Test Report. 10W/5V/2A AC/DC Adapter. Reference Design Using UCC28700
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1 Test Report 0W/5V/2A AC/DC Adapter Reference Design Using UCC28700
2 Table of Content Introduction Electrical Performance Specifications Schematic Function Test Report Test Equipment Efficiency Output V-I Characteristics Output Transient Response (Dynamic Loading) Output Ripple/Noise Output Rise Time Start Up Time Hold Up Time Over Current Protection Short Circuit Protection Over Voltage Protection Key Component Stress EMI Conduction Test without FG-GND EMI Conduction Test with FG-GND Transformer Construction Schematic and Specifications Winding Table Winding Instructions and Transformer Assembly BOM List <EVM one line description> SLUUxxx September 200
3 Introduction This reference design is a 0W USB charger driver using UCC The design works with AC mains from 90Vrms to 264Vrms and provides a 5V/2A output. The PCB dimensions: 45mm(L) x 30mm(W) x 5mm(H, with PCB.2mm), PCB material: FR406 or compatible, single layer and 2-oz copper... Photograph 2 Electrical Performance Specifications PARAMETER TEST CONDITIONS MIN TYP MAX UNITS Input Characteristics Voltage range Vrms Frequency Hz Start up time 000 ms Output Characteristics Output voltage, Vout V Output load current, Iout 2 A Output Power 0.5 Watt Output voltage ripple/noise 50 mvpp Output rise time 30 ms Protection Characteristics Over voltage protection 5.8 V Over current protection 2. A Systems Characteristics Efficiency (Peak) Test in board end 78 % 3
4 3 Schematic L FD N FUSE250VA F 3 P R k 0603 R50 24k BD00 TB6S 600V C504 NC/0603 AUXW + C50 4.7uF/400V 2 L00 680uH P C nF/0805 R506 NC 4 CS DRV 3 5 GND VDD 2 6 VS CBC IC500 UCC28700DBV P P 2 + C502 0uF/400V L0 7mH ZD500 NC 2 R50 7.5M//4W R M//4W P R508 2k 0603 D503 NC 2 R D502 US002 SOD-23 2 R D500 US008/SOD-23 2 C505 nf/ C5 680uF/0V C nF/206 R507 ohm 206 AOU3N60/TO-25 P Q500 AUXW 9 P R503 00/0805 R K/206 T500 C506 00pF SW22 S4 D50 SV540 S 2 + C50 680uF/6.3V 2 R52 33/0805 R5.24k/ GND 4
5 4 Function Test Report 4. Test Equipment Instrument Manufacturer Model No. AC Source Chroma 6530 Power Analyzer Chroma 6630 Multimeter Fluke 89 Multimeter Electronic Load Chroma Oscilloscope Tektronix TDS 304B Differential Probe Tektronix P5205 Current Amplifier Tektronix TCPA Voltage Probe Tektronix P639A 4.2 Efficiency 4.2. Test Board End Vac Pi Iin Vo Io Load Eff 3.257W 63.9mA 5.094V 0.50A 25% 78.20% W 0.2mA 5.0V.00A 50% 78.48% 9.878W 54.2mA 5.8V.50A 75% 77.7% 3.277W 97.7mA 5.52V 2.00A 00% 77.59% 3.385W 42.9mA V 0.50A 25% 75.30% W 73.7mA 5.3 V.00A 50% 78.0% 9.833W 0.9mA 5.33 V.50A 75% 78.30% 3.45W 28.mA 5.6V 2.00A 00% 78.52% Average Eff 77.99% 77.53% Output No-Load Condition Vac Input Power Vo 5 42mW 5.7V mW 5.6V 5
6 4.3 Output V-I Characteristics Measure the output of constant voltage (CV) curve and constant current (CC) curve Test Waveform 90Vac 5Vac 5.25V 4.75V 5.25V 4.75V 230Vac Vout (V/Div) Vout (V/Div) 5.25V 4.75V Iout (0.5A/Div) 2.A 2.3A Iout (0.5A/Div) 2.2A 2.3A 264Vac Vout (V/Div) Vout (V/Div) 5.25V 4.75V Iout (0.5A/Div) 2.2A 2.3A Iout (0.5A/Div) 2.2A 2.3A 6
7 4.4 Output Transient Response (Dynamic Loading) The output voltage will remain within their regulation limits specified for the load steps. The load slew rate will not exceed 2.5A/uS. Frequency of the dynamic load will be 00Hz and KHz with a duty cycle of 50% Hz Test Result AC Input Vo at 0 ~ A max min Hz Test Waveform CH: Output voltage, CH2: Output current 90Vac 5Vac 230Vac 264Vac 7
8 4.4.3 khz Test Result AC Input Vo at 0 ~ A, khz max min khz Test Waveform CH: Output voltage, CH2: Output current 90Vac/60Hz 5Vac/60H 230Vac/60Hz 264Vac/60Hz 8
9 4.5 Output Ripple/Noise Measurements will be made with an oscilloscope set to 20MHz bandwidth limit. Output will be tested with 0uF aluminum electrolytic capacitor and 0.uF ceramic capacitor in parallel Test Result AC Input Vout (mvp-p) p) Test Waveform CH: Output voltage, CH2: Output current 5Vac, 5V@2A 230Vac, 5V@2A 9
10 4.6 Output Rise Time The output load set at maximum loading and no loading. Measure the time interval between 0% to 90% output voltage during startup Test Result AC Input No Load Max. Load ms 27.8ms ms 29.06ms Test Waveform CH: Output voltage 5Vac/No load 5Vac/Maximum load 230Vac/No load 230Vac/Maximum load 0
11 4.7 Start Up Time The output load set at maximum loading. Measure the time interval between 90VAC power up and stable of output voltage Test Result AC Input Delay Time ms Test Waveform CH: Output voltage, CH4: AC input 90Vac/No load
12 4.8 Hold Up Time The output load set at maximum loading. Measure the time interval between 5VAC turn off at zero degree and the output voltage falling to out of regulation Test Result AC Input Hold up Time ms Test Waveform CH: Output voltage, CH4: AC input 5ac/Maximum load 2
13 4.9 Over Current Protection The output current ramp starts from full load. Measure the maximum output current when the output voltage going to hiccup mode Test Result Vac OCP A A Test Waveform CH: Output voltage, CH2: Output Current 90Vac 264Vac 4.0 Short Circuit Protection A short circuit, which is defined as an impedance of 0. ohms or less, applied to any output start-up or while running will not cause any damage to the power supply. The output voltage will be restart when the short circuit is removed Test Waveform CH: Output voltage, CH2: Output current 90Vac 264Vac 3
14 4. Over Voltage Protection The output load set at minimum loading. Measure the maximum output voltage. After over voltage protection, the output voltage will go to non-latch mode. 4.. Test Result AC Input No Load V V 4..2 Test Waveform CH: Output voltage 90Vac 2640Vac 4
15 4.2 Key Component Stress 4.2. Test Result Item 264Vac Q 580V Q@SCP 578V Q (AOU3N60) Voltage Stress CH: Vds voltage 264Vac Q (AOU3N60) Voltage Stress when SCP CH: Vds voltage CH2: Output Current 264Vac 5
16 4.3 EMI Conduction Test without FG-GND Vac Line Vac Neutral 6
17 Vac Line Vac Neutral 7
18 4.4 EMI Conduction Test with FG-GND Vac Line Vac Neutral 8
19 Vac Line Vac Neutral 9
20 5 Transformer Construction 5. Schematic and Specifications Schematic Primary Secondary S 72T 5T S4 20T Specifications Electrical:. Primary Inductance = 700uH+/-0% at 00KHz V 2. Primary Leakage Inductance = 40uH Maximum 3. D.C.R Measure at 25Deg. C P7-5: 580m ohm Maximum P9-0: 20m ohm Maximum S-S4: 0m ohm Maximum W 36T Materials: 4. Core: EPC-7 (Ferrite Mn-Zn Material TDK PC40 or Equivalent) 5. Bobbin: EPC-7 Horizontal 6. Wires: Primary for Type 2-UEW, Secondary for Triple Insulated Wires 7. Layer Insulation Tape: 3M350F or Equivalent 5.2 Winding Table Winding# Start Pin Finish Pin Turns Wire Size & Type Note W UEW 0.23mm x Clockwise W UEW 0.23mm x Clockwise W UEW 0.23mm x Clockwise W UEW 0.23mm x Primary shielding W4 S S4 5 Triple Insulated Wire 0.45mm(only copper) x 2 Anti-Clockwise 5.3 Winding Instructions and Transformer Assembly Winding Instructions Assembly Instructions W Pin 0 Pin W 28T P0 P0 P9 P6 P7 W4 5T W3 20T + 8T W2 36T W 36T S4 S W 36T 20
21 6 BOM List Item Number Part Number Value Description Quantity BD00 TB6S 600V DIO 600V 0.5A 2 C50 CAP 4.7uF 400V 8x.5 p3.5 3 C502 CAP 0uF 400V 8x20 p3.5 4 C503 CAP 330nF 25V X7R C505 CAP nf 50V NPO C506 CAP 00pF Y 7 C507 CAP 2.2nF kv C50 CAP 680uF 6.3V 9 C5 CAP 680uF 0V 0 D500 US008 DIO 800V A SOD-23 D50 SV540 DIO 40V 5A TO D502 US002 DIO 200V A SOD-23 3 F FUSE FUSE 250VAC 2A 4 IC500 UCC28700DBV IC CV/CC PWM with PSR 5 L00 Inductor DM 680uH 6 L0 Inductor CM 7mH 7 Q500 AOU3N60 MOS 600V 3A TO-25 8 R500 RES 7.5M R50 RES 7.5M R502 RES 220K R503 RES R504 RES R505 RES R506 RES k R507 RES R508 RES 2k R509 RES 29.4k R50 RES 24k R5 RES.24k R52 RES T500 SW22 Transformer EFD-7 2
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