10W Adaptor Module Using UPSR1103 - Unisonic€¦ · 1.4. Protection Function 3 ... A dynamic...

UNISONIC TECHNOLOGIES CO., LTD

10W Adaptor Module Using UPSR1103

Subject

Key features:

●Primary Side Regulation with High Volatge Start-up

●AC Input Full Range 90Vac~264Vac

●Programmable Cable Compensation

●Average Efficiency > 80 % Meet DoE level 6 Spec. 78.70%

●Standby Power Consumption <0.1W Meets DoE level 6 Spec.

●OCP/OLP/SCP Protection

Revision History

Revise Date Version Reason/Issue

2013/12/6 A

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

UPSR1103 / 10W / 5V_ 2A Demo Board Manual

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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 42.3 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 Input Current and Standby Power 83.1.2 Efficiency 83.2 Output Characteristics 83.2.1 Line Regulation & Load Regulation 83.2.2 IV-Curve 93.2.3 Cable Compensation 103.2.4 Ripple & Noise 113.2.5 Overshoot & Undershoot 123.2.6 Dynamic Test 133.2.7 Time Sequence 133.3 Protection 153.3.1 Short Circuit Protection 153.3.2 Open Loop Protection 153.3.3 Over Load Protection 153.3.4 Thermal Testing 16

4 Other Important Waveforms 174.1 Vds, Vcc, Vcs& Vs Waveform at No Load/Full Load 174.2 Vds& Vf Waveform at Full Load, Start / Normal / Output Short 174.2.1 Vds& Vf at Full Load, Start / Normal / Output Short 174.2.2 Vds& Vf at full load, start waveform 184.2.3 Vds& Vf at full load, normal waveform 184.2.4 Vds& Vf at full load, output short waveform 18

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 300mA (rms)max. @ 90Vac/60Hz

1.2. Output Characteristics● Output Voltage 5V● Output Tolerance < ±5%● Min. load current Approx.0 mA● Max. load current 2.0A

1.3. Performance Specifications● Maximum Output Power 10W● Standby Power < 0.1W@ 115Vac ~ 230Vac

( Meet DoE Level 6 Spec. )● Average Efficiency >80% @ 115Vac ~ 230Vac

( Meet DoE Level 6 Spec. 78.70%)● Line Regulation < 3%● Load Regulation(Cable End) < 5%● Ripple & Noise < 100mV● Hold up Time Minimum 10msec. @100Vac● Turn on Delay time Maximum 2 sec, @90Vac

1.4. Protection Function● Short Circuit Protection Shut down and auto recovery● Open Loop Protection● 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 19 210 111 212 113 114 215 1

Capacitor, ceramic, 102pF/1000V, X7R, ±10%, SMD1206Capacitor, ceramic, 105pF/50V, X7R, ±10%, SMD0805Capacitor, aluminum electrolytic, 680uF/16V, 105℃,±20%Inductor, choke,1mHInductor, choke, 4.7uHResistor, chip, 3R3, 1/4W,±5%, SMD1206


C1C2

C5,C11

C9,C10L1L3

Position

C3C4

D1,D2,D3,D4D5D6D7

Description

Capacitor, aluminum electrolytic, 10uF/400V, 105℃,±20%Capacitor, aluminum electrolytic, 22uF/400V, 105℃,±20%Capacitor, aluminum electrolytic, 47uF/50V, 105℃,±20%Capacitor, Y1, 102pF/400V, 105℃,±20%

Diode, fast recovery, 1N4007, 1A/1000VDiode, fast recovery, FR107, 1A/1000VDiode, fast recovery, RS1D, 1A/200V, SMDDiode, dual Schottky, MGBR2045, 2*10A/45V, TO-220

Resistor, chip, 2R2, 1/4W,±5%, SMD1206

C7

R1R2

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16 117 118 119 120 121 122 123 124 125 126 128 129 129 129 1

2.3. Adaptor Module Snapshot


MOSFET,MOS power N-channel, 4N/65,4A/650V, TO-220FTransformer, 0.95mH ,1KHz/1V, EE-22IC, PWM controller, UTC UPSR1103, SOP-8

Resistor, chip, 62K, 1/8W,±5%, SMD0805

R4

PCB 38mmx62mmx1.6mm

R6

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

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

Resistor, chip, 1K2, 1/8W,±5%, SMD0805Resistor, chip, 0R, 1/8W,±5%, SMD0805

R10

Q1T1IC2

Resistor, chip, 0R, 1/8W,±5%, SMD0805Fuse,1A/250V

Resistor, chip,15K, 1/8W,±5%, SMD0805Resistor, chip,100R, 1/4W,±5%, SMD1206

R17R15

R7R8R9

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

F1R18

R5

62mm

38mm 24mm

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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 1-5: 0.95mH,±10% (1KHz )

2.4.2. Transformer Diagram

1)

) ( A● 3Ts Tape

3● ) ( ○ ○

) ( N2 ● ○ 2T Tape) ( 5Ts ● ○ 1T Tape

5● ) ( ● ○ 1T Tape

( ○ ○

2● ( ● ○

) ( B) Bottom

Transformer Winding DataLayer No. Start Finish

1 5 32

45 2 467 3 18


A 5 B

351

110

0.37Φ 2 UEW

Tape

35

Turns

N4(3-1)=0.37Φ, 35Ts

0.37Φ 2 UEWTape

TapeN3

3

1

Triple Insulated Wire0.4Φ X 2

0.37Φ 2 UEWTape

Tape

N1

N135Ts

N310Ts 4

N4Tape

N2

Tape

Tape

3

N435Ts

Winding Material

N1(5-3)=0.37Φ, 35Ts

N2(A-B)=0.4ΦX2, 5TsN3(2-4)=0.37Φ, 10Ts

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3. Performance EvaluationThis document presented here is to describe the Adaptor Module performance.The measuring data are tested at the 18AWG& 6 feet long wire cable end, unless otherwise specified.

The Summarized Result :

Test Equipment:


Test result

294mA58mw

496mVp-p

Line Regulation< ±4%

Over Load Protection

4.50%54mV0%

Ripple of DynamicTest3. Protection Short Circuit Protection Shutdown and Auto Recovery

Item

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

Output Tolerance

Open Loop Protection

2. Output characteristics81.26% /80.84%

2.54%

Chroma

1. Input Characteristics

Item Vendor Model No:

Load Regulation(Cable End) Ripple & Nnoise Overshoot

Shutdown and Auto Recovery

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

616026620263102

DPO30142000

PT-3S

ChromaChroma

TektronicsKeithleyOpex

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3.1 Input Characteristics3.1.1 Input Current and Standby PowerTable 1 Input current at full loadInput VoltageInput Current(A)

Table 2 Standby power at no loadInput Voltage

Pin(mW)

3.1.2 EfficiencyTable 3A Efficiency at board endInput Voltage115Vac/60Hz230Vac/50Hz

Table 3B Efficiency at cable end (18AWG, 6FT)Input Voltage115Vac/60Hz230Vac/50Hz

3.2 Output Characteristics3.2.1 Line Regulation & Load RegulationTable 4 Line Regulation & Load Regulation at cable end

90Vac/60Hz115Vac/60Hz230Vac/50Hz264Vac/50Hz

LineRegulation%


81.25Level 6 spec.

>78.70

Level 5 spec.

>73.37

81.1381.22

Avg.

25% 50% 75% 100% Avg.

80.84

264Vac/50Hz230Vac/50Hz0.134 0.120

64264Vac/50Hz230Vac/50Hz

58

25%

79.85 78.79 77.27 76.08 77.99

81.23

100%81.26

< 5%

115Vac/60Hz47 48

78.66 78.23 77.23

50%81.47

0.23290Vac/60Hz

0.294

90Vac/60Hz

LoadRegulation%

4.9724.977

80.92

75%

4.9254.905

Full Load

4.50%

2.54%

4.869

4.816 4.9675.0085.0894.8675.094

Half LoadInput Voltage

81.2280.02

115Vac/60Hz

No Load (V)Remark

Load

4.847

77.575.91

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3.2.2 IV-Curve

Fig.1 IV-Curve at board end

Fig.2 IV-Curve at cable end


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3.2.3 Cable Compensation


Cable compensation is programmable by varying VS pin resistors( R8, R9). An equal proportionalityenlarge the resistors would increase the amount of cable compensation, and vice versa.

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3.2.4 Ripple & NoiseTable 5 Ripple & Noise

90Vac/60Hz115Vac/60Hz180Vac/50Hz264Vac/50Hz


Remark

Fig.6 264Vac/50Hz@Full Load

Ripple & Noise(mV)

Fig.3 90Vac/60Hz@ No Load Fig.4 90Vac/60Hz@Full Load

Fig.5 264Vac/50Hz@ No Load

16.817.218.018.4

Input VoltageNo. Load

Fig 650 —

5044

Full LoadFig 4

—Fig 3

Fig 5 54

—

—

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3.2.5 Overshoot & UndershootTable 6 Overshoot & undershootInput Voltage

Fig.7 90Vac / 60Hz, Overshoot @ No Load Fig.8 90Vac / 60Hz, Overshoot @ Full Load

Fig.9 264Vac / 60Hz, Overshoot @ no Load Fig.10 264Vac / 60Hz, Overshoot @ Full Load

Fig.11 90Vac/60Hz,Undershoot @ Full Load Fig.12 264Vac/60Hz, Undershoot @ Full Load


No Load

Over shoot / Under shootOvershootUndershootOvershootOverShootUndershootOvershoot

No Load

Full Load

No Load

Full Load

Fig.8Fig. 11Fig. 7Fig.10Fig. 12

Remark

0

Data (%)

Fig. 9264Vac/50Hz

90Vac/60Hz

00

0

0

0

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3.2.6 Dynamic Test

T able 7 Dynamic Test

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

3.2.7 Time SequenceTable 11 Time Sequence


Output (mV)496488

Fig. 161.45s

Remark

Fig. 17Fig. 18Fig. 19Fig. 20Fig.21Fig. 2210.2ms

Falling Time11.4ms110ms

Rise Time119ms

Hold-UpTime15.4ms100Vac/60Hz

1.45sItem

Input Voltage90Vac/60Hz

Fig. 15Input Voltage90Vac/60Hz264Vac/50Hz

240Vac/50Hz

Turn on Delay Time

Meas. Data

264Vac/50Hz

124ms

RemarkFig.13Fig.14


A dynamic loading with low set at 1A lasting for 50mS and high set at 2A lasting for 50mS is added tooutput. The ramp is set at 0.25A/uS at transient.


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Fig. 16 264Vac/50Hz, Full load Turn-on Delay TimeCH1=AC Input, CH2=Vout

CH1=AC Input, CH2=Vout CH1=AC Input, CH2=Vout

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


CH1=AC Input, CH2=Vout

Fig.18 240Vac / 50Hz,Full Load Hold-Up TimeFig. 17 100Vac / 60Hz, Full Load Hold-UpTime

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

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Fig. 21 100Vac/60Hz Full load FallingTime Fig. 22 240Vac/50Hz Full load Falling Time

3.3 Protection

Table 12 Short Circuit Protection

3.3.2. Open Loop ProtectionTable 13 Open loop protection

When over load condition is removed and the power automatically recover.Table 14 OLP


170%180%

PASSPASS

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

Input Voltage

115Vac/60Hz

Input Voltage90Vac/60Hz264Vac/50Hz

Open Loop Protection

3.3.1 Short Circuit Protection

Remark

PASS

3.3.3 Over Load Protection

264Vac/50Hz90Vac/60HzInput Voltage

5V OutputCurrent 2A

OLP(A) Over %90Vac/60Hz 3.0 150%

PASS

3.4

Short Circuit Protection

230Vac/50Hz

264Vac/50Hz 3.6

155%3.1

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Tested at Room temperature 35℃ in Plastic ABS Case.(Case Dimension 61mmX35mmX120mm).Table 15 Thermal TestingInput Voltage90Vac/60Hz


Transformer61.5℃ 61.4℃ 69℃ 80.6℃

3.3.4 Thermal Testing

UPSR1103 MOSFET Schottky

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4 Other Important Waveforms4.1 Vds, Vcc, Vcs& Vs Waveform at No Load/Full Loadfrom Top to Bottom :Vds;Vcc;Vcs;Vs

4.2 Vds& Vf Waveform at Full Load, Start / Normal / Output Short4.2.1 Vds& Vf at Full Load, Start / Normal / Output ShortTable 16 Measuring Data at Full Load, Operating Start/ Normal / Output Short Test.

RemarkFig 25Fig 26Fig 27


Fig.23 Vds,Vcc,Vcs&Vs waveform@90Vac/60Hz, no load

Fig.24 Vds,Vcc,Vcs&Vs waveform@90Vac/60Hz, full load

Fig.23 Vds,Vcc,Vcs&Vs waveform@264Vac/50Hz, no load

Fig.24 Vds,Vcc,Vcs&Vs waveform@264Vac/50Hz, full load

Vds(p-p)476V

Vf(p-p)31.2V

264V/50HZ

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

Input voltage

264V/50HZ 580V520V

37.6V30.8VShort at full load

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Fig.25 Vds& Vf start waveform@264Vac/50Hz, full load

Fig.26 Vds& Vf normal waveform@264Vac/50Hz, full load

Fig.27 Vds& Vf output short waveform@264Vac/50Hz, full load


4.2.4 Vds& Vf at full load, output short waveform

4.2.2 Vds& Vf at full load, start waveform

4.2.3 Vds& Vf at full load, normal waveform

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10W Adaptor Module Using UPSR1103 - Unisonic€¦ · 1.4. Protection Function 3 ... A dynamic...

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