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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
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40W 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
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.
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40W 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 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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40W Adaptor Module Using UC3863
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
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Capacitor, X2, 0.22uF/275VAC, 105℃ ,±20%
Capacitor, ceramic, 102pF/1KV, ±20%, SMD1206Capacitor, aluminum electrolytic, 470uF/35V, 105℃,±20%
C5,C15,C16
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Capacitor, Y1, 102pF/400V, 105℃,±20%Diode ,fast recovery, 1N4148, 0.15A/75V,SMD1206.
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40W Adaptor Module Using UC3863
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
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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,1K, 1/8W,±5%, SMD0805
Resistor, chip, 100K, 1/8W,±5%, SMD0805Resistor, chip, 100R, 1/4W,±5%, SMD1206
Resistor, chip,180K, 1/8W,±1%, SMD0805
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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40W Adaptor Module Using UC3863
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
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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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40W 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:
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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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40W 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 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(%)
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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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40W Adaptor Module Using UC3863
Table 4 CEC Average Efficiency :
Fig.1 Wire End Efficiency VS Load
Fig. 2 Board End Efficiency VS Load
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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
90Vac/60Hz115Vac/60H230Vac/50H264Vac/50H
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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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40W Adaptor Module Using UC3863
3.2 Output Characteristics3.2.1 Line Regulation & Load RegulationTable 7 Line Regulation & Load Regulation
90Vac/60Hz115Vac/60H230Vac/50H264Vac/50H
LineRegulation%
3.2.2 Ripple & NoiseTable 8 Ripple & Noise
90Vac/60Hz115Vac/60H180Vac/50H264Vac/50H
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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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40W 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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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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40W 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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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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40W Adaptor Module Using UC3863
Fig. 16 264Vac/50Hz, Full load Turn-on Delay Time
CH1=AC Input, CH2=Vout
CH1=AC Input, CH2=Vout
Fig. 19 100Vac/60Hz,Full Load Rising Time
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CH1=AC Input, CH2=Vout
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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40W Adaptor Module Using UC3863
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
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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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40W Adaptor Module Using UC3863
When over load condition is removed and the power automatically recover.
Table 14 OLP
Table 15 Thermal Testing
Input Voltage
90Vac/60Hz115Vac/60H230Vac/50H264Vac/50H
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(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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40W 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=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
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Fig.25 90Vac/60Hz, No Load
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40W Adaptor Module Using UC3863
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
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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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40W 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 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
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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
20
40W Adaptor Module Using UC3863
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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