 7 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Bill of Materials …Continued Qty RefDes Value Description Package Manufacturer Manufacturer_PN 1 R10 3.3Ω Film Resistor;1% 1206 Royalohm 1206F330KT5E 1 R11 1.1Ω Film Resistor;1% 1206 Yageo RC1206FR-071R1L 1 R12 1Ω Film Resistor;1% 1206 Royalohm 1206F100KT5E 2 R13,R14 20Ω Film Resistor;5% 1206 Yageo RC1206JR-0720RL 1 R15 560Ω Film Resistor;1% 0603 Yageo RC0603FR-07560RL 1 R16 2kΩ Film Resistor;1% 0603 Yageo RC0603FR-072KL 1 R17 20kΩ Film Resistor;1%; 0603 Yageo RC0603FR-0720KL 1 R18 10Ω Film Resistor;1%; 0603 Yageo RC0603FR-0710RL 1 R19 43kΩ Film Resistor;1% 0603 LION RC0603FR-0743KL 1 R20 11.3kΩ Film Resistor;1% 0603 Yageo RC0603FR-0711K3L 1 R21 30kΩ Film Resistor;5%; 0603 LIZ CR0603JA0303G 1 R22 3kΩ Film Resistor;5% 0603 Yageo RC0603JR-073KL 0 R26,R27 NC 1 RT1 2Ω NTC Resistor DIP Xingshun 2D2-10 1 RT2 NC 1 RV1 TVR10431 MOV; 430V/1mA;0.4W; DIP TKS TVR10431 1 T1 750uH PQ26/25; Np:Ns:Np_aux:Ns_axu=42:5:5:5 DIP Any Any 1 U1 HFC0500 Offline controller SOIC8-7 MPS HFC0500HS 1 U2 EL817B Photocoupler;1-Channel DIP Sharp EL817B 1 U3 CJ431 2.5V shut regulator SOT-23 Changdian CJ431 1 U4 MP6902DS SR controller; SOIC8 MPS MP6902DS MPS Confidential- Power Factory Use Only 8 The Future of Analog IC Technology® Transformer Information 5. Transformer Information 5.1 Winding Spec Primary inductance: 750uH(±5%) Leakage inductance: 40uH(Max) Core/Bobbin: PQ26/25 Core material: PC40 N1:N2:N3:N4:N5:N6=18:5:15:5:5:24 PRI. N5(10-11): 5Ts, 0.2mm(T.I.W)*1 SEC. 11 5 N6(4-5): 24Ts, 0.32mm*2 N4(11-7,8,9): 5Ts, 0.6mm(T.I.W)*4 N6 4 N4 N3(3-NC): 15Ts, 0.2mm*1 N1 7,8,9 10 6 2 N2 3 NC N3 N2(2-3): 5Ts, 0.2mm*1 N1(6-4): 18Ts, 0.32mm*2 N5 11 Winding Start 起绕脚 Teflon Tube 套管 9 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Transformer Information 5.2 Winding Details Winding Order Pin Number Wire Type (Φ) Number of Wires Number of Turns Winding Type Start Finish N1 6 4 0.32mm 2 18 N2 2 3 0.2mm 1 5 Spread Out N3 3 NC 0.2mm 1 15 Spread Out N4 11 7,8,9 0.6mm(T.I.W) 4 5 N5 10 11 0.2mm(T.I.W) 1 5 N6 4 5 0.32mm 2 24 Spread Out 10 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data 6. Performance Data 6.1 Test Setup 6.1.1 Test Equipment AC Source: Chroma, Model 61601 Power Meter: Yokogawa, Model WT210 E-Load: Chroma, Model 63101 Oscilloscope: Tektronix, Model TDS3014C Current Probe/Amplifier: Tektronix, Model TCP202 EMC Receiver: Rohde & Schwarz, Model ESPI3+ESPI-B2 … … Note: Active mode efficiency at 115VAC/60Hz MPS Confidential- Power Factory Use Only 11 The Future of Analog IC Technology® Performance Data 6.2 Efficiency 6.2.1 Active Mode Efficiency Test Conditions: The unit was set to maximum load and well pre-heated until temperature stabilization was achieved. Temperature stabilization was established for every load step before recording any measurements. Criteria To Pass: The average efficiency must be > 90%. 12 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data …Continued Input (VAC/Hz) 115/60 IOUT(A) VOUT(V) POUT(W) PIN(W) Efficiency(%) 5 12.01 60.05 66.750 89.96 3.75 12.02 45.075 49.933 90.27 2.50 12.04 30.10 33.066 91.03 1.251 12.04 15.062 16.524 91.15 Average Efficiency (%) 230/50 90.60 5 12.01 60.05 66.096 90.85 3.751 12.02 45.087 49.141 91.75 2.50 12.03 30.075 33.067 90.95 1.251 12.04 15.062 16.704 90.17 Average Efficiency (%) 90.93 Comment: Pass MPS Confidential- Power Factory Use Only 13 The Future of Analog IC Technology® Performance Data 6.2.2 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. Criteria To Pass: The power consumption must be < 75mW at the maximum input voltage. VAC/Hz 90/60 115/60 230/50 264/50 PIN(mW) 68.91 63.48 68.88 72.68 Comment: Pass MPS Confidential- Power Factory Use Only 14 The Future of Analog IC Technology® Performance Data 6.3 Stress 6.3.1 Mosfet VDS Test Conditions: The main input voltage was set to 264VAC. The electronic load was set to the maximum output current. Criteria To Pass: The mosfet VDS must be < 650V at both startup and steady status. Steady CH1: VDS VMAX: 570V Startup CH1: VDS VMAX: 550V Comment: Pass MPS Confidential- Power Factory Use Only 15 The Future of Analog IC Technology® Performance Data …Continued OVP CH1: VDS VMAX: 612V SCP CH1: VDS VMAX: 642V Comment: Pass MPS Confidential- Power Factory Use Only 16 The Future of Analog IC Technology® Performance Data 6.3.2 Output Mosfet Vds Test Conditions: The main input voltage was set to 264VAC. The electronic load was set to the maximum output current. Criteria To Pass: The diode Vds must be < 100V at both startup and steady status. Steady CH2: Vds VMAX: 93.2V Startup CH2: Vds VMAX: 96.4V Comment: Pass MPS Confidential- Power Factory Use Only 17 The Future of Analog IC Technology® Performance Data …Continued OVP CH2: Vds VMAX: 83.6V SCP CH2: Vds VMAX: 88.8V Comment: Pass MPS Confidential- Power Factory Use Only 18 The Future of Analog IC Technology® Performance Data 6.4 Protection 6.4.1 Short Circuit Protection (SCP) Test Conditions: The unit was switched on with no load on the output. A short circuit was applied manually to the output at the end of the cable. The mains voltage was adopted to obtain the worst-case condition. A short circuit was applied to the output at the end of the cable before startup of the unit. The unit was switched on with a short circuit at the output. The mains voltage was adopted to obtain the worse-case condition. Criteria To Pass: The unit shall be capable of withstanding a continuous (at least 2 hours) short-circuit at the output without damage or overstress of the unit under any input conditions. After removal of the short circuit, the unit shall recover automatically. The input power consumption must be < 1.5W at the full input range. 19 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data …Continued VAC/Hz 90/60 115/60 230/50 265/50 SCP OK OK OK OK PIN 1.392W 1.830W 282.29mW 364.4W ♦ Due to at low input voltage, SCP can’t be triggered, OCP will protect the circuit instead. So the input power at low line is larger than high line. Comment: Pass MPS Confidential- Power Factory Use Only 20 The Future of Analog IC Technology® Performance Data Output short circuit at 90VAC(Worst input) SCP Startup SCP Entry SCP Recovery CH1: VDS CH1: VDS CH1: VDS CH2: VCC CH2: VCC CH2: VCC CH3: VFB CH3: VFB CH3: VFB CH4: IOUT CH4: IOUT CH4: IOUT Comment: Pass MPS Confidential- Power Factory Use Only 21 The Future of Analog IC Technology® Performance Data Output short circuit at 230VAC(Typical input) SCP Startup SCP Entry SCP Recovery CH1: VDS CH1: VDS CH1: VDS CH2: VCC CH2: VCC CH2: VCC CH3: VFB CH3: VFB CH3: VFB CH4: IOUT CH4: IOUT CH4: IOUT Comment: Pass MPS Confidential- Power Factory Use Only 22 The Future of Analog IC Technology® Performance Data 6.4.2 Over Current Protection (OCP) Test Conditions: The load was increased from the maximum value to the an estimated overcurrent value in several steps. The test was repeated for different input voltages. Criteria To Pass: The output power should be limited, just before the triggering of the over current protection, while the unit under any input conditions. VAC/Hz 90/60 115/60 230/50 265/50 OCP 5.68A 6.20A 5.69A 5.20A Comment: Pass MPS Confidential- Power Factory Use Only 23 The Future of Analog IC Technology® Performance Data …Continued OCP at 230VAC(Typical input) OCP Startup OCP Entry OCP Recovery CH1: VDS CH1: VDS CH1: VDS CH2: VCC CH2: VCC CH2: VCC CH3: VFB CH3: VFB CH3: VFB CH4: IOUT CH4: IOUT CH4: IOUT Comment: Pass MPS Confidential- Power Factory Use Only 24 The Future of Analog IC Technology® Performance Data 6.4.3 Output Over Voltage Protection (OVP) Test Conditions: An output over voltage was created by applying a short circuit across the opto LED. An AC input voltage was selected so that the worst-case condition occurred. There was full load or no load on the output. Criteria To Pass: The output voltage may not exceed 18V or stabilize between 18V and the rated voltage. At the moment OVP occurs, the primary side controller should be stay in latched mode or other protect mode. Input (VAC/Hz) 90/60 115/60 230/50 264/50 OVP Trip Point (V) 16.6 16.8 17.5 17.5 Comment: Pass MPS Confidential- Power Factory Use Only 25 The Future of Analog IC Technology® Performance Data …Continued OVP at 230VAC Full Load CH1: VDS CH2: VCC No Load CH1: VDS CH2: VCC CH3: VOUT CH3: VOUT Comment: Pass MPS Confidential- Power Factory Use Only 26 The Future of Analog IC Technology® Performance Data …Continued OVP at 230VAC OVP Startup CH1: VDS OVP Entry CH1: VDS CH2: VCC CH2: VCC CH3: VOUT CH3: VOUT Comment: Pass MPS Confidential- Power Factory Use Only 27 The Future of Analog IC Technology® Performance Data 6.5 Output and Timing 6.5.1 Load Regulation (Optional, only for multiple output) Test Conditions: The output voltage deviation was measured while the load current on the output was increased from 0A to 5A. The measurement was repeated for different input voltages. Criteria To Pass: The output voltage deviation must remain within 1%. Comment: Pass MPS Confidential- Power Factory Use Only 28 The Future of Analog IC Technology® Performance Data …Continued Output Input No Load ¼ Load ½ Load ¾ Load Full Load 115VAC 12.05V 12.04V 12.04V 12.02V 12.01V 230VAC 12.05V 12.04V 12.03V 12.02V 12.01V Comment: Pass MPS Confidential- Power Factory Use Only 29 The Future of Analog IC Technology® Performance Data 6.5.2 Output Ripple Test Conditions: The measurement was made with an oscilloscope having a full bandwidth. The output was shunted at the end of the output ceramic disk capacitor or electrolytic capacitor. There was full load on the output. Criteria To Pass: The ripple of the output must remain within the specified limits (120mVp-p) at a maximum load current of 5A. VAC/Hz 90/60 115/60 230/50 264/50 Ripple (mV) 1050 916 944 1010 Comment: Not Good MPS Confidential- Power Factory Use Only 30 The Future of Analog IC Technology® Performance Data …Continued Input Ripple waveform Input CH2: VRIPPLE 90VAC Ripple waveform CH2: VRIPPLE 230VAC VP-P: 1.05V VP-P: 944mV CH2: VRIPPLE 115VAC CH2: VRIPPLE 264VAC VP-P: 916mV VP-P: 1.01V Comment: Not Good MPS Confidential- Power Factory Use Only 31 The Future of Analog IC Technology® Performance Data 6.5.3 Transient Response Test Conditions: The load of the unit changed from 1A to 4A at a slew rate of 0.1A/us. The frequency of change was set to give the best readability of the deviation and setting time. Criteria To Pass: The output was not allowed to have an overshoot or undershoot beyond the specified limits (+0.6V to -0.6V) after a load change. 115VAC/60Hz Input 230VAC/50Hz Input CH2: VOUT CH2: VOUT CH4: IOUT CH4: IOUT VP-P: 770mV VP-P: 790mV Comment: Pass MPS Confidential- Power Factory Use Only 32 The Future of Analog IC Technology® Performance Data 6.5.4 Turn-on Delay and Output Rise Time Test Conditions: The electronic load was set to CC mode and VON= 0V. The electronic load was set to the maximum output current. Criteria To Pass: Turn on delay: 1 Seconds maximum after the AC mains voltage was applied to the time when the output was within regulation. Output rise time: The output voltage shall rise from 10% of the maximum to the regulation limit within 25mS. There must be a smooth and continuous ramp-up of the output voltage. No voltage with a negative polarity shall be present at the output during startup. 33 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data …Continued 90VAC/60Hz Input CH1: VDS 264VAC/50Hz Input CH1: VDS CH2: VCC CH2: VCC CH3: VFB CH3: VFB CH4: VOUT CH4: VOUT VOUT Rise Time: 466ms VOUT Rise Time: 394ms 34 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data …Continued 90VAC/60Hz Input CH4:V OUT VOUT Rise Time: 21.6ms 265VAC/50Hz Input CH4:V OUT VOUT Rise Time: 24.2ms Comment: Pass MPS Confidential- Power Factory Use Only 35 The Future of Analog IC Technology® Performance Data 6.6 Thermal 6.6.1 Parts Thermal Test Conditions: The input voltage was set to minimum input. The electronic load was set to the maximum output current. The unit was covered, and the data was recorded until temperature stabilization was achieved. Ta=30℃ 36 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data …Continued Top Bottom Copper Thickness: 1 Oz 37 MPS Confidential- Power Factory Use Only The Future of Analog IC Technology® Performance Data 6.7 EMC and Safety 6.7.1 Conducted Emission Test Conditions: The unit was subjected to 115VAC or 230VAC line and with maximum load. The test should include both L and N test. Criteria To Pass: CISPR22 Class B with -6dB margin. L(115VAC) Att dBµV 1 120 10 dB MHz RBW 9 MT 20 PREAMP OFF N(115VAC) kHz ms Att 10 MHz dBµV 110 1 120 10 dB MHz RBW 120 kHz MT 100 ms PREAMP OFF 10 MHz 110 SGL 1 PK 100 2 AV SGL 1 PK CLRWR 100 CLRWR 90 TDS CLRWR 2 AV 90 TDS CLRWR 80 80 70 70 EN55022Q EN55022Q 60 60 EN55022A 6DB 50 6DB 50 40 40 30 30 20 20 10 10 0 150 EN55022A 0 kHz Date: 30.JUN.2014 30 MHz 14:34:15 MPS Confidential- Power Factory Use Only 150 kHz Date: 30.JUN.2014 30 14:39:17 MHz Comment: Pass 38 The Future of Analog IC Technology® Performance Data …Continued N(230VAC) L(230VAC) Att dBµV 1 120 10 dB MHz RBW 9 MT 20 PREAMP kHz ms Att OFF 10 dBµV MHz 1 120 10 dB MHz RBW 9 MT 20 PREAMP OFF kHz ms 10 MHz 110 110 SGL SGL 1 PK 1 PK 100 2 AV 100 CLRWR CLRWR 90 2 AV TDS CLRWR 90 TDS CLRWR 80 80 70 70 EN55022Q EN55022Q 60 60 EN55022A EN55022A 6DB 50 40 40 30 30 20 20 10 10 0 0 150 6DB 50 kHz Date: 30.JUN.2014 30 MHz 14:45:28 150 kHz Date: 30.JUN.2014 30 MHz 14:42:22 Comment: Pass MPS Confidential- Power Factory Use Only 39 The Future of Analog IC Technology®