HFC0400+MP2681 Customer Support Test Report AE John Liu Manager En Li Date 2014-07-10 1 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Contents 1. Specification 6.4.2 Output Over Voltage Protection 2. Schematic 6.5 Output and Timing 3. Circuit Board 6.5.1 Output Ripple 3.1 PCB Layout 6.5.2 Turn-on Delay and Output Rise Time 3.2 Board Photograph 6.6 Thermal 4. Bill of Materials 6.6.1 Parts Thermal 5. Transformer Information 6.7 EMC and Safety 6.7.1 Conducted Emission 5.1 Winding Spec 5.2 Winding Details 6. Performance Data 6.1 Test Setup 6.1.1 Test Equipment 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 Diode VRRM 6.4 Protection 6.4.1 Short Circuit Protection MPS Confidential- Keyang Use Only 2 The Future of Analog IC Technology® Specification 1. Specification Description Parameter Units 180~265 VAC Input frequency 47~63 Hz Output voltage 12.5/16.7/20.87 V Output current 4 A Input voltage Comment 3 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Schematic 2. Schematic R16 51/1206 T1 Lm=434uH Np:Np_aux:Ns=57:29:12 L F1 3.15A/250V LX1 90~265Vac RV1 NC L1 7,8,9 2.2uH/DIP BATT+ 3 ZD2 P6KE170A C1 150uF/400V Q4 AM4417P -60V/9.3A Q3 AM4417P -60V/9.3A ZD3 BZT52C16 D7 Np LX2 20mH/3A CX1 470nF 275V 150uH/3A 1 C2 4.7nF/DIP 1kV R3 150k/DIP R2 150k/DIP BD1 GBU406 600V/4A C9 470pF/1206 R17 51/1206 Ns 4 MBR20150FCT 150V/20A R4 20/1206 C10 680uF 35V C11 680uF 35V C14 10uF/1210 R18 10k C13 470uF 35V C12 680uF 35V 5 R19 10,11,12 D5 FR107 1kV/1A RT1 5/DIP D3 NC D2 IN4007 1kV/1A 100m/2512 6 R20 R39 10k 0805 CY1 D4 IN4007 1kV/1A R6 0/1206 4 VCC GND DRV TMR CS LED1 6 5 R23 R8 2 20/0805 1 R9 20/0805 2 1 Q1 IPP65R280E6 65V/39A 0.1uF/25V 1.5k FB 1k 100nF D6 1N4148W 75V/0.15A R38 C18 U3 R10 20k PC817A/DIP R22 1k R37 C17 100nF 1k 16 15 LDO 3 GND ID 4 VFB 12 TMR 7 LDO LEDR MP2681GS LEDR FLT NTC 8 LEDG CR LED2 JP1 ID U2 BATT 1 VFB 47uF/25V CS VDD 2k CCON R21 R26 18k 10 JP2 R31 1.8k LDO JP3 R32 1.8k JP4 R33 6.8k JP5 R34 6.8k JP6 R35 15k JP7 R36 15k R27 10k 13 C20 2.2uF 0805 R29 20k NTC 14 11 9 1 2 C8 22pF 50V IFB IFB FB C5 3 BATT- 200m/2512 6 2 C15 2.2uF/1206 GND C4 CS C16 2.2uF/1206 COMP BZT52C16 8 ZD5 BZT52C30 C3 22uF/50V N/C ZD1 FB C6 47nF 50V C7 1nF 50V ZD4 BZT52C30 Q2 MMBTA06LT1G 80V/0.5A U1 HFC0400 HV BATT- CCON R7 5.1k/1206 TIMER NTC VDD R5 NC R1 20k/1206 1 ID NTC 2.2nF/4kV 2 D1 IN4007 1kV/1A Np_aux 5 N BATT+ ID JP8 3 R30 10k LDO LEDG R28 IFB IFB 10k R15 1k C19 100nF CS R14 1 1206 1% R11 1 1206 1% R12 1 1206 1% R13 1 1206 1% COMP COMP R25 470 R24 2.2k IFB 4 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Circuit Board 3. Circuit Board 3.1 PCB Layout TOP & TSK BOT & BSK 5 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Circuit Board 3.2 Board Photograph L*W*H=122mm*71mm*30mm 6 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Bill of Materials 4. Bill of Materials Item Qty RefDes Value Description Package Manufacturer Manufacturer_PN 1 1 BD1 GBU406 Diode;600V;4A DIP Diodes GBU406 2 1 C1 150uF Electrolytic Capacitor;400V; DIP Jianghai CD267-400V150 3 1 C2 4.7nF High Voltage Capacitor;1kV DIP Any Any 4 1 C3 22uF Capacitor;50V DIP Rubycon 50YXM22MEFC5*11 5 1 C4 47uF Electrolytic Capacitor;25V; DIP Jianghai CD28L-25V47 6 4 C5,C17,C18,C19 100nF Ceramic Capacitor;50V;X7R; 0603 muRata GRM188R71H104KA93D 7 1 C6 47nF Ceramic Capacitor;50V;X7R; 0603 muRata GRM188R71H473KA61D 8 1 C7 1nF Ceramic Capacitor;50V;X7R; 0603 muRata GRM188R71H102KA01D 9 1 C8 22pF Ceramic Capacitor;50V;C0G; 0603 muRata GRM1885C1H220JA01D 10 1 C9 470pF Ceramic Capacitor;1000V;U2J; 1206 muRata GRM31B7U3A471JW31L 11 3 C10,C11,C12 680uF Electrolytic Capacitor;35V; DIP Jianghai CD287-35V680 12 1 C13 470uF Electrolytic Capacitor;35V; DIP Jianghai CD263-35V470 13 1 C14 10uF Ceramic Capacitor;50V;X7R 1210 Murata GRM32ER71H106KA12L 14 2 C15,C16 2.2uF Ceramic Capacitor;50V;X7R; 1206 muRata GRM31CR71H225KA88L 15 1 C20 2.2uF Ceramic Capacitor;16V;X7R; 0805 TDK C2012X7R1C225K 16 1 CX1 470nF Capacitor;275V;10% DIP Carli PX474K3ID42L270D9R 17 1 CY1 2.2nF Capacitor;4000V;20% DIP Hongke JN12E222MY02N 18 4 D1,D2,D3,D4 1N4007 Diode;1000V;1A DO-41 Diodes 1N4007 7 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Bill of Materials …Continued Item Qty RefDes Value Description Package Manufacturer Manufacturer_PN 29 1 D5 FR107 Diode;1000V;1A DO-41 Diodes FR107 20 1 D6 1N4148W Diode;75V;0.15A; SOD-123 Diodes 1N4148W 21 1 D7 MBR20150FCT Diode;150V;20A TO-220AB Xutong MBR20150FCT 22 1 F1 SS-5-3.15A Fuse;250V;3.15A DIP Cooper Bussmann SS-5-3.15A 23 1 L1 2.2uH Inductor;2.2uH;20m;6.3A DIP Wurth 7447462022 24 1 LED1 Green LED LED;Green DIP F3D02HG-1A 25 1 LED2 Red LED LED;Red DIP F3D02R-4A 26 1 LX1 150uH Inductor;2A DIP Emei TP4U150-00 27 1 LX2 20mH Inductor;10mH;55mohm;5A DIP Wurth 744825320 28 1 Q1 IPP65R280E6 Mosfet;650V;39A;0.28ohm; TO-220 Infinon IPP65R280E6 29 1 Q2 MMBTA06LT1G Transistor;80V;0.5A; SOT-23 Diodes MMBTA06LT1G 30 2 Q3,Q4 AM4417P P-Channel Mosfet;-60V;9.3A; SO-8 Analog Power AM4417P 31 2 R1,R10 20kΩ Film Resistor;5%; 1206 LIZ CR1206J40203G 32 2 R2,R3 150kΩ Resistor;5%;1W DIP Any Any 33 1 R4 20Ω Film Resistor;5%; 1206 Royalohm 1206J0200T5E 34 1 R5 NC 35 1 R6 0Ω Film Resistor;1% 1206 Yageo RC1206FR-070RL 36 1 R7 5.1kΩ Film Resistor;5%; 1206 LIZ CR06T05NJ5K1 37 2 R8,R9 20Ω Film Resistor;5%; 0805 Yageo RC0805JR-0720RL 8 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Bill of Materials …Continued Item Qty RefDes Value Description Package Manufacturer Manufacturer_PN 38 4 R11,R12,R13,R14 1Ω Film Resistor;1% 1206 Yageo RC1206FR-071RL 39 3 R15,R37,R38 1kΩ Film Resistor;1% 0603 Yageo RC0603FR-071KL 40 2 R16,R17 51Ω Film Resistor;5%; 1206 Yageo RC1206JR-0751RL 41 1 R18 10kΩ Film Resistor;5%; 0603 Yageo RC0603JR-07100KL 42 1 R19 100mΩ Sense Resistor;1%;2W; 2512 CYNTEC RL-3264-9-R100-FN 43 1 R20 200mΩ Sense Resistor;1%;1W 2512 CYNTEC RL3264-6-R050-FN 44 1 R21 2kΩ Film Resistor;1% 0603 Yageo RC0603FR-072KL 45 1 R22 1kΩ Film Resistor;1% 0603 Yageo RC0603FR-071KL 46 1 R23 1.5kΩ Film Resistor;1%; 0603 Yageo RC0603FR-071K5L 47 1 R24 2.2kΩ Film Resistor;1%; 0603 Yageo RC0603FR-072K2L 48 1 R25 470Ω Film Resistor;1% 0603 Yageo RC0603FR-07470RL 49 1 R26 18kΩ Film Resistor;1% 0603 Yageo RC0603FR-0718KL 50 4 R27,R28,R30,R39 10kΩ Film Resistor;1%; 0603 Yageo RC0603FR-0710KL 51 1 R29 20kΩ Film Resistor;5%; 0603 Yageo RC0603JR-0720KL 52 2 R31,R32 1.8kΩ Film Resistor;5%; 0603 LIZ CR0603JA0182G 53 2 R33,R34 6.8kΩ Film Resistor;1%; 0603 Yageo RC0603FR-076K8L 54 2 R35,R36 15kΩ Film Resistor;1%; 0603 Yageo RC0603FR-0715KL 55 1 RT1 5Ω NTC Resistor; DIP Xingshun 5D2-10LC 56 1 RV1 NC 57 1 T1 434uH EER28;Np:Np_aux:Ns=57:29:12 DIP Emei FX0370 9 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Bill of Materials …Continued Item Qty RefDes Value Description Package Manufacturer Manufacturer_PN 58 1 U1 HFC0500 Flyback Ccontroller; SOIC8-7A MPS HFC0500HS 59 1 U2 MP2681 CC/CV Controller; SOIC16 MPS MP2681GS 60 1 U3 PC817A Photocoupler;1-Channel DIP Sharp PC817A 61 2 ZD1,ZD3 BZT52C16 Zener Diode;16V;5mA/500mW; SOD-123 Diodes BZT52C16 62 1 ZD2 P6KE170CA Diode;145V;1mA DO-15 Brightking P6KE170CA 63 2 ZD4,ZD5 BZT52C30 Zener Diode;30V;5mA/500mW; SOD-123 Diodes BZT52C30 10 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Transformer Information 5. Transformer Information 5.1 Winding Spec Primary inductance: 434uH(±5%) Leakage inductance: 22uH(Max) Core/Bobbin: EER28 Core material: PC40 N1:N2:N3:N4= 29:29:12:28 10mm Copper Belt outside of the core Connected to pin 5 1 2 N4: 0.36mm*2 28Ts 15mm Copper Belt Connected to pin 5 5 7,8,9 10,11,12 PRI N3: 0.6mm*3 12Ts T.I.W 1 SEC N4 28Ts 10,11,12 5 2 6 N1 29Ts N3 12Ts 3 6 5 15mm Copper Belt Connected to pin 5 5 N2: 0.2mm*2 29Ts 2 3 N1: 0.36mm*2 29Ts 7,8,9 N2 29Ts WINDING START Tube 11 MPS Confidential- Keyang 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 Tube Start Finish N1 3 2 0.36mm 2 29 matching with wire N2 6 5 0.20mm 2 29 matching with wire N3 10,11,12 7,8,9 0.6mm(T.I.W) 3 12 matching with wire N4 2 1 0.36mm 2 28 matching with wire 12 MPS Confidential- Keyang 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- Keyang Use Only 13 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 efficiency must be > 75% at the maximum continuous output load. Input (VAC/Hz) 230/50 IOUT(A) VOUT(V) POUT(W) PIN(W) Efficiency(%) 3.77 20.00 75.400 89.188 84.54 3.77 16.70 62.959 74.702 84.28 3.77 12.52 47.200 56.929 82.91 Average Efficiency (%) 83.91 14 MPS Confidential- Keyang Use Only 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 < 1W at the maximum input voltage. VAC/Hz 220/50 240/50 265/50 PIN(mW) 161.9 177.83 184.2 Comment: Pass MPS Confidential- Keyang Use Only 15 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 265VAC. 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: 580V Startup CH1: VDS VMAX: 572V Comment: Pass MPS Confidential- Keyang Use Only 16 The Future of Analog IC Technology® Performance Data …Continued SCP CH1: VDS VMAX: 594V OVP CH1: VDS VMAX: 572V Comment: Pass MPS Confidential- Keyang Use Only 17 The Future of Analog IC Technology® Performance Data 6.3.2 Output Diode VRRM Test Conditions: The main input voltage was set to 265VAC. The electronic load was set to the maximum output current. Criteria To Pass: The diode VRRM must be < 150V at both startup and steady status. Steady Startup CH2: VRRM CH2: VRRM VMAX: 121V VMAX: 147V Comment: Pass MPS Confidential- Keyang Use Only 18 The Future of Analog IC Technology® Performance Data …Continued SCP CH2: VRRM CH1: V DS VMAX: 147V OVP CH2: VRRM VMAX: 132V Comment: Pass MPS Confidential- Keyang Use Only 19 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 < 0.5W at the full input range. VAC/Hz 220/50 230/50 240/50 265/50 SCP OK OK OK OK PIN 336.68mW 346.18mW 363.28mW 389.91mW MPS Confidential- Keyang Use Only 20 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 Comment: Pass MPS Confidential- Keyang Use Only 21 The Future of Analog IC Technology® Performance Data 6.4.2 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 35V. At the moment OVP occurs, the primary side controller should shut down and stay in a latched mode. 22 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Performance Data …Continued Input Input CH2: VOUT CH2: VOUT 230VAC 220VAC VMAX: 24.5V VMAX: CH2: VOUT CH2: VOUT 265VAC 240VAC VMAX: 24.4V 24.1V VMAX: CH1: VOUT 24.3V Comment: Pass MPS Confidential- Keyang Use Only 23 The Future of Analog IC Technology® Performance Data 6.5 Output and Timing 6.5.1 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 (500mVp-p) at a maximum load current of 4A. VAC/Hz 220/50 230/50 240/50 265/50 Ripple (mV) 46.0 46.8 45.6 44.4 Comment: Pass MPS Confidential- Keyang Use Only 24 The Future of Analog IC Technology® Performance Data …Continued Input Ripple waveform Input CH2: VRIPPLE 220VAC 240VAC Ripple waveform CH2: VRIPPLE 230VAC CH1: VRIPPLE VP-P: 46.0mV VP-P: 46.8mV CH2: VRIPPLE CH2: VRIPPLE CH1: VRIPPLE VP-P: 45.6mV 265VAC CH1: VRIPPLE VP-P: 44.4mV Comment: Pass MPS Confidential- Keyang Use Only 25 The Future of Analog IC Technology® Performance Data 6.5.2 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 50mS. 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. 26 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Performance Data …Continued 220VAC/50Hz Input CH1: VDS CH2: VCC 265VAC/50Hz Input CH1: VDS CH2: VCC CH3: VFB CH4: IOUT Turn on delay : 840ms CH3: VFB CH4: IOUT Turn on delay : 780ms Comment: Pass MPS Confidential- Keyang Use Only 27 The Future of Analog IC Technology® Performance Data …Continued 220VAC/50Hz Input CH2: VOUT VOUT Rise Time: 19.4ms 265VAC/50Hz Input CH2: VOUT VOUT Rise Time: 18.6ms Comment: Pass MPS Confidential- Keyang Use Only 28 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℃ Criteria To Pass: The △ temperature must be < 65℃. 29 MPS Confidential- Keyang Use Only The Future of Analog IC Technology® Performance Data …Continued RefDes Description Temperature (oC) Temperature Rise (oC) BD1 Input Rectifier 54.6 24.6 C10,C11,C12 Output Capacitor 70.0 40 D7 Secondary Diode 93.8 63.8 Q1 Primary MOS 94.8 64.8 Q3,Q4 Secondary MOS 82.0 52.0 R19,R20 Sensing Resistor 80.0 50.0 T1 Transformer 91.9 61.9 U1 Primary Side Controller 68.0 38.0 U2 Secondary Side Controller 60.0 30.0 Comment: Pass 30 MPS Confidential- Keyang 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 230VAC line and with maximum load. The test should include both L and N test. Criteria To Pass: CISPR22 Class B with -8dB margin. L (230VAC) N (230VAC) Comment: Pass MPS Confidential- Keyang Use Only 31 The Future of Analog IC Technology®