SYSTEM GENERAL

Customer Design Service Report

Title Adaptor using SG6902

Application Adaptor
Date 03-15-2006

Contents
A. General Spec…………………………………………………………………..2
B. Schematic………………………………………………………………………3
C. PCB Layout…………………………………………………………………….4
D. BOM……………………………………………………………………………..7
E. PFC Choke Inductor………………………………………………………….8
F. Transformer & Output Inductor…………………………………………….9
G. Function Check Report….…………………………………………………10
 System
General CDS Report

A. General Spec.

Input voltage………………………………………..………………..90Vac~264Vac

Output voltage/current..……………………………………………………...19V/6A

Efficiency……………….……………………85% at full load and 115Vac、230Vac

Green mode………………………………………...………………..<1W at no load

Over load protection……..……………………………………….…..Auto recovery

Short circuit protection……………………………….……………….Auto recovery

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General CDS Report

B. Schematic

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General CDS Report

C. PCB Layout

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D. BOM
Part Type Designator Part Type Designator Part Type Designator
R911 0ohm 0805 R938 R/100 0805 L905 PQ-2625
R922 33K 2W R921 R/200 0805 C916 C/47uF/50V
R905 R/0.22R/2W NR903 short C905 C/100uF/450V
R920 R/0.255R/1W NR901 TG07002 C910 C/103pF/1KV
R939 R/1.2K 0805 D907 1N4148 C935 C/104pF
R913 R/1M 1206 D906 1N4148 C900 C/222
R914 R/1M 1206 D908 1N4148 C913 C/104 0805
R901 R/1M D902 D/1N4007 C917 C/105 1206
R930 R/1R D901 D/1N4007 C937 C/472 0805
R907 R/2.4M 1206 D903 D/BYV10600 C911 103pF/1KV
R908 R/2.4M 1206 D905 D/FR103 C914 C/10uF
R932 R/4.7K 0805 D904 D/FR107 C901 YC 222pF
R940 R/4.7K 0805 D913 MBR20150 C902 YC 222pF
R933 R/4.7K D911 MBR20150 C907 C/0.33uF
R934 R/10K 0805 D912 MBR20150 C906 C/0.47uF
R942 R/10K 0805 BD901 B/6A/600V C919 C/101 0805
R928 R/10R Q903 11N60C3 C922 C/102 0805
R915 R/24K 0805 Q901 15N60C3 C920 C/102 0805
R936 R/24K 0805 Q904 2N2907 C925 C/103 0805
R912 R/47K 0805 Q902 2N2907 C923 C/103 0805
R937 R/61K 0805 T901 PQ-3225 C915 C/104 0805
R941 R/68K 0805 F901 250V/4A C934 C/330uF/35V
R910 R/604K 1206 VR901 MOV C936 C/330uF/35V
R909 R/604K 1206 IC901 SG6902 C933 C/680uF/25V
R916 R/10 0805 IC903 TL431 C932 C/680uF/25V
R918 R/10 0805 IC902 PC-817 C931 C/680uF/25V
R917 R/10 0805 L906 L-1 C930 C/222 1KV
R919 R/33 0805 L902 L/2mH C909 C/0.47uF/450V
R944 R/33 1206 L901 L/10mH C908 C/0.47uF/450V
R943 R/33 1206 L903 L/350uH C924 10uF 1206
R929 short

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General CDS Report

E. PFC Choke Inductor

Electrical

Structure
Winding Terminal Width Turn Note
Bobbin
N1 3-4 0.65*1 90
Mayer Tape * 3T
Core-PQ 2625 (12 Pin)
Mayer Tape * 3T
Copper-Foil Pin P1 1.2T open loop
Mayer Tape * 3T
Primary inductance (Pin3-4)=1.3mH

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General CDS Report

E. Transformer & Output Inductor

Electrical

Structure
Winding Terminal Width Turn Note
Bobbin
Copper-Foil Pin P6 1.2T open loop
Mayer Tape * 1T
N1 5-2 0.55*1 22
Mayer Tape * 1T
Copper-Foil Pin P6 1.2T open loop
Mayer Tape * 3T
N2 11、12-8、9 1.0*2 9
Mayer Tape * 3T
N3 6-3 0.2*1 9
Mayer Tape * 1T
Copper-Foil Pin P6 1.2T open loop
Mayer Tape * 1T
N4 2-4 0.5*1 25
Mayer Tape * 3T
Core-PQ 3225 (12 Pin)
Mayer Tape * 2T
Copper-Foil Pin P6 1.2T close loop
Mayer Tape * 2T
Primary inductance (Pin4-5)=870µH

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F. Function Check Report

Test model CDS-060201

Test date 2006-03-15
Test temperature Ambient

AC source: 6220 AC POWER SOURCE

Electronic load: Chroma 63030
Test Equipment
Power meter: WT210
Oscilloscope: TDS3014B

1. Input Current
2. Input wattage at no load condition
3. Turn on time
4. DC output rising time
5. Line & load regulation
6. Efficiency
7. Output ripple & noise
8. Step response
9. Over current protection
10. Hold up time
Test items
11. Short circuit protection
12. PF & THD
13. Brownout test
14. Vdd voltage level
15. Voltage stress on MOSFET & rectifiers
16. EMI test
17. Surge test
18. ESD test
19. Current Harmonic test

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1 Input current
1.1 Test condition
Measure the AC input current at maximum loading

1.2 Test result

Input Voltage Input current (A) Spec.
90V/60Hz 1.207
240V/50Hz 0.569

2 Input wattage at no-load condition

2.1 Test condition
Measure the input wattage and output voltage at no load

2.2 Test result

Input Voltage Input wattage(W) Output voltage(V) Spec.
90V/60Hz 0.162 19.302
230V/50Hz 0.296 19.302
264V/50Hz 0.355 19.302

2.3 Measured waveform

90V/60Hz @ NO load

Ch1: Vdd
Ch2: Vds

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264V/50Hz @ NO load

Ch1: Vdd
Ch2: Vds

3 Turn on time
3.1 Test condition
Set output at maximum loading. Measure the interval between AC
plug-in and stable output.

3.2 Test result

Input Voltage Max load(Sec) Spec.
90V/60Hz 3.14
120V/60Hz 2.16
264V/50Hz 0.94

4 DC output rising time

4.1 Test condition
Set output at maximum loading and no loading. Measure the time
interval between 10% to 90% output during startup.

4.2 Test result

Input Voltage Max load(mS) No load(mS) Spec.
90V/60Hz 28.6 6.24
120V/60Hz 22.8 5.36
264V/50Hz 13.8 4.72

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4.3 Measured waveform

90V/60Hz @ max load

Ch1: Vo

264V/50Hz @ max load

Ch1: Vo

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90V/60Hz @ NO load

Ch1: Vo

264V/50Hz @ NO load

Ch1: Vo

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5 Line & load regulation

5.1 Test condition
Measure line & load regulation according to below table

5.2 Test result

Output V at Output V at Load Spec.
Input Voltage Max. Min. regulation(%)
load(V) load(V)
90V/60Hz 19.292 19.308 0.084
115V/60Hz 19.284 19.292 0.042
132V/60Hz 19.276 19.290 0.074
18.05V<Vo<19.95V
180V/50Hz 19.274 19.288 0.074
230V/50Hz 19.270 19.286 0.084
264V/50Hz 19.268 19.282 0.074
Line
0.126 0.137
regulation(%)

6 Efficiency
6.1 Test condition
Output at max. load

6.2 Test result

Input Voltage Input Output Efficiency (%) Spec.
Wattage(W) Wattage(W)
90V/60Hz 133.3 115.86 86.92
115V/60Hz 131.3 115.80 88.19
132V/60Hz 130.6 115.76 88.64
180V/50Hz 130.8 115.74 88.49
230V/50Hz 130.1 115.69 88.92
264V/50Hz 129.3 115.66 89.45

6.3 Test result

Efficiency(%)
Input 25% Load 50% Load 75% Load 100% Load Spec.
Voltage
115V/60Hz 87.95 87.30 88.16 88.19
230V/50Hz 88.18 86.91 88.54 88.92

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7 Output ripple & noise

7.1 Test condition
Ripple & noise are measured by using 20MHz bandwidth limited
oscilloscope with a 10uF capacitor paralleled with a high-frequency 0.1uF
capacitor across each output.

7.2 Test result

Input Voltage Max. load(mV) Min. load(mV) Spec.
90V/60Hz 48.0 9.80
115V/60Hz 46.4 9.80
230V/50Hz 48.8 13.4
264V/50Hz 41.2 12.6

7.3 Measured waveform

90V/60Hz @ max. load

Ch1: Vo

264V/50Hz @ max. load

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Ch1: Vo

8 Step response
8.1 Test condition
Dynamic loading (20%~80% of the full load, 5msec duty cycle, 2.5 A/usec
rise/fall time)
8.2 Test result
Input Voltage Over shoot (mV) Under shoot (mV) Spec.
90V/60Hz 168 172
264V/50Hz 148 151
8.3 Measured waveform(20%~80% of the full load)
90V/60Hz @ max. load

Ch1: Vo

264V/50Hz @ max. load

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Ch1: Vo

9 Over Current Protection

9.1 Test condition
Increase output loading gradually.

9.2 Test result

Input Volatge Output current(A) Spec
90V/60Hz 7.365
115V/60Hz 7.410
230V/50Hz 7.560
264V/50Hz 7.575

10 Hold-up time
10.1 Test condition
Set output at maximum load. Measure the time interval between AC off
and output voltage falling to lower limit of rated value. The AC waveform
should be off at zero degree.
10.2 Test result
Input Voltage Hold-up time (msec) Spec.
90V/60Hz 21.6
120V/60Hz 21.4
230V/50Hz 50.8
264V/50Hz 50.8
10.3 Measured waveform
90V/60Hz @ max. load

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Ch1: Vo
Ch2: Vac

264V/50Hz @ max. load

Ch1: Vo
Ch2: Vac

11 Short circuit protection

11.1 Test condition
Short the output of the power supply. The power supply should enter hiccup
mode protection.

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11.2 Test result

Input Voltage Input wattage at Input wattage at Spec.
maximum loading(W) minimum loading(W)
90V/60Hz 0.6 0.2
264V/50Hz 2.0 0.5

11.3 Measured waveform

90V/60Hz @ max. load

Ch1: Vdd
Ch2:
GATE

264V/50Hz @ max. load

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 System
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Ch1: Vdd
Ch2:
GATE

12 PF & THD

13 Brown out test

13.1 Test condition
Set output at maximum loading. Decrease input voltage with 5VAC step. Record
input wattage and output voltage. After the output is off, increase the AC voltage
gradually and record the recovery voltage.

13.2 Test result

Full Load
Input voltage Input Wattage (W) Output voltage(V)
90V/60Hz 133.6 19.288
85V/60Hz 133.8 19.286
80V/60Hz 134.3 19.284
75V/60Hz 135 19.282
70V/60Hz 0 0

13.3 Test result

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Vo Recovery voltage: 80Vac

13.4 Test result

No Load--0.18A
Input voltage Input Wattage (W) Output voltage(V)
90V/60Hz 4.4 19.294
85V/60Hz 4.4 19.294
80V/60Hz 4.5 19.294
75V/60Hz 4.5 19.294
70V/60Hz 4.5 19.294
65V/60Hz 4.5 19.294
60V/60Hz 4.6 19.294
55V/60Hz 0 0

13.5 Test result

Vo Recovery voltage: 71Vac

14 Vdd voltage level

14.1 Test result
Input voltage Min. load(V) Max. load(V) Near OPP(V) Output S.C. Spec
(max value) (V)
90V/60Hz 14.6 20.1 21.1 18.8
264V/50Hz 12.9 19.5 20.6 18.6

14.2 Measured waveform

90V/60Hz @ max. load

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Ch1: Vdd
Ch2:
Sense

90V/60Hz @ output short-ciruited

Ch1: Vdd
Ch2:
Sense

264V/50Hz @ max. load

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Ch1: Vdd
Ch2:
Sense

264V/50Hz @ output short-ciruited

Ch1: Vdd
Ch2:
Sense

15 Voltage stress on MOSFET & rectifiers

15.1 Test condition
Measure the voltage stress on MOSFET and secondary rectifiers under
below specified condition

15.2 Test result

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Stress on Rating Stress on Rating

MOSFET output
rectifier
90V/60Hz, max.
load 438V 111V

90V/60Hz, max.
load, 458V 118V
startup
90V/60Hz, max.
load, 458V 116V
output short
264V/50Hz, max.
650V 150V
load 558V 144V

264V/50Hz, max.
load, 622V 145V
startup
264V/50Hz, max.
load, 602V 145V
output short
264V/50Hz, max.
608V 150V
load turns off
15.3 Measured waveform
90V/60Hz max load

Ch1:
Vds_mos
Ch2:
Vak_rectifier

264V/50Hz max load

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Ch1:
Vds_mos
Ch2:
Vak_rectifier

264V/50Hz max load (turns off)

Ch1: Vds
Ch2: Vo

15 EMI test

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Conduction-Line @ 110Vac
RBW 9 kHz
MT 50 ms
Att 10 dB PREAMP OFF
dBµV 100 1 MHz 10 MHz

90
SGL
1 QP
CLRWR
80

2 AV
CLRWR
70 TDF

EN55022Q
60
PRN
EN55022A
50

40

30

20

10

150 kHz 30 MHz

Date: 13.MAR.2006 16:34:19

Conduction-Line @ 230Vac
RBW 9 kHz
MT 50 ms
Att 10 dB PREAMP OFF
dBµV 100 1 MHz 10 MHz

90
SGL
1 QP
CLRWR
80

2 AV
CLRWR
70 TDF

EN55022Q
60
PRN
EN55022A
50

40

30

20

10

150 kHz 30 MHz

Date: 13.MAR.2006 16:43:51

Conduction-Neutral @ 110Vac

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RBW 9 kHz
MT 50 ms
Att 10 dB PREAMP OFF
dBµV 100 1 MHz 10 MHz

90
SGL
1 QP
CLRWR
80

2 AV
CLRWR
70 TDF

EN55022Q
60
PRN
EN55022A
50

40

30

20

10

150 kHz 30 MHz

Date: 13.MAR.2006 16:25:24

Conduction-Neutral @ 230Vac
RBW 9 kHz
MT 50 ms
Att 10 dB PREAMP OFF
dBµV 100 1 MHz 10 MHz

90
SGL
1 QP
CLRWR
80

2 AV
CLRWR
70 TDF

EN55022Q
60
PRN
EN55022A
50

40

30

20

10

150 kHz 30 MHz

Date: 13.MAR.2006 16:52:10

16 Surge test

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Mode Polarity Phase Voltage Condition

+/- 0∘ Pass
+/- 90∘ Pass
L-N 1KV
+/- 180∘ Pass
+/- 270∘ Pass
+/- 0∘ Pass
+/- 90∘ Pass
L-PE 2KV
+/- 180∘ Pass
+/- 270∘ Pass
+/- 0∘ Pass
+/- 90∘ Pass
N-PE 2KV
+/- 180∘ Pass
+/- 270∘ Pass

17 ESD test

Air Discharge (+/-8KV) Contact Discharge (+/-4KV)

Pass Pass Pass Pass

18 Current Harmonic test

18.1 Test condition
Load： Max Load
18.2 Test result
Input voltage PF THD(%) Spec
90V/60Hz Pi=75W 0.995 3.19
Max Load 0.999 1.52
110V/60Hz Pi=75W 0.987 3.39
Max Load 0.995 2.61
230V/50Hz Pi=75W 0.901 7.80
Max Load 0.960 5.54
264V/50Hz Pi=75W 0.851 9.12
Max Load 0.936 6.35

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