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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
2
12W Adaptor Module Using UC3863
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.
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3
12W Adaptor Module Using UC3863
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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4
12W Adaptor Module Using UC3863
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
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Capacitor, ceramic, 102pF/50V, X7R, ±10%, SMD1206C8
UNISONIC TECHNOLOGIES CO., LTD
CY1
C5,C12, Capacitor, ceramic, 104pF/50V, X7R, ±10%, SMD0805
5
12W Adaptor Module Using UC3863
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
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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,220R, 1/4W,±5%, SMD1206
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%
Resistor, chip,15R, 1/16W,±5%, SMD0603
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
6
12W Adaptor Module Using UC3863
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
UNISONIC TECHNOLOGIES CO., LTD www.unisonic.com.tw
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
7
12W Adaptor Module Using UC3863
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:
UNISONIC TECHNOLOGIES CO., LTD www.unisonic.com.tw
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
8
12W Adaptor Module Using UC3863
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(%)
UNISONIC TECHNOLOGIES CO., LTDwww.unisonic.com.tw
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
9
12W Adaptor Module Using UC3863
Table 4 CEC Average Efficiency :
Fig1 Wire End Efficiency VS Load
Fig 2 Board End Efficiency VS Load
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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
10
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
90Vac/60Hz115Vac/60H230Vac/50H264Vac/50H
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Meet Level 6 < 0.1W
Meet Level 6 < 0.1W Meet Level 6 < 0.1W Meet Level 5 < 0.3W
5.03~5.51
8
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
11
12W Adaptor Module Using UC3863
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
90Vac/60Hz115Vac/60H180Vac/50H264Vac/50H
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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
12
12W Adaptor Module Using UC3863
Table 9 Overshoot
Fig.8 90Vac / 60Hz, Overshoot @ No Load
Fig.10 264Vac / 60Hz, Overshoot @ Full Load
Fig.12 264Vac/60Hz, Undershoot @ Full Load
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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
13
12W Adaptor Module Using UC3863
3.2.4 Dynamic Test
Table 10 Dynamic Test
3.2.5 Time SequenceTable 11 Time Sequence
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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
14
12W Adaptor Module Using UC3863
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
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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
15
12W Adaptor Module Using UC3863
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
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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
12W Adaptor Module Using UC3863
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
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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℃
17
12W Adaptor Module Using UC3863
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
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Fig.29 V90Vac/60Hz, No Load --No Burst occurred.
18
12W Adaptor Module Using UC3863
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
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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
12W Adaptor Module Using UC3863
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
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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
12W Adaptor Module Using UC3863
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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