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

This test report provides detailed performance data and specifications for the HR1200 Demo Board, including efficiency, input and output parameters, startup and shutdown behavior, and protection features.

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

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

  2. Contents • 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

  3. 1. Specification

  4. 2. Schematic and PCB 2.1 Schematic

  5. 2. Schematic and PCB 2.2 PCB and photograph Top View

  6. 2. Schematic and PCB 2.2 PCB and photograph Bottom View

  7. 3. Performance Data 3.1 Test Setup3.1.1 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 Efficiency3.2.1 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. • With 250mW output load, record the input power consumption .

  11. 3. Performance Data 3.3 Input 3.3.1 Input voltage and current Test Conditions: • The AC lineinput 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 lineinput 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. 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. 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 3.5 Protection3.5.1 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.

  27. 3. Performance Data Test Condition: VAC=90V/60Hz, Vo=12V, Io=20A During SCP SCP recovery SCP entry 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 During SCP SCP recovery SCP entry Vo Vo Vbus Vbus Vbus 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 During SCP SCP recovery SCP entry Vo Vo Vbus Vbus Vbus 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 During SCP SCP recovery SCP entry 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 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 With half load condition

  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. 220Vac full load 120Vac full load

  35. 4. Inductor and Transformer Specification 4.1 Boost Inductor Electrical Diagram Electric Characteristic Pin Definition of Bobbin Winding Diagram Winding Specification

  36. 4. Inductor and Transformer Specification 4.2 LLC Resonant Inductor Electrical Diagram Electric Characteristic Winding Diagram Pin Definition of Bobbin Winding Specification

  37. 4. Inductor and Transformer Specification 4.3 LLC Power Transformer Electrical Diagram Electric Characteristic Winding Diagram Pin Definition of Bobbin Winding Specification

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