Fairchild FEBFAN6920MR_T02U120A User manual

© 2011 Fairchild Semiconductor Corporation FEBFAN6920MR_T02U120A • Rev. 1.0.0
User Guide for
FEBFAN6920MR_T02U120A
Evaluation Board
FAN6920MR BCM PFC with a QR PWM
Combination Controller, FAN7382MX High-
Side Driver, FAN6204MY Secondary-Side
Synchronous Rectifier 19V/120W
Featured Fairchild Product:
FAN6920MR
Direct questions or comments
about this evaluation board to:
“Worldwide Direct Support”
Fairchild Semiconductor.com

© 2011 Fairchild Semiconductor Corporation 2 FEBFAN6920MR_T02U120A • Rev. 1.0.0
Table of Contents
1.Introduction............................................................................................................................... 4
1.1.General Specifications.................................................................................................. 4
2.Input Current............................................................................................................................. 5
2.1.Test Condition .............................................................................................................. 5
2.2.Test Result.................................................................................................................... 5
3.Input Wattage at No-Load Condition ....................................................................................... 5
3.1.Test Condition .............................................................................................................. 5
3.2.Test Result.................................................................................................................... 5
3.3.Measured Waveform .................................................................................................... 6
4.Turn-On Time........................................................................................................................... 7
4.1.Test Condition .............................................................................................................. 7
4.2.Test Result.................................................................................................................... 7
4.3.Measured Waveform .................................................................................................... 7
5.DC Output Rising Time............................................................................................................ 8
5.1.Test Condition .............................................................................................................. 8
5.2.Test Result.................................................................................................................... 8
5.3.Measured Waveform .................................................................................................... 8
6.Line & Load Regulation ......................................................................................................... 10
6.1.Test Condition ............................................................................................................ 10
6.2.Test Result.................................................................................................................. 10
7.Efficiency................................................................................................................................ 10
7.1.Test Condition ............................................................................................................ 10
7.2.Test Result.................................................................................................................. 10
8.Light-Load Specification........................................................................................................ 11
8.1.Test Condition ............................................................................................................ 11
8.2.Test Result.................................................................................................................. 11
9.Light-Load Efficiency............................................................................................................. 11
9.1.Test Condition ............................................................................................................ 11
9.2.Test Result.................................................................................................................. 11
10.Output Ripple & Noise ........................................................................................................... 12
10.1.Test Condition ............................................................................................................ 12
10.2.Test Result.................................................................................................................. 12
10.3.Measured Waveforms................................................................................................. 12
11.Step Response......................................................................................................................... 13
11.1.Test Condition ............................................................................................................ 13
11.2.Test Result.................................................................................................................. 13
11.3.Measured Waveform .................................................................................................. 13
12.Over-Voltage Protection......................................................................................................... 14
12.1.Test Condition ............................................................................................................ 14
12.2.Test Result.................................................................................................................. 14
12.3.Measured Waveform .................................................................................................. 14
13.Over-Power Protection............................................................................................................ 15
13.1.Test Condition ............................................................................................................ 15
13.2.Test Result.................................................................................................................. 15

© 2011 Fairchild Semiconductor Corporation 3 FEBFAN6920MR_T02U120A • Rev. 1.0.0
14.Hold-Up Time......................................................................................................................... 15
14.1.Test Condition ............................................................................................................ 15
14.2.Test Result.................................................................................................................. 15
14.3.Measured Waveform .................................................................................................. 16
15.Short-Circuit Protection.......................................................................................................... 17
15.1.Test Condition ............................................................................................................ 17
15.2.Test Result.................................................................................................................. 17
15.3.Measured Waveforms................................................................................................. 17
16.Brownout Test......................................................................................................................... 18
16.1.Test Condition ............................................................................................................ 18
16.2.Test Result.................................................................................................................. 18
17.VDD Voltage Level.................................................................................................................. 18
17.1.Test Result.................................................................................................................. 18
17.2.Measured Waveform .................................................................................................. 19
18.Voltage Stress on MOSFET & Rectifiers............................................................................... 21
18.1.Test Condition ............................................................................................................ 21
18.2.Test Result.................................................................................................................. 21
18.3.Measured Waveforms................................................................................................. 21
19.Current Harmonic Test ........................................................................................................... 23
19.1.Test Condition ............................................................................................................ 23
19.2.Test Result.................................................................................................................. 23
20.EMI Test ................................................................................................................................. 24
21.Surge Test ............................................................................................................................... 27
22.ESD Test................................................................................................................................. 27
23.System Reliability Test........................................................................................................... 28
24.Photographs............................................................................................................................. 29
25.Schematic................................................................................................................................ 30
26.Board Layout .......................................................................................................................... 31
27.Bill of Materials, Main Board................................................................................................. 33
27.1.Bill of Materials, FAN7382 Card............................................................................... 35
28.Specification Approval ........................................................................................................... 36
29.Revision History ..................................................................................................................... 50

© 2011 Fairchild Semiconductor Corporation 4 FEBFAN6920MR_T02U120A • Rev. 1.0.0
The following user guide supports the demonstration kit for the FAN6920MR. It
should be used in conjunction with the FAN6920MR, FAN7382MX, and
FAN6204MY datasheets as well as Fairchild’s application notes and technical
support team. Please visit Fairchild’s website at www.fairchildsemi.com.
1. Introduction
This document describes the FAN6920MR BCM PFC with a QR PWM
combination controller, as well as FAN7382MX high-side driver, and the
FAN6204MY secondary-side synchronous rectifier 19V/120W evaluation board.
1.1. General Specifications
Specification Min. Max. Units
Input
Voltage 90 264 VAC
Frequency 60 50 Hz
Output
Output Voltage 1 19 19 V
Output Current 1 0 6.3 A
Total Output Power
Full-load Output Power 120 W
Table 1. Test Details
Test Model FEBFAN6920MR_T02U120A
Test Date 2011-08-12
Test Temperature Ambient
Test Equipment
AC Source: 6220 AC POWER SOURCE
Electronic Load: Chroma 63030
Power Meter: WT210
Oscilloscope: LeCroy 24Xs
Test Items
Input current
Input wattage at no-load condition
Turn-on time
DC output rising time
Line & load regulation
Efficiency
Light-load specification
Light-load efficiency
Output ripple & noise
Step response
Over-voltage protection
Over-power protection
Hold up time
Short-circuit protection
Brownout test

© 2011 Fairchild Semiconductor Corporation 5 FEBFAN6920MR_T02U120A • Rev. 1.0.0
VDD voltage level
Voltage stress on MOSFET & rectifiers
Current harmonic test
EMI test
Surge test
ESD test
System reliability test
2. Input Current
2.1. Test Condition
Measure the AC input current at maximum loading.
2.2. Test Result
Input Voltage Input Current
90V / 60Hz 1.485A
264V / 50Hz 0.505A
3. Input Wattage at No-Load Condition
3.1. Test Condition
Measure the input wattage and output voltage at no load.
3.2. Test Result
Input Voltage Input Wattage(W) Output Voltage(V) Specification
90V / 60Hz 0.161 19.154
240VAC
< 0.3W
115V / 60Hz 0.166 19.154
230V / 50Hz 0.184 19.154
240V / 50Hz 0.188 19.154
264V / 50Hz 0.196 19.154

© 2011 Fairchild Semiconductor Corporation 6 FEBFAN6920MR_T02U120A • Rev. 1.0.0
3.3. Measured Waveform
Figure 1. 90V / 60Hz at No Load, Ch1: VDD, Ch4: VDS
Figure 2. 264V / 50Hz at No Load, Ch1: VDD, Ch4: VDS

© 2011 Fairchild Semiconductor Corporation 7 FEBFAN6920MR_T02U120A • Rev. 1.0.0
4. Turn-On Time
4.1. Test Condition
Set output at maximum loading. Measure the interval between AC plug-in and
stable output.
4.2. Test Result
Input Voltage Turn-On Time (s)
90V / 60Hz 1.563
264V / 50Hz 0.914
4.3. Measured Waveform
Figure 3. 90V / 60Hz at Maximum Load, Ch1:VO, Ch4:VAC
Figure 4. 264V / 50Hz at Maximum Load, Ch1:VO, Ch4:VAC

© 2011 Fairchild Semiconductor Corporation 8 FEBFAN6920MR_T02U120A • Rev. 1.0.0
5. DC Output Rising Time
5.1. Test Condition
Set output at maximum loading. Measure the time interval between 10% and
90% output during startup.
5.2. Test Result
Input Voltage Maximum Load (ms) No Load (ms) Specification
90V / 60Hz 10.039 4.976 <30ms
264V / 50Hz 9.070 4.583
5.3. Measured Waveform
Figure 5. 90V / 60Hz at Maximum Load, Ch1: VO, Ch4: VDC
Figure 6. 264V / 50Hz at Maximum Load, Ch1: VO, Ch4: VDC

© 2011 Fairchild Semiconductor Corporation 9 FEBFAN6920MR_T02U120A • Rev. 1.0.0
Figure 7. 90V / 60Hz at No Load, Ch1 VO, Ch4: VDC
Figure 8. 264V / 50Hz at No Load, Ch1: VO, Ch4: VDC

© 2011 Fairchild Semiconductor Corporation 10 FEBFAN6920MR_T02U120A • Rev. 1.0.0
6. Line & Load Regulation
6.1. Test Condition
Measure line & load regulation according to the table below.
6.2. Test Result
Input Voltage Output Voltage at
Maximum Load (V) Output Voltage at Minimum Load (V) Load Regulation (%)
90V / 60Hz 19.091 19.101 0.052
115V / 60Hz 19.090 19.100 0.052
132V / 60Hz 19.089 19.099 0.052
180V / 50Hz 19.084 19.098 0.073
230V / 50Hz 19.083 19.097 0.073
264V / 50Hz 19.083 19.097 0.073
Line Regulation (%) 0.042 0.021
7. Efficiency
7.1. Test Condition
Output at 25%, 50%, 75%, and 100% load.
7.2. Test Result
Output Watt 30W 60W 90W 120W Avg. Specification
90V / 60Hz 87.61 90.84 90.78 90.02 89.81
>87%
115V / 60Hz 88.39 91.72 91.95 91.65 90.93
230V / 50Hz 91.92 91.54 92.64 93.15 92.31
264V / 50Hz 91.50 91.45 92.78 93.33 92.27

© 2011 Fairchild Semiconductor Corporation 11 FEBFAN6920MR_T02U120A • Rev. 1.0.0
8. Light-Load Specification
8.1. Test Condition
Output wattage at light load.
8.2. Test Result
Output Wattage Actual Output Wattage Input Wattage Specification
0W 115VAC 0 0.166
Input Watt <0.3W
230VAC 0 0.184
0.5W 115VAC 0.484 0.737
Input Watt <1W
230VAC 0.484 0.747
1W 115VAC 0.998 1.348
Input Watt <1.7W
230VAC 0.994 1.303
1.15W 115VAC 1.142 1.504
Input Watt <2.16W
230VAC 1.142 1.528
1.5W 115VAC 1.486 1.902
Input Watt <2.4W
230VAC 1.486 1.934
1.7W 115VAC 1.687 2.174
Input Watt <2.4W
230VAC 1.683 2.149
9. Light-Load Efficiency
9.1. Test Condition
Output efficiency at light load.
9.2. Test Result
Output Wattage Output Wattage Input Wattage Efficiency Specification
≤1W 115VAC 0.998 1.348 74.03
≥58%
230VAC 0.994 1.303 76.29
≤1.7W 115VAC 1.687 2.174 77.60
≥68%
230VAC 1.683 2.149 78.32
≤2.4W 115VAC 2.377 2.984 79.66
≥73%
230VAC 2.398 2.985 80.34
≤14W 115VAC 13.990 16.290 85.88
≥83%
230VAC 14.000 15.900 88.05
≤22W 115VAC 21.970 25.150 87.36
≥85%
230VAC 21.990 24.570 89.50

© 2011 Fairchild Semiconductor Corporation 12 FEBFAN6920MR_T02U120A • Rev. 1.0.0
10. Output Ripple & Noise
10.1. Test Condition
Ripple and noise are measured by using a 20MHz bandwidth-limited oscilloscope
with a 10F capacitor paralleled with a high-frequency 0.1F capacitor across
each output.
10.2. Test Result
Input Voltage Maximum Load (mV) Minimum Load (mV)
90V / 60Hz 91.6 27.4
115V / 60Hz 89.6 31.6
230V / 50Hz 78.6 31.6
264V / 50Hz 75.8 36.6
10.3. Measured Waveforms
Figure 9. 90V / 60Hz at Maximum Load, Ch3: VO
Figure 10. 264V / 50Hz at Maximum Load, Ch3: VO

© 2011 Fairchild Semiconductor Corporation 13 FEBFAN6920MR_T02U120A • Rev. 1.0.0
11. Step Response
11.1. Test Condition
Dynamic loading (20%~80% of the full load, 5ms duty cycle, and 2.5A/µs rise /
fall time).
11.2. Test Result
Input Voltage Overshoot (mV) Undershoot (mV)
115V / 60Hz 187.5 167.5
230V / 50Hz 181.5 171.5
11.3. Measured Waveform
Figure 11. 115V / 60Hz at Maximum Load, Ch3: VO
Figure 12. 230V/50Hz at Maximum Load, Ch3: VO

© 2011 Fairchild Semiconductor Corporation 14 FEBFAN6920MR_T02U120A • Rev. 1.0.0
12. Over-Voltage Protection
12.1. Test Condition
Short the secondary side of opto-coupler at maximum load.
12.2. Test Result
Input Voltage Output Voltage (Maximum Value) (V)
115V/60Hz 23.4
230V/50Hz 23.4
12.3. Measured Waveform
Ch1: VO
Ch2:DET
Ch3:OPWM
Ch4:OPFC
Figure 13. 115V
/
60Hz at Maximum Load
Ch1: VO
Ch2:DET
Ch3:OPWM
Ch4:OPFC
Figure 14. 230V
/
50Hz at Maximum Load

© 2011 Fairchild Semiconductor Corporation 15 FEBFAN6920MR_T02U120A • Rev. 1.0.0
13. Over-Power Protection
13.1. Test Condition
Increase output loading gradually.
13.2. Test Result
Input Voltage Output Power (W) Output Current (A) Specification
90V/60Hz 156.01 8.236
>120%
<150% Full Load
115V/60Hz 155.78 8.221
230V/50Hz 168.24 8.880
264V/50Hz 168.45 8.865
14. Hold-Up Time
14.1. Test Condition
Set output at maximum load. Measure the time interval between AC off and
output voltage falling to the lower limit of the rated value. The AC waveform
should be off at zero degree.
14.2. Test Result
Input Voltage Hold-Up Time (ms)
90V / 60Hz 21.31
115V / 60Hz 20.80
230V / 50Hz 51.95
264V / 50Hz 51.95

© 2011 Fairchild Semiconductor Corporation 16 FEBFAN6920MR_T02U120A • Rev. 1.0.0
14.3. Measured Waveform
Ch4: VO
Ch1: VAC
Figure 15. 90V
/
60Hz at Maximum Load
Ch4: VO
Ch1: VAC
Figure 16. 264V / 50Hz at Maximum Load

© 2011 Fairchild Semiconductor Corporation 17 FEBFAN6920MR_T02U120A • Rev. 1.0.0
15. Short-Circuit Protection
15.1. Test Condition
Short the output of the power supply. The power supply should enter “Hiccup”
Mode protection with less than 2W input voltage.
15.2. Test Result
Input Voltage Input Wattage at
Maximum Loading (W) Input Wattage at Minimum Loading (W) Specification
90V/60Hz 1.231 1.25 <2W
264V/50Hz 1.344 1.45
15.3. Measured Waveforms
Ch2: VDD
Ch3: OPWM
Figure 17. 90V
/
60Hz at Maximum Load
Ch2: VDD
Ch3 OPWM
Figure 18. 264V
/
50Hz at Maximum Load

© 2011 Fairchild Semiconductor Corporation 18 FEBFAN6920MR_T02U120A • Rev. 1.0.0
16. Brownout Test
16.1. 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.
16.2. Test Result
Input Voltage Input Wattage Output Voltage
90V / 60Hz 132.9 19.088
85V / 60Hz 133.5 19.088
80V / 60Hz 134.4 19.086
75V / 60Hz 135.4 19.084
70V / 60Hz 136.9 19.084
67V / 60Hz 0 0
Recovery voltage: 77 VAC
17. VDD Voltage Level
17.1. Test Result
Input Voltage Min. Load (V) Max. Load (V) Near OPP(V) Output S.C.
(Max. Value) (V)
90V / 60Hz 10.35~11.65 16.40 17.35 11.65
264V / 50Hz 10.25~11.95 16.00 17.65 11.65

© 2011 Fairchild Semiconductor Corporation 19 FEBFAN6920MR_T02U120A • Rev. 1.0.0
17.2. Measured Waveform
Ch2: VDD
Ch3: OPWM
Figure 19. 90V
/
60Hz at Maximum Load
Ch2: VDD
Ch4: CSPWM
Figure 20. 90V
/
60Hz at Output Short Circuited

© 2011 Fairchild Semiconductor Corporation 20 FEBFAN6920MR_T02U120A • Rev. 1.0.0
Ch2: VDD
Ch3: OPWM
Figure 21. 264V
/
50Hz at Maximum Load
Ch2: VDD
Ch3: OPWM
Figure 22. 264V
/
50Hz at Output Short Circuited