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UTC Semiconductor
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Page 1.
UTC Semiconductor
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Page
01-01 02-02 03-03 04-06 07-07 08-09
Transformer Design
Bill Of Materials Test Data
AC Input DC Output Feature Test Function Test Operating Temperature
10-10
11-12 13-45 13-15 16-25 26-34 35-43 44-45
Page 2.
UTC Semiconductor
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Secondary Side
DC Output
EMI Filter
Converter
Rectifier
DC Filter
AC To DC Power Supply
(Adaptor)
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 3.
UTC Semiconductor
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Adaptor UC3863 10W/5V/2.0A
Comment
Voltage
AC Input Frequency Output Voltage DC Output Output Current Ripple & Noise No Load Efficiency Feature Active Mode Time Sequence Soft Start Voltage Current Function Protection Power Short Temperature Safety EMI Burning Conduction & Radiation Temperature
Vin
F Vout Iout Vp-p
90
47 4.75 2.0
115/230
50/60 5.0
264
63 5.25 3.0 100.0 0.1 50.0 27.0
VAC
Hz VDC A mV W % mS mS V A W No Damaged & Auto-Recovery At Primary Section Vin at 115VAC/60Hz & 230VAC/50Hz Measured at end of DC-Cable, Vin at 115VAC/60Hz & 230VAC/50Hz Refer to Test Data
78.704 0.5
3.0 15.00
150
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 4.
UTC Semiconductor
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Green Mode PWM Controllerer UC3863
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 5.
UTC Semiconductor
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Green Mode PWM Controllerer UC3863
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 6.
UTC Semiconductor
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34mm
50mm
22mm
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 7.
UTC Semiconductor
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UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 8.
UTC Semiconductor
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Art Work:
Component Side Solder Mask
34mm
50mm
50mm
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 9.
UTC Semiconductor
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Hole View
10 3 Layers of Tape
2. Electrical start could be different mechanical start. 3. Copper film is to connect to Pin(10), at layer 2 and layer 4.
7 (F) 6 (S)
2 UTM 0.2mm 11Ts Bias (Anti-Clockwise) 2 Layers of Tape 2 UTM 0.16mm2 22Ts Primary (Clockwise) 2 UTM 0.16mm2 23Ts Primary (Clockwise)
8 (F)
Electrical Specification:
1. Primary inductance ( Lp )=4.50mH 7% @ 10KHz ( Measure Pin 8 to 10 ). 2. Primary leakage inductance 5% * Lp ( Short Pin 1, 5, 6, 7 ;Measure Pin 8 to 10 ). 3. Electrical Strength = 3 KV, 50/60Hz, 1 Min.
2 Layers of Tape
6 (F)
3 (S) 9 (C)
Triple Insulated Wire (Anti-Clockwise) 0.6mm1 6Ts- Secondary
Materials:
1. Core: EE-22 ( TDK PC-40 or equivalent ). 2. Bobbin: TF-2219 (5+5) 10 Pin Vertical. 3. Magnet Wire( Pri. ): Type 2-UEW. 4. Magnet Wire( Sec. ): Triple Insulated Wires. 5. Layer Insulation Tape: 3M1298 or equivalent. 6. Pin Assignment: Pin 9 Cut off 1/2, Pin 2,4,5 Cut off.
1 (F)
3 Layers of Tape
10 (S)
Finished:
1. Varnish the complete assembly.
Bobbin TF-2219(5+5)
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 10.
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Location
PCB R1,R2 R3 R4 R5 R6 R7 R8 R9,R10 R11,R13 R12 R15 R16 R17 R18.R19 R20 D1,D2, D3,D4
Qty
1 2 1 1 1 1 1 1 2 2 1 1 1 1 2 1 4
Description
50*34.0mm CEM1 1M , SMD-1206 220K , SMD-1206 330 , SMD-1206 4.7 , SMD-0805 42.2 , SMD-0805 10 , SMD-0805 51K , SMD-0805 3.6 , SMD-1206 0 , SMD-0805 182K , SMD-0805 220 , SMD-0805 1K , SMD-0805 10K , SMD-0805 22K , SMD-0805 300K , SMD-0805 1N4007 DO-41
Note
S/N
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 D5 D6 D7 D8
Location
Description
FR107 DO-41 RS1D DO-214AC 1N4148 SOD-123 SB560 SMC PC-817, DIP-4 UTC UC3863, SOT-26 TL431, SOT-23 4N65K,TO-220F EE-2219 (Standard) 2.0A/250V 33uH (D=3.5,H=8,P=3) 102P/400V 4.7uF/400V 22uF/400V 4.7uF/50V 102P/1KV, SMD-1206 104P/50V, SMD-0805
Note
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 11.
UTC Semiconductor
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Location
C8 C9 C10,C11 C12 C15
Qty
1 1 2 1 1
Description
103P, SMD-0805 470F/10V 220F/10V 104P/50V , SMD-0805 103P/50V , SMD-0805
Note
S/N
Location
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 12.
UTC Semiconductor
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Specification AC Input O/P Low 90.0VAC/47Hz 4.75V O/P High 5.25V Data 5.013V
264.0VAC/63Hz
4.75V
5.25V
5.013V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 13.
UTC Semiconductor
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Graphic A B
: 18.1 A
: 20.2 A
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 14.
UTC Semiconductor
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Graphic C D
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 15.
UTC Semiconductor
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Specification O/P Low 4.75V 4.75V 4.75V 4.75V O/P High 5.25V 5.25V 5.25V 5.25V Data
5.203V 5.014V 5.203V 5.014V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 16.
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AC Input
Specification O/P Low 4.75V 4.75V 4.75V 4.75V O/P High 5.25V 5.25V 5.25V 5.25V Data 5.014V 5.014V 5.014V 5.014V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 17.
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AC Input
DC Output Current
0.02A 1.0A 2.0A 0.02A 1.0A 2.0A
Specification O/P Low 4.75V 4.75V 4.75V 4.75V 4.75V 4.75V O/P High 5.25V 5.25V 5.25V 5.25V 5.25V 5.25V Data 5.203V 5.109V 5.014V 5.203V 5.109V 5.014V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 18.
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Reject
Graphic E F G H I J
Note:
Measurement is made with an oscilloscope of 20MHz bandwidth. Output should be bypassed at connector with a 0.1uF/50V ceramic disk capacitor and 10uF/50V electrolytic capacitor to simulate system load. The length of ground wire on probe should not longer than 40mm, if a non-differential type of scope was used. At any load and AC input. UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 19.
UTC Semiconductor
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: 16mV
: 89mV
: 15mV
: 90mV
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 20.
UTC Semiconductor
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: 18mV
: 95mV
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 21.
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O/P Low
O/P High
115.0VAC/60Hz
1.0A(50%) 1.0A(50%)
4.75V
5.25V
4.93V
5.20V
115.0VAC/60Hz
2.0A(100%)
4.75V
0.0A(0%)
5.25V
4.92V
5.19V
230.0VAC/50Hz
1.0A(50%) 1.0A(50%)
4.75V
5.25V
4.95V
5.21V
230.0VAC/50Hz
2.0A(100%)
4.75V
5.25V
4.92V
5.19V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 22.
UTC Semiconductor
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: 394mV
: 282mV
: 312mV
: 276mV
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 23.
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AC Input
Specification O/P High 5.50V 5.50V 5.50V 5.50V O/P High 5.50V 5.44V 5.46V 5.48V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 24.
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Vout= : 5.50V
Vout= : 5.44V
Vout= : 5.46V
Vout= : 5.48V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 25.
UTC Semiconductor
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Accept
Reject
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 26.
UTC Semiconductor
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DoE Level 6 for O/P at no load power consumption. AC Input : From 115VAC/60Hz to 230VAC/50Hz. Output: At no load (0.0A) Input power 0.1W Meet DoE Level 6 with lots of margin. Specification I/P W 0.1 0.1 I/P W
0.0046W 0.0191W
AC Input
115.0VAC/60Hz 230.0VAC/50Hz
DC Output Current
0.0A 0.0A
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 27.
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Pin (W)
3.213 6.207
Pout (W)
2.578 5.108
EFF. (%)
80.236 82.294
AV-EFF. (%)
Accept
Reject
81.133
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 28.
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Graphic S T
Hold up time UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 29.
UTC Semiconductor
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UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 30
UTC Semiconductor
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Graphic U V
AC Input
DC Output Vout=5.0V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 31.
UTC Semiconductor
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UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 32.
UTC Semiconductor
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Graphic W X
AC Input
DC Output Vout=5.0V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 33.
UTC Semiconductor
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UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 34.
UTC Semiconductor
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AC Input : AC Input : 115.0VAC/60Hz. Output: At full load (2.0A) Method: Put in chamber, set temperature 100.
AC Input
Specification
Result
15030
Conditional
Auto-Recovery
Data
Accept
Reject
115.0VAC/60Hz
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 35.
UTC Semiconductor
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AC Input : AC Input : 115.0VAC/60Hz. Output: At full load (2.0A) Method: Short of photo couple of diode. If Vcc pin voltage is over 26.0V, this power supply will be shut down and auto recovery. DC Output Current 2.0A 2.0A Specification Vcc 26.0V 26.0V Conditional Auto-Recovery Auto-Recovery Data (V) 24.0 24.8 Result Accept Reject Graphic Y Z
Ch1 24.0V
Ch1 24.8V
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 36.
UTC Semiconductor
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Reject
Graphic AA AB
AC Input
DC Output Vout=5.0V
Soft start time UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 37.
UTC Semiconductor
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UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 38.
UTC Semiconductor
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AC Input
Specification Min. (V) 13.20 13.20 Max. (V) 18.00 18.00 Data (V) 23.2 24.4
90.0VAC/47Hz 264.0VAC/63Hz
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 39.
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PSU can not damage and fuse shall not blow up, this PSU shall be shut down and auto-recovery.
AC Input
Specification Min. (A) 2.20 2.20 2.20 2.20 Max. (A) 3.00 3.00 3.00 3.00 Data (A) 2.56 3.08 3.32 3.42
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 40.
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Iout= : 2.56A
Iout= : 3.08A
Iout= : 3.32A
Iout= : 3.42A
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 41.
UTC Semiconductor
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PSU can not damage and fuse shall not blow up, this PSU shall be shut down and auto-recovery.
AC Input
Specification Min. (W) 11.0 11.0 11.0 11.0 Max. (W) 15.0 15.0 15.0 15.0 Data (W) 12.80 15.40 16.60 17.10
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
Page 42.
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AC Input : AC Input : 90VAC/47Hz and 264VAC/63Hz. Output: At no load (0.0A) and full load (2.0A). PSU can not damage and fuse shall not blow up, this PSU shall be shut down and auto-recovery.
AC Input
Specification Method With GND. With GND. With GND. With GND. Result No Damaged No Damaged No Damaged No Damaged Data (W) No Damaged No Damaged No Damaged No Damaged
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.)
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UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 44.
UTC Semiconductor
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90.0VAC/47Hz
76
65
87
115
65
81
40
264.0VAC/63Hz
75
64
88
118
66
84
40
UTC Green Switching Power Supply for 5V/2.0A Adaptor Design (DoE Level 6.) Page 45.