TEST EQUIPMENT LIST: AC Source : Chroma programmable AC source Model 61504 Power Analyzer : Chroma Power Analyzer Model 6630 Load : Chroma Electronic DC Load 63103 Oscilloscope : Lecroy wave surfer 424 200MHZ Oscilloscope Digit Multimeter : Fluke 8808A Multimeter INPUT FUNCTION TEST NO TEST ITEM SPECIFICATION TEST CONDITION 1 INRUSH CURRENT 115 VAC 35 A(MAX) I/P : 115 VAC 60 HZ 115 VAC 28.1 A COLD START 230 VAC 70 A(MAX) 230 VAC 55.4 A COLD START O/P : MIN LOAD 2 INPUT VOLTAGE RANGE 88 VAC ~ 264 VAC I/P : TESTING I/P : 88 V ~ 264 V I/P : TEST : OK LOW-LINE -3V = 85 V HIGH-LINE+36V = 300 V (AC POWER ON/OFF NO DAMAGE) / MIN LOAD ON:30SEC OFF:30SEC 10MIN 3 INPUT FREQUENCY RANGE 47 HZ ~ 63 HZ I/P : 100 VAC ~ 264 VAC TEST : OK / MIN LOAD (NO DAMAGE) 4 EFFICIENCY I/P : 230 VAC 82 % (TYP) I/P : 100 VAC 60 HZ 100 VAC 79.60 % 230 VAC 82.35 % 5 INPUT CURRENT 100 VAC < 2.8 A I/P : 100 VAC 60 HZ 100 VAC 2.23 A 115 VAC < A I/P : 115 VAC 60 HZ 115 VAC A 230 VAC < A 230 VAC A 6 POWER FACTOR CORRECTION I/P : 115 VAC 60 HZ 115 VAC P.F > PF 230 VAC P.F 7 LEAKAGE CURRENT I/P : 264 VAC 50 HZ I/P : 264 VAC 50 HZ L-PE : 0.76 ma < 1 ma O/P : MIN LOAD N-PE : 0.76 ma PASS: FAIL : X QR0415-2 REV:2.1 MUST KEEP 1PCS FIGURE 1/5
OUTPUT FUNCTION TEST NO TEST ITEM SPECIFICATION TEST CONDITION PASS: 1 LINE REGULATION V1 : ± 1.5 % (max) I/P : 100 VAC ~ 264 VAC Vmax Vmin Vnormal ±% V2 : ± 2.5 % (max) 5.028 5.025 5.000 0.060% 24.897 24.845 24.000 0.217% 2 LOAD REGULATION V1 : ± 3 % (max) I/P : 115 VAC 60 HZ Vmin load Vfull load Vcent ±% V2 : ± 5 % (max) / MIN LOAD 5.042 5.030 5.034 0.238% 24.897 24.882 24.896 0.060% Vmin load Vfull load Vcent ±% / MIN LOAD 5.042 5.025 5.035 0.337% 24.871 24.845 24.818 0.104% 3 CROSS REGULATION I/P : 115 VAC 60 HZ O/P : V1 : 20 % V2 : 100 % 5 V 24 V 230 VAC 50 HZ V3 : % INPUT 2.4 A 3.5 A VOLTAGE 20 % 100 % 115V 5.039 23.534 230V 5.041 23.463 I/P : 115 VAC 60 HZ O/P : V1 : 100 % V2 : 20 % 5 V 24 V 230 VAC 50 HZ V3 : % INPUT 12 A 0.7 A VOLTAGE 100 % 20 % 115V 5.026 24.894 230V 5.025 24.834 I/P : 115 VAC 60 HZ O/P : V1 : 20 % V2 : 20 % 5 V 24 V 230 VAC 50 HZ V3 : % INPUT 2.4 A 0.7 A VOLTAGE 20 % 20 % 115V 5.038 24.028 230V 5.038 23.905 I/P : 115 VAC 60 HZ O/P : V1 : 100 % V2 : 50 % 5 V 24 V 230 VAC 50 HZ V3 : % INPUT 12 A 1.75 A VOLTAGE 100 % 50 % 115V 5.024 24.882 230V 5.024 24.824 MAX LOAD I/P : 115 VAC 60 HZ O/P : V1 : V2 : NO LOAD 5 V 24 V 230 VAC 50 HZ V3 : NO LOAD INPUT 12 A 0 A VOLTAGE 100 % 0 % 115V 5.024 V2 V3 VOLTAGE < 130% 230V 5.023 4 SET UP TIME 115 VAC < 1000 ms I/P : 115 VAC 60 HZ V1: 470.75 ms 230 VAC < 1000 ms V1: 513.52 ms 5 RISE TIME 115 VAC < 20 ms I/P : 115 VAC 60 HZ V1: 19.23 ms 230 VAC < 20 ms V1: 17.75 ms 6 HOLD UP TIME 230 VAC > 60 ms V1: 94.48 ms V2: 98.68 ms 24.873 24.833 7 OVERSHOOT & UNDERSHOOT I/P : 230 VAC Vmax Vtop Vbase ±% TEST OUTPUT < < ±5% O/P : 20% LOAD 5.100 5.045 0.014 1.100% 24.500 24.130 0.166 1.400% 8 DYNAMIC LOAD OUTPUT < 1000 mvp-p(max) V1 : 106.3 mvp-p(max) / MIN LOAD 75% DUTY CYCLE 1K HZ 9 RIPPLE & NOISE V1 : < 70 mvp-p I/P : 100 VAC 60 HZ V1 11.94 mvp-p(max) 20% LOAD V2 : < 240 mvp-p O/P : 20% / 50% / 100% LOAD JUST PFC FUNCTION ONLY 19.40 32.70 mvp-p(max) 50% LOAD mvp-p(max) 100% LOAD V2 19.70 mvp-p(max) 20% LOAD 88.10 mvp-p(max) 50% LOAD 51.30 mvp-p(max) 100% LOAD I/P : 254 VAC 50 HZ V1 17.50 mvp-p(max) 20% LOAD O/P : 20% / 50% / 100% LOAD 22.20 mvp-p(max) 50% LOAD 25.50 mvp-p(max) 100% LOAD V2 6.69 mvp-p(max) 20% LOAD 8.19 mvp-p(max) 50% LOAD 12.69 mvp-p(max) 100% LOAD 10 Power Good Signal Hi-Limt ms V1 : ms Lo-Limt ms V2 : ms 11 REMOTE CONTROL ON/OFF POWER ON : ~ V I/P : VAC ~ VAC POWER ON : ~ (OPTION) POWER OFF : ~ V / MIN LOAD POWER OFF : ~ SINK CURRENT: ~ ma 12 CAPACITOR LOAD I/P : 115 VAC 60 HZ V1 : 108,000 μf (Max) V2 : 36,000 μf (Max) V1 : 108,000 μf (Max) O/P : MIN LOAD V2 : 108,000 μf (Max) QR0415-2 REV:2.1 MUST KEEP 1PCS FIGURE 2/5
PROTECTION FUNCTION TEST Protect function:any of below conditions 1.Limiting voltage latch 2.Hiccup and recovers automatically after the fault is removed. 3.Shutdown and recovers automatically 2 hours 1 OVER LOAD PROTECTION O/P : 105 % ~ 150 % I/P : 115 VAC 60 HZ 115 VAC 126 % 230 VAC 125 % O/P : SPEC. maximum OLP point I/P : 115 VAC 60 HZ to repeat 30 times Each I/P 30 times 2 OVER VOLTAGE PROTECTION I/P : 230 VAC OP: VDC (MIN LOAD) O/P : V ~ V O/P : MIN LOAD / FULL LOAD OP: VDC (FULL LOAD) Each load condition duration OVP point after the fault is removed. I/P : 230 VAC OP: 6.13 VDC (MIN LOAD) O/P : 5.8 V ~ 7 V O/P : MIN LOAD / FULL LOAD OP: 6.14 VDC (FULL LOAD) Protect function: Shutdown and latch off, recover after re-start up. 3 SHORT CIRCUIT PROTECTION SHORT EVERY OUTPUT I/P : 100 VAC 60 HZ V1 SHORT 1.10 W I/P : 264 VAC 50 HZ 100VAC, OP: V2 SHORT 9.10 W PASS: Continued short circuit : 2 Hour Power turn on / off 3 times Each I/P 1 time V1 SHORT 18.00 W 264VAC, OP: V2 SHORT 25.00 W COMPONENT STRESS TEST 1 Power Transistor Q Rated I/P : 264 VAC 50 HZ (1) V (D to S) or (C to E) Peak Voltage A V O/P : (1)Full Load Turn on (2) V (PFC or Non PFC) (2)Full Load (3) V 2 Power Transistor(PWM) Q 1 Rated I/P : 264 VAC 50 HZ (1) 628 V (D to S) or (C to E) Peak Voltage 6 A 900 V O/P : (1)Full Load Turn on (2) 564 V (2)Full Load (3) 598 V MOS 2SK3878 3 Clamp Diode Peak Voltage D 1 Rated I/P : 88 VAC 60 HZ 88V 60HZ (1) 375 V 1 A 1000 V I/P : 264 VAC 50 HZ (2) 365 V O/P : (1)Full Load 264V 50HZ (1) 526 V (2)Dynamic Load (2) 520 V FAST-D FR107 75% DUTY CYCLE 1K HZ 4 Input Capacitor Voltage C 5, 6 Rated I/P : 264 VAC 50 HZ (1) 363 V 150 μf 400 V O/P : (1)Full Load Turn on (2) 372 V (2)Min Load Turn on (3) 363 V (3)Full Load / Min Load Change 5 Control IC Voltage & Vcc Capacitor U 1 Rated I/P : 88 VAC 60 HZ 88V 60HZ (1) 14.43 V Voltage 18 V I/P : 264 VAC 50 HZ (2) 11.35 V O/P : (1)Full Load Turn on (3) 14.42 V SMD IC NCP1203D60R2G (2)Min Load Turn on 264V 50HZ (1) 14.39 V C 12 Rated (3)Full Load / Min Load Change (2) 11.37 V 220 μf 25 V (3) 14.39 V 6 AUX Vcc Diode Peak Voltage D 4 Rated I/P : 264 VAC 50 HZ (1) 53.4 V 1 A 200 V O/P: (1)Full Load Turn on (2) 53.1 V (2)Full Load (3) 49.1 V SMD FAST-D ES1002FL 7 Output Diode Peak Voltage D 6 Rated I/P : 264 VAC 50 HZ D6: (1) 17.4 V 30 A 45 V O/P : (1)Full Load Turn on (2) 17.4 V (2)Full Load (3) 24.3 V STKY MBRP3045N D 7 Rated D7: (1) 184 V 20 A 200 V (2) 180 V (3) 156 V FAST-D BYQ28X-200 PASS: QR0415-2 REV:2.1 MUST KEEP 1PCS FIGURE 3/5
SAFETY TEST 1 WITHSTAND VOLTAGE I/P-O/P : 3 KVAC/min I/P-O/P : 3.6 KVAC/min I/P-O/P : 8.309 ma I/P-PE : 1.5 KVAC/min I/P-PE : 1.8 KVAC/min I/P-PE : 6.985 ma O/P-PE : 0.5 KVAC/min O/P-PE : 0.6 KVAC/min O/P-PE : 7.438 ma Ta : 25 2 ISOLATION RESISTANCE I/P-O/P : 500VDC>0.1GΩ I/P-O/P : 500 VDC I/P-O/P : 2.210 GΩ I/P-PE : 500VDC>0.1GΩ I/P-PE : 500 VDC I/P-PE : 2.416 GΩ O/P-PE : 500VDC>0.1GΩ O/P-PE : 500 VDC O/P-PE : 2.983 GΩ Ta : 25 3 GROUNDING CONTINUITY PE TO CHASSIS CONDITION : 40A / 2min 35.7 mω OR TRACE < 100 mω 4 APPROVAL TUV : Certificate NO : R 50155761 UL : File NO : E 129733 PASS: E.M.C TEST NO TEST ITEM SPECIFICATION TEST CONDITION 1 HARMONIC IEC1000-3-2 CLASS A MEET EN61000-3-2 Class A CLASS C MEET EN61000-3-2 Class C CLASS D MEET EN61000-3-2 Class D 2 CONDUCTION EN55022 MEET EN 55022 FCC CFR 47 PART 15 SUBPART B I/P : 115 VAC 60 HZ FCC CFR 47 PART 15 PASS: 3 RADIATION EN55022 MEET EN 55022 FCC CFR 47 PART 15 SUBPART B I/P : 115 VAC 60 HZ FCC CFR 47 PART 15 4 ESD IEC1000-4-2 AIR : MEET EN61000-4-2 Level III LIGHT INDUSTRY CONTACT : MEET EN61000-4-2 AIR:±8KV/ CONTACT:±4KV Level II 5 E.F.T IEC1000-4-4 LIGHT INDUSTRY INPUT:1KV MEET EN61000-4-4 Level II 6 SURGE IEC1000-4-5 LIGHT INDUSTRY O/P : Min LOAD L-N:1KV L,N-PE:1.5KV 2KV 2.4KV MEET EN61000-4-5 Level III 7 POWER FREQUENCY IEC1000-4-8 MEET EN61000-4-8 Level II MAGNETIC FIELD 8 VOLTAGE DIP AND IEC1000-4-11 MEET EN61000-4-11 Level B INTERRUPTS >95% dip 0.5 periods 30% dip 25 periods >95% interruptions 250 periods QR0415-2 REV:2.1 MUST KEEP 1PCS FIGURE 4/5
M.T.B.F & LIFE CYCLE CALCULATION 1 CAPACITOR SUPPOSE C5 IS THE MOST CRITICAL COMPONENT (Bulk Capacitor) LIFE CYCLE I/P : 230 VAC LIFE TIME = 232,938 HRS I/P : 230 VAC Ta : 50 LIFE TIME = 128,338 HRS PASS: SUPPOSE C12 IS THE MOST CRITICAL COMPONENT (Control IC Vcc Capacitor) I/P : 230 VAC LIFE TIME = 188,436 HRS I/P : 230 VAC Ta : 50 LIFE TIME = 128,706 HRS SUPPOSE C34 IS THE MOST CRITICAL COMPONENT (V1 Output Side First E/C Capacitor) I/P : 230 VAC LIFE TIME = 573,910 HRS I/P : 230 VAC Ta : 50 LIFE TIME = 241,325 HRS SUPPOSE C29 IS THE MOST CRITICAL COMPONENT (V2 Output Side First E/C Capacitor) I/P : 230 VAC LIFE TIME = 469,120 HRS I/P : 230 VAC Ta : 50 LIFE TIME = 231,331 HRS 2 MTBF MIL-HDBK-217D PARTS COUNT TOTAL FAILURE RATE : 261K HRS ENVIRONMENT TEST 1 TEMPERATURE RISE TEST SPS-100P-D2 1.ROOMAMBIENT BURN-IN : 1.5HRS I/P : 230 VAC Ta= 25 2.HIGHAMBIENT BURN-IN : 3HRS I/P : 230 VAC Ta= 50 PARTS LOCATION ROOM AMBIENT HIGH AMBIENT Ta : 50 SPEC. Line Filter LF1 45.1 60.1 130 Bridge Diode BD1 47.1 62.1 130 Input Filter Capacitor C5 44.4 58.7 105 Vcc Capacitor C12 49.3 64.8 105 Switching Transistor Q1 62.1 82.1 130 Main transformer wire T1 55.7 75.7 110 Main transformer core T1 56.5 76.5 110 Output Diode V1 D6 75.6 95.6 130 Output Diode V2 D7 66.5 86.5 130 Output Capacitor V1 C34 51.4 63.9 105 Output Capacitor V2 C29 54.3 64.5 105 Output Choke V1 L6 65.4 85.4 130 Output Choke V2 L7 63.2 83.2 130 PASS: 2 OVER LOAD BURN-IN TEST NO DAMAGE I/P : 230 VAC 2 HOUR(MIN) O/P : 120 % LOAD 3 MIN LOAD BURN-IN TEST DURATION ROOM TEMPERATURE 1 LOW VOLTAGE: 88 VAC TEST : HOURS HIGH VOLTAGE: 264 VAC I/P:INPUT RANGE LOW VOLTAGE O/P : MIN LOAD I/P:INPUT RANGE HIGH VOLTAGE 4 LOW TEMPERATURE DURATION POWER 2 HOURS MORE I/P : 100 VAC TEST : TURN ON TEST AFTER TURN ON / OFF 3 TIMES Ta : -20 5 HIGH HUMIDITY DURATION IN CHAMBER: I/P : 277 VAC TEST : HIGH VOLTAGE 1 HOURS TURN ON TEST AT 50 Ta : 50 AFTER TURN ON / OFF 3 TIMES HUMIDITY : 90% R.H 6 TEMPERATURE ± % ( -20 ~ 50 ) I/P : 230 VAC -20 25 50 ±% COEFFICIENT Voltage variation within ±0.03% / each 5.025 5.005 4.992 0.009% Ta : -20 ~ 50 24.891 24.721 24.742 0.008% Remark : Pass : ; Fail : Χ ; Not Apply :. DATE SAMPLE TEST TESTER APPROVER DEC.05.2011 PRODUCT SAMPLE PASS YI MING LIAO JACK CHANG QR0415-2 REV:2.1 MUST KEEP 1PCS FIGURE 5/5