台湾崇贸公司提供的一款60W电源的Demo Board

PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw C o n t e n t s 1 . G e n e r a l S p e c i f i c a t i o n . . . . . . . . . . . . . . . P 2 2 . D e m o B o a r d C i r c u i t D i a g r a m . . . . P 3 3 . B O M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4 4 . T r a n s f o r m e r S p e c i f i c a t i o n . . . . . . . P 6 5 . C h e c k L i s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 8 6 . T e m p e r a t u r e R e c o r d . . . . . . . . . . . . . . . P 1 3 7 . E M I T e s t R e p o r t . . . . . . . . . . . . . . . . . . . . . P 1 4 8 . E M S Te s t R e p o r t . . . . . . . . . . . . . . . . . . . . P 1 8 9 .SG6840 Data S h eet . . . . . . . . . . . . . . . . . .P23 1 0 . P C B L a yo u t N o t e . . . . . . . . . . . . . . . . . . P 3 4 -1- PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw G e n e r a l S p e c i f i c a t i o n s Input voltage...................................90V AC to 264V AC Input frequency.........................................47Hz to 63Hz Outputs...................................(12V/5A),60W 19V/3.16A Efficiency.................................................................85% Hold up time..................................................≧17mSec Over load protection Short circuit protection Over voltage protection Cooling.............................................Free air convection Storage temperature..................................-20c to +85c EMI test standard ............................CISPR-22 Class B EMS test standard.......................EN61000-4-X VER:97 Notes: 1.Dimensions shown in mm as above. Tolerance specified is 0.4mm 2.PCB Size L:113.5 mm W:53mm H:20mm 113.5 mm 53mm 20mm 7mm - 2 - PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 3 - D e m o B o a r d C i r c u i t D i a g r a m PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 4 - BOM Quantity Part Number Description Note 1 BD1 BD KBJ406G 1 C1 XC 0.68u/275V 1 C1A XC 0.1u/275V (mini) 1 C3 YC 222P/250V F/mini 1 C6 EC 120u/400V-105℃(18Ø*31mm) Nippon-KMG 1 C8 EC 10u/50V-105℃ 1 C9 CC 102P(100V/X7R) 1206 2 C10,C11 EC 680u/25V-105℃ TEAPO(10fØ20mm) 1 C12 CC 104P(50V/X7R) 0805 1 C13 EC 220u/35V-105℃ Nippon LXE(8Ø*20mm) 0 C16 OPEN 1 C15 CC 102P(50V/X7R) 0805 1 C17, CC 471P(50V/X7R) 0805 2 C6A,C11A CC 103P(500V) DIP 2 D2,D6 BYV95C D2:W (with ferrite bead ) D6:W (with ferrite bead) 1 C7 TVS P6KE150A 1 D8 TVS P6KE16A W 1 F1 FUSE 4A/250V W/5*15 1 T1 TRN0018 1 T2 TRN0002-121(REV:2.0) 1 L1 TRN0003 1 L4 TRN0083 1 Q1 2SK2996 1 Q2, BAW56 SMD 1 Q3 20CTQ100 S.G.S 4 R1,R2,R15,R19 ER 1M 1206 0 R3,R4,R5,R6,R10 Open 0 R17,R18,R31,TR2 Open 3 R8A,R8B,R8C CR 1.2W 1206 PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 5 - 1 R8D CR 2.2Ω 1206 1 R11 CR 10Ω 0805 2 R16, R22 ER 15K 0805 2 R14,R29 CR 47Ω 1206 1 R20 CR 6.8K 0805 1 R21 ER 180K 0805 1 R23 CR 10K 0805 1 R25 ER 154KΩ/1/8W±1% 0805 1 R26 ER 40.2KΩ/1/8W±1% 0805 1 R27 CR 220Ω 1206 1 R28 30mR Mn-Cu Wire 1 R33 ER 33K 0805 1 R46 0Ω 1206 1 U1 K1010H DIP (4 Pin) 1 U2 TL431 1% 1 U4 SG6840 SMD(8PIN) 1 U5 LM358 SMD(8PIN) 1 FB1 BEAD CORE(MCH0041) (C8B 3.5*3.2*1.0+T) 3 D6,D2 BEAD Core (MCH0040) (C8B 3.5*3.2*1.0) 3 J1,2,3 JUMPER 2 Q1,Q3 3*8 screw 1 Q3 TR-220 Isolator- 1 1 Q3 TO-220 Isolator- 2 1 Q1 Heatsink MCH0089 1 Q3 Heatsink MCH0090 1 AC Socket SC-8R(3P1S) 3 J1,C6 1Ø*10mm Silicon tube MCH0340 1 PCB PC-2103 REV: C PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 6 - T r a n s f o r m e r S p e c i f i c a t i o n 1.Safety reference standard IEC950 2.Surface, Structure 2.1Surface: damage, rusting, etc. are not permitted 2.2The shape, dimension and marking of the transformer: are as below mention. 3.Mechanical Performance Terminal strength: Each terminal of the transformer must be withstandinga pull 5Kg for 10 second ,without loosen- ing ,breaking. 4.Electrical: Insulation Tape Winding Terminal Wire Gauge (mm) Turns (T) Note P N1 4 - 5 0.4*1 20 ( A ) 1 Copper-Foil -> Pin1 1.2T open loop S 3 N2 TP5-TP4 1.0 7 ( B ) 3 Copper-Foil -> Pin1 1.2T open loop P 1 N3 5 - 6 0.4*1 18 ( A ) P 1 N4 1 - 3 0.25*2 9 ( C ) 3 PQ2620 Ferrite Code 5.Winding Table (A)Lp1(Pin4-6) inductance = 680~730uH;Leakage induc- tance < 10uH(Shortcircuit N2, measure the inductance of pin 4-6) (B)By using ”Triple insulated wire” for N2; winding is from the bottom to the top of bobbin. (C)N4:loosely winding (D)The output with tube 6.Core Core Type : PQ2620 7.Core Gap Bobbin & Pin Model No: PQ2620 8.Magnet Wire Polyurethane Enamel Copper Wire≧130°C Pacific; UL E84081 9.Triple insulated winding wire TEX-E ; No.1950 UL E57568(S) 10.Tape 0.025mm, Polyester film tape; No.35660 Four Pillars; UL E520292(S) Teraoka Seisakusho; UL E56086(S) 11.Impregnation Varnish Ts-2414V(Tesh Chemical Co.)≧130°C 12.Insulation Outerwrap : Three layers min.;0.025mm/layer polyester film tap total0.075mm. Primary to Primary : One layer min.; 0.025mm polyester film tape. Secondary to Primary :Three layers min.; 0.025mm/layer Polyester film tape total 0.075mm. Primary to Core : obbin,1.0mm min. thick. Crossover : One layer min.; 0.025mm polyester film tape. 13.Isolation Primary to Secondary : 100M ohms min. Primary to Core : 100M ohms min. All winding to each other : 100M ohms min. Primary to Secondary : 3000VAC,50/60Hz,0.5mA max. Primary to Core : 500VAC,50/60Hz,0.5mA max. 14.Primary Inductance of Pin4 To Pin6:770- 820uH PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw C h e c k L i s t - 7 - Test Model SG6840 for 60W - 12V/5A Test Date: Test Temperature Ambient Test Equipment AC Source: CHROMA 6530 Electronic Load: Zentech 2600A Multimeter: BRYMEN BM729 Oscilloscope: Tektronix TDS3032 Test Summary 1 Input Current: √ Pass Fail 2 Input Wattage at DC output no-load condition: √ Pass Fail 3 Line Regulation & Load Regulation: √ Pass Fail 4 Ripple & Noise: √ Pass Fail 5 Over shoot & Under Shoot Test: √ Pass Fail 6 Current Limit & Constant Power: √ Pass Fail 7 Short circuit protection: √ Pass Fail 8 Efficiency: √ Pass Fail 9 DC output rise time: √ Pass Fail 10 Turn on time: √ Pass Fail 11 Hold up time: √ Pass Fail 12 Dynamic load: √ Pass Fail 13 Over Voltage Protection: √ Pass Fail 14 Burn-in test: √ Pass Fail 15 Brown out test: √ Pass Fail Note Max. Load=5A Mid. Load=2.5A Min. Load=0A PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 8 - 1.Input Current: 1.1 Test Condition: 1.2 Test Result: 2.Input Wattage at DC output no-load condition: 2.1 Test Condition: 2.2 Test Result: 3.Line Regulation & Load Regulation: 3.1 Test Condition: 3.2 Test Result: Load: Max. Load Input current: 1.3A Max. Input Voltage Input Current Test Specifications 115V/60Hz 1.25A 230V/60Hz 0.7A Load: Min. Load Less than 1.0Watt at nominal line condition. Input Voltage Input Power Stability Test Specifications 120V/60Hz 0.25W 12V <1W 240V/50Hz 0.35W 12V <1W 264V/50Hz 0.4W 12V <1W Line regulation: 1% Max. Load regulation: 5% Max. Input Voltage Max. Load Mid. Load Min. Load Test Spec. 90V/60Hz 11.78V 11.88V 12V 11.4V~12.6V 115V/60Hz 11.78V 11.88V 12V 11.4V~12.6V 132V/60Hz 11.78V 11.88V 12V 11.4V~12.6V 180V/50Hz 11.78V 11.88V 12V 11.4V~12.6V 230V/50Hz 11.78V 11.88V 12V 11.4V~12.6V 264V/50Hz 11.78V 11.88V 12V 11.4V~12.6V Line Regulation 0% 1% Load Regulation 1.8% 5% PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw = 9 - 4.Ripple & Noise: 4.1 Test Condition: 4.2 Test Result: 5.Over shoot & Under Shoot Test: 5.1 Test Condition: 5.2 Test Result: 6.Current Limit & Constant Power: 6.1 Test Condition: 6.2 Test Result: Tested by DC loading side parallel with a 10uF/EC and 0.1uF/CC capacitor and Measured Band-width with DC-20MHz Input Voltage Max. Load Mid. Load Min. Load Test Spec. 90V/47Hz 40mV 30mV 10mV 100mV 115V/60Hz 35mV 25mV 10mV 230V/63Hz 25mV 15mV 10mV Less than 5% of nominal voltage value Load: Max. load Input Voltage Over Shoot Under Shoot Test Spec. 90V/47Hz; Min. Load 160mV 0mV <5% 90V/47Hz; Max. Load 240mV 100mV <5% 264V/63Hz; Min. Load 160mV 0mV <5% 264V/63Hz; Max. Load 240mV 100mV <5% An over current from the output to return line will not damage the power supply. The protection will be enabled if the output current exceeds 5.5A ~ 6.5A. Input Voltage Output Current (A) Test Spec. 90V/60HZ 5.8A 115V/60HZ 5.8A 132V/60HZ 5.8A 180V/50HZ 5.8A 230V/50HZ 5.8A 264V/50HZ 5.8A PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 0 - 7.Short circuit protection: 7.1 Test Condition: 7.2 Test Result: 8.Efficiency 8.1 Test Condition: 8.2 Test Result: 9.DC output rise time: 9.1 Test Condition: 9.2 Test Result: Short-circuit the output the power supply will be protected and AC power input will be less than 5W (auto recovery) Input Voltage Max. Load Mid. Load Min. Load Test Condition 90V/47Hz √ Pass Fail √ Pass Fail √ Pass Fail <5W 264V/63Hz √ Pass Fail √ Pass Fail √ Pass Fail <5W Load: Max. load Efficiency: 80% minimum at nominal line input Input Voltage Max. Load Test Spec. 90V/60HZ 85% >80% 115V/60HZ 85% >80% 132V/60HZ 85% >80% 180V/50HZ 86% >80% 230V/50HZ 87% >80% 264V/50HZ 87% >80% Load: Max. load & Min. load DC Output rise time: 20mS max. Input Voltage Max. Load Min. Load Test Spec. 90V/47Hz 9mS 2.5mS < 20mS 264V/63Hz 9mS 2.5mS < 20mS PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw 10.Turn on time: 10.1 Test Condition: 10.2 Test Result: 11.Efficiency 11.1 Test Condition: 11.2 Test Result: 12.DC output rise time: 12.1 Test Condition: 12.2Test Result: 13.Over Voltage Protection: 13.1 Test Condition: 13.2Test Result: Load: Max. load & Min. load AC Switch on time: 4Sec max. Input Voltage Max. Load Min. Load Test Spec. 90V/47Hz 3.3Sec 3.3Sec <4Sec 110V/60Hz 2.2Sec 2.2Sec <3Sec 220V/50Hz 1Sec 1Sec <3Sec Load: Max. load & Min. load DC Hold up time: Input Voltage Max. Load Min. Load Test Spec. 90V/47Hz 8mS N/A 110V/60Hz 15mS N/A 220V/50Hz 80mS N/A Dynamic loading (20% ~ 80% of the full load, 50mesc duty cycle) Input Voltage Over Shoot Under Shoot Stability Test Spec. 115V 250mV 250mV N/A 230V 250mV 250mV N/A Over voltage protection: 16~ 17 VDC Load: Max. load & Min. load Input Voltage Max. Load Min. Load Test Spec. 115V N/A 17V 230V N/A 17V - 1 1 - PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 2 - 14.Burn-in test: 14.1 Test Condition: 14.2 Test Result: 15.Brown out test 15.1 Test Condition: 15.2 Test Result: 100% Burn-in at full load and 1 hours at least. Burn-in test √ Pass Fail Test Spec. : >1hours The power supply shall meet its output specification while the line voltage is reduced in 5 voltage decrements from 264Vac to 90Vac, with a minimum dwell at each increment of 15 minutes. The voltage transition time shall be equal to or less than 5 seconds. The power supply shall recover and continue to meet its output specification after the line voltage is reduced in 5 volt decrements from 264Vac to 0Vac and subsequently increased to 85Vac (minimum dwell at each increment of 15 minutes). The voltage transi- tion time shall be equal to or less than 5 seconds. Input Voltage Vin=90V 71W Vin=85V 71.3W Vin=80V 71.9W Vin=75V 72.6W Vin=70V 72.8W Vin=65V 71W Vin=60V 67W Vin=55V 62W Vin=50V 56W Vin=45V 50W Vin=40V 42W Vin=35V 0W Vin=30V 0W Vin=25V 0W Vin=20V 0W Vin=15V 0W Vin=10V 0W Input Power PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 3 - T e m p e r a t u r e R e c o r d 1、BD1 83.7 ℃ 2、C6 58.2 ℃ 3、Q1 70.5 ℃ 4、T2 63.4 ℃ 5、Q3 90.1 ℃ 6、C10 86.1 ℃ PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 4 - E M I T e s t R e p o r t 1. Radiation Vertical Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 5 - 2. Radiation Horizontal Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw 3.Conduction Line Test - 1 6 - PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 7 - 4. Conduction Neutral Test PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 8 - E M S T e s t R e p o r t 1.EFT/Burst Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 1 9 - 2.Injection Current Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 2 0 - 3.Voltage Dips/Interruption Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 2 1 - 4.Surge 2KV Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw - 2 2 - 5.Surge 4KV Testing PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw FEATURES OVERVIEW ●Green-mode PWM to support “Blue Angle”Norm ●Low start up current 30uA ●Low operation current 3mA ●Leading-edge blanking ●Built-in synchronized slope compensation ●Totem pole output includes soft driving ●Constant output power ●Current mode operation ●Cycle-by-cycle current limiting ●Under voltage lockout (UVLO) ●Short circuit protection ●Programmable over-temperature protection ●Few external components & low cost solution - 2 3 - S G 6 8 4 0 D a t a S h e e t DESCRIPTION This high-integrated PWM controller provides several special enhancements to satisfy the needs for low power standby and protection features. In standby mode, PWM frequency reduction is used to lower the power consump- tion and support a stable output voltage. Due to Bi-CMOS process, the SG6840 reduces start- up and operation current to achieve a higher efficiency power conversion. Start-up current has been reduced to 30uA typical and operating current has been shrunk to 3mA. The SG6840 is a fixed frequency PWM controller in normal operation; its patented green-mode function will decrease the PWM frequency in response to the decrease of the load. This green function dramatically reduces the power loss in no load and light load conditions that assist the power supply to meet the power conservation require- ment. The proprietary synchronized slope com- pensation ensures the stability of the current loop for continuous-mode operation. Built-in line -voltage compensation maintains an identical output power for a wide input range. An NTC thermistor is applied to sense the temperature for over-temperature protection. The SG6840 is available in 8-pin DIP and SO packages. APPLICATIONS General-purpose switching mode power sup- plies and flyback power converters, and ●Power Adapter ●Open-frame SMPS ●Battery Charger Adapter PIN CONFIGURATION PN B60121T-SG 6840 Demo Board Manual PNB60121T-SG6840 2002 System General Corporation Ver1.0 http://www.sg.com.tw