40w adaptor module using uc3863 - unisonic · uc3863 /40w / 19v_ 2.1a demo board manual. 2. 40w...

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UNISONIC TECHNOLOGIES CO., LTD

40W Adaptor Module Using UC3863

Subject

Key features:

●AC Input Full Range 90Vac~264Vac

●DC Output 19Vdc /2.1A

●Average Efficiency >85.28 % Meet DoE level 5 Regulation

●OCP/OVP/OLP/SCP Protection

Revision History

Revise Date Version Reason/Issue

2013/12/19

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

UC3863 /40W / 19V_ 2.1A 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

4 Other Important Waveforms 174.1.1 Vds;Ids;Vcc;Vfb waveform at No Load @90Vac/60Hz 174.1.2 Vds;Ids;Vcc;Vfb waveform at Full Load@90Vac/60Hz 174.1.3 Vds;Ids;Vcc;Vfb waveform at No Load@264Vac/50Hz 174.1.4 Vds;Ids;Vcc;Vfb waveform at Full Load@264Vac/50Hz 174.2. Waveform at Full Load, Operate Start/Normal/Output Short to Ground Tes 17

4.2.1 Start up at Full Load Waveform from Top to Bottom :Vds; Ids;Transformer 18 Secondary Voltage.

4.2.2 Normal Full Load Waveform from Top to Bottom :Vds; Ids;Transformer 19 Secondary Voltage.

4.2.3 Output Short to Ground Waveform from Top to Bottom :Vds; Ids;Transform 20 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 19V● Output Tolerance < ±5%● Min. load current Approx.0 mA● Max. load current 2.1A

1.3. Performance Specifications● Maximum Output Power 40W● Standby Power <350mW● Average Efficiency >85.28% @ 115Vac ~ 230Vac ● Line Regulation >0.01%● Load Regulation(Cable End) <±2%● Ripple & Noise < 45mV● Hold up Time Minimum 10msec. @100Vac● Turn on Delay time Maximum 2.5 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. BOM1 12 23 14 15 36 17 18 19 2

10 111 112 113 114 115 116 1

Diode ,fast recovery, FR107, 1.0A/1000VD5D6D7D8CY1

C2C4

C14,C12CX1CY1

Diode ,fast recovery, RS1D ,1A/200V SMDDiode, dual Schottky, MBR20200CT, 2*10A/100V,TO-220

BD1

C11

C6C10

GBLA06_4A_600V

Capacitor, aluminum electrolytic,,22uF/50V; 105℃,±20%Capacitor, ceramic, 102pF/50V, X7R, ±10%, SMD0805

C1,C3 Capacitor, ceramic, 103pF/1KV, ±20%, SMD1206

Capacitor, Y1, 102pF/400V, 105℃,±20%

Capacitor, aluminum electrolytic,68uF/400V, 105℃,±20%Capacitor, ceramic, 103pF/50V, X7R, ±10%, SMD0805Capacitor, ceramic, 104pF/50V, X7R, ±10%, SMD0805

UNISONIC TECHNOLOGIES CO., LTD

Capacitor, X2, 0.22uF/275VAC, 105℃ ,±20%

Capacitor, ceramic, 102pF/1KV, ±20%, SMD1206Capacitor, aluminum electrolytic, 470uF/35V, 105℃,±20%

C5,C15,C16

www.unisonic.com.tw

Capacitor, Y1, 102pF/400V, 105℃,±20%Diode ,fast recovery, 1N4148, 0.15A/75V,SMD1206.

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17 118 119 120 121 222 223 224 225 226 227 228 129 130 131 132 133 134 135 136 137 138 139 1

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

2.3. Adaptor Module Snapshot


Fuse, 2.0A / 250V

Resistor, chip, 2.2M, 1/4W,±5%, SMD1206

Resistor, chip,27K, 1/8W,±5%, SMD0805

Resistor, chip, 820R, 1/8W,±5%, SMD0805

Resistor, chip,1M, 1/4W,±5%, SMD1206


Resistor, chip, 100K, 1/8W,±5%, SMD0805Resistor, chip, 100R, 1/4W,±5%, SMD1206


Resistor, chip, 10K, 1/8W,±5%, SMD0805

R34

IC2Transformer,680uH ,1KHz, RM-8

R35

IC3IC1

T1IC, PWM controller, UTC UC3863, SOT26

R33

R20

R31R32

Resistor, chip,0R, 1/8W,±5%, SMD0805

Inductor, choke, dual winding,5mHQ1 MOSFET,MOS power N-channel,UTC 6N65, 6A/650V, TO-220F

LF1Q1R1,R2

R16,R18

F1

R17

Resistor, chip,1.8R, 1/4W,±5%, SMD1206Resistor, chip, 1.5R, 1/4W,±5%, SMD1206

R11,R19

R14,R15R12,R13

R4,R5R6,R9

Resistor, chip,680R, 1/8W,±5%, SMD0805

Resistor, chip100K, 1/4W,±5%, SMD1206Resistor, chip,22R, 1/8W,±5%, SMD0805

L3 Inductor, choke,3uH

R30

IC, TL431 SOT-23IC, Opto-Coupler, PC-817B, DIP-8

70mm

33mm 25mm

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2.4. Transformer Design2.4.1. Transformer Specification

1) Bobbin: RM -82) Core material : PC40 (TDK) or equivalent.3) Lm 7-5: 680uH,±10% (1KHz )

2.4.2. Transformer DiagramN7 EMI /Shielding Layer

5 3Ts Tape

） ● ○ 1T Tape） (( A● ● ○ 1T Tape

6● ） (( ● N6(4-8)= 0.2Φ X10Ts ○ 1T Tape

） (( N3,N4 ● N4(A-B)=0.6Φ X10Ts ○ 1T Tape） (( 10Ts ● N3(A-B)=0.6Φ X10Ts ○ 1T Tape

7● ） (( ● ○ 1T Tape(( ● ○

4● ((） (( B Bottom）

N5 EMI /Shielding LayerTransformer Winding DataLayer No. Start Finish

1 5 EMI /Shielding23 7 64

6

89 4 81011 9 EMI /Shielding1213 6 514


5 A 10 B

Tape

1

7 Triple InsulatedWire 0.6Φ B

3

110

0.2Φ 2 UEWTape

Tape 0.2Φ 2 UEW

1161

0.4Φ 2 UEWTape

Turns101291

29

A 10

TapeN1

Tape

N3

TapeN6

Tape

Tape

Tape

N5

Triple InsulatedWire 0.6Φ

Tape

Tape

N4

TapeN2

N129Ts

0.2ΦX4 2 UEWTape

0.4Φ 2 UEW

N7

N229Ts

N610Ts 8

N7(5)=0.2Φ X4X10TsN2(7-6)=0.27Φ X29Ts

Winding Material

N1(6-5)=0.27Φ X29Ts N5(8)=0.2Φ X4X10Ts

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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:


Averaged Efficiency (@115/230Vac, 25%~100% Load by Cable En 87.45% / 86.93%. Meet DoE Level 5 85.28% .

2. Output characteristics

Shut Down and Auto RecoveryShut Down and Auto Recovery

Test result

875mA179.2mw

236mVp-p

Item

Input Current (90V/60Hz, full load) Standby Power at No Load (230Vac/50Hz)

Output Tolerance Line Regulation

Chroma

Over Voltage Protection Over Load Protection

1.52%>0.03% 1.52%

Overshoot Ripple of DynamicTest3. Protection

1. Input Characteristics

Item Vendor Model No:

Load Regulation(Cable End) Ripple & Nnoise

Short Circuit Protection

Shut Down and Auto Recovery

42.8mV0%

PT-3S

TektronicsKeithleyOpex

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

ChromaChroma

616026620263102

DPO30142000


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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 Regulation 85.28%.

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(%)


45.2845.46

BVO : PCB side measured 5V output. B.Eff :PCB side measured Efficiency.

115Vac/60Hz

230Vac/50Hz

87.6518.975

Input Voltage

90Vac/60Hz

115Vac/60Hz

230Vac/50Hz

0.363

264Vac/50Hz

11.57

12.10

Io(A)

2.118.93518.971 87.12

46.41

Irms(mA)

0.875

Eff(%)Vo(V)

18.9762.12.1

85.68

88.010.4030.693 45.73

90Vac/60Hz

19.205

19.206

34.25264Vac/50Hz

19.201

19.201

19.148 22.94

45.4687.52

88.02

88.30

87.12

19.201 87.6518.975

89.05 88.01

18.971

88.70

18.976

86.89

19.161

11.55 19.206 87.04

19.195

19.033

87.89 45.73

87.14

87.60

2.1

83.08

Table 2 CEC Efficiency :

34.521 19.201

19.207 19.093

19.091

86.70

19.149 83.33

88.15

22.85

85.68

87.91

87.17 86.6623.13 19.203

19.091

Pin(W)

88.25

87.86

87.39

19.149 87.30 19.205 19.092

22.95 19.203

Input Voltage25%(0.525A) 50%(1.05A)

87.73

11.92 19.204 19.148 84.58 84.33 87.34

46.41 18.935

19.035

34.06 19.202 19.034 88.79

88.67

45.28

19.033

75%(1.575A) 100%(2.1A)

86.84

34.11 19.204


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Table 4 CEC Average Efficiency :

Fig.1 Wire End Efficiency VS Load

Fig. 2 Board End Efficiency VS Load


115Vac/60Hz

Input Voltage W.Aver.Eff.(%)

86.57

Average

87.57

86.87

B.Aver. Eff.(%)

86.23

90Vac/60Hz

87.45

86.93230Vac/50Hz

264Vac/50Hz

87.34

88.09

Remark

Meet DoE Level 5 85.28%

82.00 83.00 84.00 85.00 86.00 87.00 88.00 89.00 90.00

Boar

d Ef

ficie

ncy

( % )

Board End Efficiency VS Load

90Vac/60Hz

115Vac/60Hz

230Vac/50Hz

264Vac/50Hz

82.00 83.00 84.00 85.00 86.00 87.00 88.00 89.00 90.00

Wire

end

Effi

cien

cy (

% )

Wire End Efficiency VS Load

115Vac/60Hz

230Vac/50Hz

264Vac/50Hz

90Vac/60Hz


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40W Adaptor Module Using UC38633.1.3 Standby power

Fig. 3 Hiccup Operation

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

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

3.1.3.2 Normal ModeTable 6 Normal Mode Standby PowerTest Data



Meet Level 6 < 0.1W

There are two kinds of modes can be chosen; Hiccup mode and Normal mode .

3.1.3.1 Hiccup mode: The R1 resistor change 22Ωto 100Ω,then the module will go to Hiccup mode.

Stand by power

Remark

18.91~19.28

19.21

CH2 19V Output waveform

19.2119.21

Pin(mW)304.50

179.20

19.434.6

323.60

95.6

Vo(V)

InputVoltage Pin(mW) Vo(V)

Stand by powerRemark

198.80

18.43~19.24

18.53~19.2518.86~19.23

19.21

12.5

InputVoltage


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


LineRegulation%

3.2.2 Ripple & NoiseTable 8 Ripple & Noise



1.52%18.879

0% 0.01% 0.03%

18.951

Fig 5

19.168

RemarkFull Load

Ripple & Noise(mV)

18.874

Fig 4

1.52

42.80

Fig.4 90Vac/60Hz@ No Load Fig.5 90Vac/60Hz@Full Load

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

—

Fig 6

30.60

26.20 19.40

—

— 22.80Fig 7

—

1.521.5519.168

18.953

InputVoltage No. Load

InputVoltage No Load (V)

19.168 18.87918.951 18.879

Full Load

5.004.8038.20

18.953

LoadRegulation%Half Load

19.168 1.52

LoadRemark


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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


AC Power switch ON for overshoot, and switch OFF for undershoot

RemarkData (%)

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

Fig.12

Fig. 11Fig. 8

OverShoot

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

Fig.10264Vac/50Hz

00

Fig.9Undershoot

UndershootOvershoot

—

Full LoadOvershoot

Full Load

90Vac/60Hz0—

00

No Load

Load ConditionInput Voltage Over shoot / Undershoot

Undershoot

3.2.3 Overshoot


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3.2.4 Dynamic Test

Table 10 Dynamic Test

3.2.5 Time SequenceTable 11 Time Sequence


9.40ms (Full Load)

100Vac/60HzHold-UpTime

RemarkInput Voltage90Vac/60Hz

Fig. 18Fig. 19Fig. 20

Rise Time

100Vac/60Hz

100Vac/60Hz240Vac/50Hz

11.20ms (Full Load)240Vac/50Hz

Fig. 170.39s (Full Load)2.31s (Full Load)

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

RemarkFig. 15Fig. 16

Fig.21Fig. 22

100Vac/60Hz11.04ms (Full Load)

Falling Time10.72ms (Full Load)6.32ms (Full Load)

102.0ms (Full Load)

Fig.14

240Vac/50Hz

CH4 Current Probe Waveform

240Vac/50Hz

CH4 Current Probe Waveform

Turn on Delay Time

Meas. DataInput VoltageItem

Fig. 13 90Vac / 60Hz Dynamic Test Fig. 14 264Vac / 50Hz Dynamic Test

90Vac/60Hz

264Vac/50Hz

Output (mV)Fig.13216

236

264Vac/50Hz

The test current set High Level current is 2.1A ; and the Low Level is set to 1.0A.


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Fig. 16 264Vac/50Hz, Full load Turn-on Delay Time

CH1=AC Input, CH2=Vout


Fig. 19 100Vac/60Hz,Full Load Rising Time



CH1=AC Input, CH2=VoutFig. 17 100Vac / 60Hz, Full Load Hold-UpTime Fig.18 240Vac / 50Hz,Full Load Hold-Up Time

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

Fig.20 240Vac/50Hz,Full load Rising Time


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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 19V


Fig 24 264Vac/50Hz OVP (Full load) CH1:Vcc,CH2: Ouput19V

Vcc 25.6V(Full Load)

Fig. 21 100Vac/60Hz Full load FallingTim

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

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

Fig. 24

Over VoltageP t ti

Input Voltage90Vac/60Hz

Input Voltage

Short Circuit Protection

RemarkFig. 23

PASSPASS

Vcc 25.6V(Full Load)264Vac/50Hz90Vac/60Hz

264Vac/50Hz


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

Table 14 OLP

Table 15 Thermal Testing

Input Voltage



(Case Dimension 110(L)mmX47(W)mmX37(H)mm).

2.942.92

3.3.4 Thermal Testing

Remark

19V OutputCurrent 2.1 A3.56

Input Voltage

115Vac/60Hz

147140

3.3.3.1 Over load Protection

3.35

OLP(A)90Vac/60Hz

139264Vac/50Hz

131150

3.3.3 Over load Protection

Over %

180Vac/50Hz

2.77

230Vac/50Hz

96℃96℃

Transformer

117℃114℃108℃ 118℃

117℃

UC3863

84℃82℃82℃80℃

MOSFET

98℃97℃

Case Surface

78℃76℃74℃75℃107℃

Schottky

125℃119℃


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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=256Vp-p; Ids=128mAp-p;Vcc=14.4V;Vfb=1.62V; Frequency:31.85KHz

4.1.2. Waveform from Top to Bottom :Vds;Ids;Vcc;Vfb @90Vac/60Hz,Full Load Measuring Data:Vds=322Vp-p; Ids=1.54Ap-p;Vcc=18.8V;Vfb=3.72V; Frequency:62.50KHz

Fig. 26 Vds;Ids;Vcc;Vfb @90Vac/50Hz,Full Load


Fig.25 90Vac/60Hz, No Load


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4.1.3. Waveform from Top to Bottom :Vds;Ids;Vcc;Vfb@264Vac/50Hz,No Load Measuring Data:Vds=5200p-p; Ids=190mAp-p;Vcc=11.20V;Vfb=1.12V; Frequency:21.37KHz

4.1.4 Waveform fromTop to Bottom :Vds;Ids;Vcc;Vfb@ 264Vac/50Hz, Full Load Measuring Data:Vds=616Vp-p; Ids=1.64Ap-p;Vcc=19.6V;Vfb=3.12V; Frequency:61.88KHz

Fig.29 Vds;Ids;Vcc;Vfb 264Vac/50Hz, Full Load


Fig.27 264Vac/50Hz, No load (Time Base 40uS) . Fig. 28 264Vac/50Hz, No load (Time base 10m Entering Burst Mode: Burst group freq. 35.97Hz Entering Burst Mode: Burst Freq.:21.37KHz


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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 Remark628 1.62 98 Fig30616 1.64 88 Fig 31532 1.42 90 Fig 32

Fig.30 264Vac / 50Hz,Start up at Full load. Vds;Ids;Transformer Secondary Voltage

Fig.31 264Vac / 50Hz,Normal Full Load. Vds;Ids;Transformer Secondary 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

Input voltage


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Fig.32 264Vac / 50Hz, Output Short to Ground at Full Load. Vds;Ids;Transformer Secondary Voltage

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


40w adaptor module using uc3863 - unisonic · uc3863 /40w / 19v_ 2.1a demo board manual. 2. 40w...

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