PCS - Bring Up & Test Plan

PCS Test Plan

Quick Design Test:

As a minimum, the following tests are strongly recommended:

1. Maximum Drain Voltage – Verify that VDS of InnoSwitch4-CZ does

not exceed the maximum continuous drain voltage and SR FET

do not exceed 90% of breakdown voltages at the highest input

voltage and peak (overload) output power in normal operation

and during start-up.

2. Maximum Drain Current – At maximum ambient temperature,

maximum input voltage and peak output (overload) power.

Review drain current waveforms for any signs of transformer

saturation or excessive leading-edge current spikes at start-up.

Repeat tests under steady-state conditions and verify that the

leading edge current spike is below ILIMIT(MIN) at the end of tLEB(MIN).

Under all conditions, the maximum drain current for the primary

switch should be below the specified absolute maximum ratings.

3. Thermal Check – At specified maximum output power, minimum

input voltage and maximum ambient temperature, verify that

temperature specification limits for InnoSwitch4-CZ IC,

transformer, output SR FET, and output capacitors are not

exceeded. Enough thermal margin should be allowed for

part-to-part variation of the RDS(ON) of the InnoSwitch4-CZ IC.

Under low-line, maximum power, a maximum InnoSwitch4-CZ

SOURCE pin temperature of 110 °C is recommended to allow for

these variations.

Efficiency: 

https://www.youtube.com/watch?v=WQXABq45VIg&ab_channel=RobertBolanos

Tools:

• HV supp/Oscilloscope

• Load Tester

• Oscilloscope

Load tester:

• CC Mode

  • Test with 1A, 3A, 5A as per the spreadsheet

Use this spreadsheet for testing

https://docs.google.com/spreadsheets/d/1j4ExuqtmNUZ8RIEcoD0iXZhGC9C0vgVWgL9Wz4GZ-gI/edit?usp=sharing

Voltage Regulation:

Test that output is 12V under different inputs 90V - 150V

1. 5 Test points

   1. HV side - 90V - 150V

   2. LV side - 12V

   3. Primary Bias - 10V - 15V

   4. Secondary Bias - 6V - 11V

   5. BPP - 0V - 6V

Load Stability:

Test at different current loads and modulate to see if there's any issues

Overall everything can be tested and Recorded through:

https://docs.google.com/spreadsheets/d/1j4ExuqtmNUZ8RIEcoD0iXZhGC9C0vgVWgL9Wz4GZ-gI/edit?usp=sharing