12w adaptor module using uc3863 - unisonic · standby power consumption

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UNISONIC TECHNOLOGIES CO., LTD

12W Adaptor Module Using UC3863

Subject

Key features:

●AC Input Full Range 90Vac~264Vac

●DC Output 5Vdc /2.4A

●Average Efficiency > 75 % Meet DoE level 5 Regulation 74.74%

●Standby power consumption <0.3W Meets DoE level 5 regulation

●OCP/OVP/OLP/SCP Protection

Revision History

Revise Date Version Reason/Issue

2014/1/15 1.2

UNISONIC TECHNOLOGIES CO., LTDwww.unisonic.com.tw

UC3863 / 12W / 5V_ 2.4A Demo Board Manual

http://www.unisonic.com.tw/

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Contents Index Page

1 Adaptor Module Specification 31.1. Input Characteristics 31.2. Output Characteristics 31.3. Performance Specifications 31.4. Protection Function 31.5. Environment 3

2 Adaptor Module Information 42.1. Schematic 42.2. BOM 4,52.3. Adaptor Module Snapshot 52.4. Transformer Design 62.4.1 Transformer Specification 62.4.2 Transformer Winding Data 6

3 Performance Evaluation 73.1. Input Characteristics 83.1.1 Full Load Efficiency 83.1.2 CEC Efficiency 8,93.1.3 Standby Power 103.1.3.1Hiccup Mode 103.1.3.2Normal Mode 103.2. Output Characteristics 113.2.1. Line Regulation & Load Regulation 113.2.2. Ripple & Noise 113.2.3. Overshoot & Undershoot 123.2.4. Dynamic Test 133.2.5. Time Sequence 13,14,153.3. Protection 153.3.1. Short Circuit Protection 153.3.2. Over Voltage Protection 153.3.3. Over Load Protection 163.3.4. Over Temperature Protection 163.3.5 Thermal Testing 16

3.4 EMI Test 173.4.1 Conduction EMI Test 173.4.1.1 AC110V/60Hz 173.4.1.1.1 Line1 173.4.1.1.2 Line2 183.4.1.2AC230V/50Hz 193.4.1.2.1 Line1 193.4.1.2.2 Line2 20

4 Other Important Waveforms 214.1.1 Vds;Ids;Vcc;Vfb waveform at No Load @90Vac/60Hz 214.1.2 Vds;Ids;Vcc;Vfb waveform at Full Load@90Vac/60Hz 214.1.3 Vds;Ids;Vcc;Vfb waveform at No Load@264Vac/50Hz 224.1.4 Vds;Ids;Vcc;Vfb waveform at Full Load@264Vac/50Hz 224.2. Waveform at Full Load, Operate Start/Normal/Output Short to Ground Tes 23

4.2.1 Start up at Full Load Waveform from Top to Bottom :Vds; Ids;Transformer 23 Secondary Voltage.

4.2.2 Normal Full Load Waveform from Top to Bottom :Vds; Ids;Transformer 23 Secondary Voltage.

4.2.3 Output Short to Ground Waveform from Top to Bottom :Vds; Ids;Transform 24 Secondary Voltage.

UNISONIC TECHNOLOGIES CO., LTD www.unisonic.com.tw

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1. Adaptor Module Specification1.1. Input Characteristics● AC input voltage rating 100Vac ~ 240Vac● AC input voltage range 90Vac ~ 264Vac● AC input frequency range 47Hz ~ 63Hz● Input current 310mA (rms)max. @ 90Vac/60Hz

1.2. Output Characteristics● Output Voltage 5V● Output Tolerance < ±5%● Min. load current Approx.0 mA● Max. load current 2.4A

1.3. Performance Specifications● Maximum Output Power 12W● Standby Power < 0.3W@ 115Vac ~ 230Vac

( Meet DoE Level 5 Regulation. )● Average Efficiency >75% @ 115Vac ~ 230Vac

( Meet DoE Level 5 Regulation 74.74%)● Line Regulation >0.1%● Load Regulation(Cable End) <±4%● Ripple & Noise < 50mV● Hold up Time Minimum 9 msec. @100Vac● Turn on Delay time Maximum 2.6 sec, @90Vac

1.4. Protection Function● Short Circuit Protection Shut down and auto recovery● Over Voltage Protection Shut down and auto recovery● Over Load Protection Shut down and auto recovery

1.5. Environment● Operation Temperature 0℃ to 40 ℃● Operation Humidity 20% to 90% R.H● Storage Temperature -40℃ to 60 ℃● Storage Humidity 0% to 90% R.H


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2. Adaptor Module Information2.1. Schematic

2.2. BOMNo. Quantity1 42 13 14 15 16 17 18 19 1

10 211 112 113 114 215 216 117 118 1

Capacitor, aluminum electrolytic, 10uF/50V, 105℃,±20%Capacitor, ceramic, 103pF/1000V, X7R, ±10%, SMD1206

Capacitor, aluminum electrolytic, 22uF/400V, 105℃,±20%

Bridge Diode, DB250S, 2A/600V,SMD

Capacitor, ceramic, 222pF/50V, X7R, ±10%, SMD0805C13Capacitor, Y1, 102pF/400V, 105℃,±20%

Diode, fast recovery, FR107, 1A/1000VDiode, fast recovery, US1D, 1A/200V, SMD

Diode, dual Schottky, SB2045, 2*10A/45V, TO-220D7

Position

C3

C1C2

Description

Capacitor, aluminum electrolytic, 4.7uF/400V, 105℃,±20%

Diode ,fast recovery, 1N4148, 0.15A/75V,SMD1206

C4

DN1

Capacitor, aluminum electrolytic, 470uF/16V, 105℃,±20%Capacitor, aluminum electrolytic, 220uF/16V, 105℃,±20%

C14C7

C9C10,C11

BD1D5D6

C15 Capacitor, ceramic, 104pF/50V, X7R, ±10%, SMD0603Capacitor, ceramic, 470pF/50V, X7R, ±10%, SMD1206Capacitor, ceramic, 103pF/50V, X7R, ±10%, SMD0805

www.unisonic.com.tw

Capacitor, ceramic, 102pF/50V, X7R, ±10%, SMD1206C8

UNISONIC TECHNOLOGIES CO., LTD

CY1

C5,C12, Capacitor, ceramic, 104pF/50V, X7R, ±10%, SMD0805

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19 120 121 222 123 224 325 126 327 128 130 131 Resistor, chip,22R, 1/4W,±5%, SMD1206 132 133 134 135 236 137 138 139 140 141 142 143 1

: The Yellow color block means the parts that UTC can provide.

2.3. Adaptor Module Snapshot


MOSFET,UTC Power MOS N-channel, 4N/650,4A/650V, TO-220F

Resistor, chip,22K/F,1/16W,±5%, SMD0603Resistor, chip,680R, 1/16W,±5%, SMD0603

R6

Inductor, choke, 5uH

R4

L1

R17

Resistor, chip,43R, 1/16W,±5%, SMD0603

L2

R14

Resistor, chip, 0R, 1/16W,±5%, SMD0603

R5

Inductor, choke,1mH

R8R7,R13,R11


Resistor, chip,51K, 1/16W,±5%, SMD0603

Resistor, chip, 1M5, 1/4W,±5%, SMD1206

R15

R20R18,R19

PCB

IC3

Resistor, chip, 200K, 1/4W,±5%, SMD1206

Q1

R16

Resistor, chip, 100K, 1/16W,±5%, SMD0603

F1

64mm (L) X 34.5mm (W) X1.6mm (T)

Resistor, chip,330K,1/16W,±5%, SMD0603

Resistor, chip, 820R, 1/16W,±5%, SMD0603

IC, UTC PWM controller, UC3863, SOT26

Resistor, chip,2K2, 1/16W,±5%, SMD0603

Fuse,2A/250V

Resistor,1R, 1W,±5%


R1,R2R3

R9R12

IC1 IC, Opto-Coupler, PC-817B, DIP-8T1 Transformer, 1.2mH ,1KHz/1V, EE-22

IC,UTC TL431 SOT-23IC2

64.00mm

34.50mm

25mm

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2.4. Transformer Design2.4.1. Transformer Specification

1) Bobbin: EE22 -10 Pin2) Core material : PC40 (TDK) or equivalent.3) Lm 8-9: 1.2mH,±10% (1KHz )

2.4.2. Transformer DiagramN5 EMI /Shielding Layer

10 3Ts Tape

） ○ N1(NC-10)=0.4Φ X16Ts ○ 1T Tape） ( 1● ● N1(9-NC)=0.4Φ X16Ts ○ 1T Tape

9● ） ( ● N6(6)= 0.2Φ X30Ts ○ 1T Tape

） ( N4 ● N3(7-6)=0.2Φ X17Ts ○ 1T Tape） ( 5Ts ● N4(1-4)=0.5Φ X2 X 5Ts ○ 1T Tape

8● ） ( ○ N2(NC-9)=0.4Φ X16Ts ○ 1T Tape

( ● N2(8-NC)=0.4Φ X16Ts ○ 1T Tape

7● ( ● N5(10)=0.2Φ X35Ts ○

） ( 4） Bottom

N6 EMI /Shielding LayerTransformer Winding DataLayer No. Start Finish

1 10 EMI /Shielding23 8 NC45 NC 96

89 7 61011 6 EMI /Shielding1213 9 NC1415 NC 1016


Winding Material

N2

N132Ts

N232Ts

N317Ts 6

0.2Φ 2 UEWTape

0.4Φ 2 UEWTapeN2

N1

Triple Insulated Wire0.5Φ X 2

Tape 0.4Φ 2 UEW

Tape

Tape

N5

TapeN1

Tape

N4

TapeN6

Tape

Tape

0.4Φ 2 UEWTape

163

130

Turns351161161

0.4Φ 2 UEWTape

0.2Φ 2 UEWTape

0.2Φ 2 UEW1161

Tape

7 1 5 4

Tape

117N3

Tape

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3. Performance Evaluation This document presented here is to describe the Adaptor Module performance. The measuring data are tested at the 18AWG ;8 feet long wire cable end.

The Summarized Result :

Test Equipment:


ChromaChroma

616026620263102

DPO30142000

PT-3S

TektronicsKeithleyOpex

1.AC Source2.Digital Power meter3.Electronic Load4.Digital Oscilloscope5.Multi-meter6.Thermal meter

Chroma

Over Voltage Protection Over Load Protection

1. Input Characteristics

Item Vendor Model No:

Load Regulation(Cable End) Ripple & Nnoise

Ripple of DynamicTest3. Protection Short Circuit Protection

Shut Down and Auto Recovery

Item

Input Current (90V/60Hz, full load) Standby Power at No Load (230Vac/50Hz) Averaged Efficiency (@115/230Vac, 25%~100% Load by Cable En

Output Tolerance Line Regulation

±3.2%>0.1% ±3.2%< 40mV< 4.5% Overshoot

Test result

310mA102mw

<230mVp-p

2. Output characteristics78.42% / 76.65%

Shut Down and Auto RecoveryShut Down and Auto Recovery


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3.1. Input Characteristics3.1.1 Full Load Efficiency :Table 1 Full Load Efficiency :

Input

90Vac/60Hz115Vac/60H230Vac/50H264Vac/50H

3.1.2 CEC Efficiency: Meet Level 5 Regulation74.74%.Remark: BVO : PCB side measured 5V output. B.Eff :PCB side measured Efficiency. W.VO:Wire Cable side measured 5V Output. W.Eff: Wire cable side measured Efficiency.

Pi(W) B.Vo(V) W.Vo(V) B.Eff(%) W.Eff(%) Pi(W) B.Vo(V) W.VO(V) B.Eff(%) W.Eff(%)

Table 3 CEC Efficiency :

Pi(W) B.Vo(V) W.Vo(V) BEff(%) W.Eff(%) Pi(W) B.Vo(V) W.Vo(V) B.Eff(%) W.Eff(%)


11.42 5.15

77.22

3.8 5.15

81.96

5.15

5.15

4.92 77.96

Pin(W)

80.47

79.54

78.43

5.08 81.32

5.15

80.78

2.4

80.21

82.79

7.68

81.17

5.08 76.87 75.82

75%(1.8A) 100%(2.4A)

76.88

78.13

81.80

5.08

80.85

78.6375.00 76.347.86 5.15

5.00

5.15

4.8411.36 5.15

5.15 5.00

5.00

5.00

7.775.15

5.15

77.55 14.93

81.6

76.83

4.844.92

80.33

77.80

15.11

4.84

81.2179.37 75.82

4.92

76.324.84

81.755.15

264Vac/50Hz

5.15 76.74

15.22

15.12

4.925.15

11.54

5.08 7.65

11.68

Input Voltage

90Vac/60Hz

115Vac/60Hz

3.77

4.12

0.170.154

0.27

230Vac/50Hz

Input Voltage25%(0.60A)

14.93

Table 2 CEC Efficiency :50%(1.2A)

4.02

Io(A)

2.44.844.84 77.804.83

2.42.4

76.88

76.67

15.11

15.12

73.98

5.15

Irms(mA)

0.31

Eff(%)Vo(V)

76.164.8315.22

90Vac/60Hz

5.15264Vac/50Hz

115Vac/60Hz

230Vac/50Hz


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Table 4 CEC Average Efficiency :

Fig1 Wire End Efficiency VS Load

Fig 2 Board End Efficiency VS Load


78.55264Vac/50Hz 75.61

230Vac/50Hz

90Vac/60Hz

115Vac/60Hz

Input Voltage

76.65

B.Aver. Eff.(%)

81.54

81.44 78.42

79.62

AverageW.Aver.Eff.(%)

79.13

70.00 72.00 74.00 76.00 78.00 80.00 82.00 84.00

Boar

d Ef

ficie

ncy

( % )

Board End Efficiency VS Load

90Vac/60Hz

115Vac/60Hz

230Vac/50Hz

264Vac/50Hz

70.00 72.00 74.00 76.00 78.00 80.00 82.00

Wire

end

Effi

cien

cy (

% )

Wire End Efficiency VS Load

115Vac/60Hz

230Vac/50Hz

264Vac/50Hz

90Vac/60Hz


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12W Adaptor Module Using UC38633.1.3 Standby power :There are two kinds of modes can be chosen; Hiccup mode and Normal

Fig. 3 Hiccup Operation

Table 5 Hiccup M ode S tandy P ower T est D ata List:

90Vac/60Hz115Vac/60Hz230Vac/50H264Vac/50H

3.1.3.2 Normal Mode Standyby Power

Table 6 Normal Mode Standyby PowerTest Data



Meet Level 6 < 0.1W

Meet Level 6 < 0.1W Meet Level 6 < 0.1W Meet Level 5 < 0.3W

5.03~5.51

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InputVoltage Pin(mW)

Stand by powerRemark

CH2, 5V Output Waveform

3.1.3.1 Hiccup mode: The R1 resistor change 15 ohm to 390 ohm,then the module will go to Hiccup

129

Stand by power

Remark

Meet Level 5 <0.3W

4.91~5.51

5.16

79

Vo(V)

5.16

Pin(mW)5.16

13 4.92~5.35

Hiccup Operation_ IC On Vcc Voltage is 13.8V. IC _OFF Vcc Voltage is 8.6V.

121

116102

106

Vo(V)

5.09~5.42

5.16

InputVoltage


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3.2 Output Characteristics3.2.1 Line Regulation & Load RegulationTable 7 Line Regulation & Load Regulation

90Vac/60Hz115Vac/60H230Vac/50H264Vac/50HLineRegulation%

3.2.2 Ripple & NoiseTable 8 Ripple & Noise



Remark

6.40

6.406.40

InputVoltage No. Load

$14.00

4.845.00

5.16

$15.00

Half Load

$16.2010.2010.2040.0030.40

InputVoltage No Load (V)

5.16 4.84

LoadRegulation%

Load

Full Load

5.16 5.005.00 4.84

Fig 5—

Fig 6—

$25.60—

—

> 0.1%

5.00

Fig 7

Fig.4 90Vac/60Hz@ No Load

5.16

Fig.5 90Vac/60Hz@Full Load

RemarkFull Load

Ripple & Noise(mV)

4.84

Fig 4

±3.2%6.40

Fig.6 264Vac/50Hz@ No Load Fig.7 264Vac/50Hz@Full Load


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Table 9 Overshoot

Fig.8 90Vac / 60Hz, Overshoot @ No Load

Fig.10 264Vac / 60Hz, Overshoot @ Full Load

Fig.12 264Vac/60Hz, Undershoot @ Full Load


Input Voltage

90Vac/60Hz

RemarkData (%)Over shoot / Undershoot

No Load

Full LoadOvershoot

3.2.3 Overshoot

Undershoot

—

2.480

No Load

4.14

3.9

OverShootFull Load

Fig.11 90Vac/60Hz,Under shoot @ Full Load

Undershoot

Fig.9 90Vac / 60Hz, Overshoot @ Full Load

0264Vac/50H

z

Fig. 11Fig. 8

UndershootOvershoot

Fig.9

—

Fig.10Fig.12


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3.2.4 Dynamic Test

Table 10 Dynamic Test

3.2.5 Time SequenceTable 11 Time Sequence


214

264Vac/50Hz90Vac/60Hz

Output (mV)Fig.13

100Vac/60HzHold-UpTime

240Vac/50Hz

Item

264Vac/50Hz

Input Voltage

CH1 Output ;CH4 Current Probe Waveform

90Vac/60Hz 222

The test current set Hi Level current is 2.4A ; and the Low Level set to 1.2A.

CH1 Output ;CH4 Current Probe Waveform

Remark

Fig. 13 90Vac / 60Hz Dynamic Test

Input Voltage

240Vac/50Hz

Turn on Delay Time

3.74ms (Full Load)Rise Time

100Vac/60Hz

100Vac/60Hz

Falling Time3.88ms (Full Load)

240Vac/50Hz

The Hi;Low level switching time is set to 50ms each.

100Vac/60Hz

Meas. Data

240Vac/50Hz

Fig. 22

Fig. 17Fig. 18Fig. 19Fig. 20Fig.21

96.0ms (Full Load)9.20ms (Full Load)

4.30ms (Full Load)

3.84ms (Full Load)

Fig. 160.38s (Full Load)

RemarkFig. 15

Fig. 14 264Vac / 50Hz Dynamic Test

2.54s (Full Load)

Fig.14


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Fig. 16 264Vac/50Hz, Full load Turn-on Delay TCH1=AC Input, CH2=Vout

CH1=AC Input, CH2=Vout

Fig. 19 100Vac/60Hz,Full Load Rising Time Fig.20 240Vac/50Hz,Full load Rising Tim


Fig. 15 90Vac/60Hz, Full Load Turn-on Delay Time

Fig.18 240Vac / 50Hz,Full Load Hold-Up TimeCH1=AC Input, CH2=Vout

Fig. 17 100Vac / 60Hz, Full Load Hold-UpTime

CH1=AC Input, CH2=Vout


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Fig. 21 100Vac/60Hz Full load FallingTime

3.3 Protection

Table 12 Short Circuit Protection

3.3.2. Over Voltage Protection (OVP) When Over Voltage Protectioncondition is removed and the power automatically recoverTable 13 OVP

Fig 23. 90Vac/60Hz OVP (Full Load) CH1:Vcc,CH2: Ouput 5V


CH1:Vcc,CH2: Ouput 5V

264Vac/50Hz90Vac/60Hz PASS

90Vac/60HzInput Voltage

264Vac/50Hz

Input Voltage Short Circuit Protection

PASS

Vcc 25.8V(Full Load)

Fig 24 264Vac/50Hz OVP (Full load)

Fig. 22 240Vac/50Hz Full load Falling Time

Fig. 24

Over VoltageP t tiVcc 25.8V(Full Load)

3.3.1 Short Circuit Protection

RemarkFig. 23

When short the output voltage ,and no parts are damaged.Once Short Circuit condition is removed and the power should recover automatically .


16


When over load condition is removed and the power automatically recover.

Table 14 OLP

Tested at Room temperature 35℃ in Plastic ABS Case.

Table 16 Thermal TestingInput

Voltage90Vac/60Hz115Vac/60H230Vac/50H264Vac/50H


3.3.3 Over load Protection

3.51149264Vac/50Hz

141150

3.3.3.1 Over load Protection

149146

90Vac/60Hz

230Vac/50Hz

3.39

180Vac/50Hz

3.50

Remark

5V OutputCurrent 2.4 A

OLP(A)

99℃98℃

(Case Dimension 61mmX35mmX120mm).

3.58

Over %Input Voltage

115Vac/60Hz 3.60

64℃ 76℃ 87℃86℃

3.3.4 Thermal Testing

UC3873 MOSFET Transformer Schottky

64℃ 75℃ 85℃96℃96℃

68℃ 80℃ 86℃65℃ 77℃


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4. Other Important Waveforms4.1.1. Waveform from Top to Bottom :Vds;Ids;Vcc;Vfb@90Vac/60Hz, No Load Measuring Data:Vds=216Vp-p; Ids=292mAp-p;Vcc=15.2V;Vfb=1.54V; Frequency:37.31KHz

4.1.2. Waveform from Top to Bottom :Vds;Ids;Vcc;Vfb @90Vac/60Hz,Full Load Measuring Data:Vds=300Vp-p; Ids=670mAp-p;Vcc=19.2V;Vfb=3.60V; Frequency:62.19KHz

Fig. 30 Vds;Ids;Vcc;Vfb @90Vac/50Hz,Full Load


Fig.29 V90Vac/60Hz, No Load --No Burst occurred.


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4.1.3. Waveform from Top to Bottom :Vds;Ids;Vcc;Vfb@264Vac/50Hz,No Load Measuring Data:Vds=500p-p; Ids=610mAp-p;Vcc=12.20V;Vfb=0.7V; Frequency:21.28KHz

4.1.4 Waveform fromTop to Bottom :Vds;Ids;Vcc;Vfb@ 264Vac/50Hz, Full Load Measuring Data:Vds=532Vp-p; Ids=730mAp-p;Vcc=19.20V;Vfb=3.32V; Frequency:64.935KHz

Fig.33 Vds;Ids;Vcc;Vfb 264Vac/50Hz, Full Load


Fig.31 264Vac/50Hz, No load (Time Base 40uS) . Fig 32 264Vac/50Hz, No load (Time base 10m Burst Mode: Burst group freq. 58.82Hz Entering Burst Mode: Burst Freq.:21.93KHz


19


4.2. Waveform at Full Load, Operating Start / Normal / Output Short to Ground . Table 26 Measuring Data at Full Load, Operating Start/ Normal / Output Short Test.

Vds(p-p) Ids(mA) Vsecondary Remark584 1440 45.60 Fig 34544 640 44.00 Fig 35528 500 40.20 Fig 36

Fig.34 264Vac / 50Hz,Start up at Full load. Vds;Ids;Transformer Secondary Voltage

Fig.35 264Vac / 50Hz,Normal Full Load. Vds;Ids;Transformer Secondary Voltage


Input voltage

4.2.1. Start up at Full Load Waveform from Top to Bottom :Vds;Ids;Transformer

4.2.2. Normal Full Load Waveform from Top to Bottom :Vds; Ids;Transformer Secondary Voltage.

Short at full load 264V/50HZ

Test ItemStart at full load 264V/50HZ Normal at full load 264V/50HZ


20



4.2.3 Output Short to Ground Waveform from Top to Bottom :Vds;Ids;Transformer

Fig.36 264Vac / 50Hz, Output Short to Ground at Full Load. Vds;Ids;Transformer Secondary Voltage


12w adaptor module using uc3863 - unisonic · standby power consumption

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