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This forum discusses Adapter and Charger applications based on Infineon products. This includes USB-C chargers and adapters, Automotive USB-C charging, and Battery chargers.
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Show Less1. Overview
The 140 Watt USB PD Power Charger Reference Board REF_XDPS2221_140W1 uses the XDP ™digital combo controller XDPS2221, the CoolGaN ™device IGLD60R190D1, and the EZ-PD ™controller CCG3PA CYPD3175. It is targeted at USB PD charger adapters for applications such as smartphones and mobile computers with wide input range and wide output voltage range. The figure below shows the top view of the complete board system, consisting of the main power supply board, the VCC daughter board and the EPR board. The AC input connections are X1 and X2 in the lower left corner, while the board output is the Type-C connector in the upper right corner.
1.1 AC input power supply specifications
1.2 Output power supply specifications
1.3 Main devices
1.4 Development Board PCB Information
2. Introduction to board-level systems
The system consists of a main power board, a VCC supply board, and a USD PD EPR 28 V daughter board.Both the PFC and HFB stages are controlled by one of Infineon's XDP ™digital controllers, the combination controller XDP ™ XDPS2221. On the output side, Infineon's USB PD EZ-PD ™controller CCG3PA CYPD3175 is used for communication with end devices and output voltage management. In the following subsections, the schematics of these boards are presented, and for the bill of materials (BOM) of the boards, see the subsequent series.
2.1 Main power board
The schematic and PCB layout of the motherboard are shown in the following figure. Unassembled parts are shown in gray in the schematic.
The figure above shows the power supply circuitry for the AC input and PFC stages, including input protection and EMI filters (RV100, CX100, RX100, RX101, LC100, D100, CB100, CB191, LD100, LD101, CB102, and CB103), as well as the starting battery external circuitry (D101, D102. R100, R101, and R102).The PFC zero-crossing detection (ZCD) and current sense (CS) signals are combined into a single signal, PFCzcdcs, which is connected to IC pin PFCCS.The voltage of the PFC auxiliary winding, which is coupled to the PFC main inductor (T100), is determined by the devices R103, D103, D105, R104 C100, D104, Z100, C101, and R105 are processed to generate the ZCD signal, where D103 is used for negative clamping and networks D104, Z100, C101, and R105 limit the positive voltage of the ZCD signal. The ZCD signal is effectively decoupled from the PFC CS resistors R111, R112 and R114 through resistor R109, which provide the CS signal to the control IC.The CoolGaN ™device is used as the PFC main switch, Q100, which is directly driven by the XDP ™ XDPS2221 from the PFCGD pin with external RC networks (R107, R106 and C102). Note: The devices shown in gray in the schematic are not assembled on the board. In addition, some 0 Ω resistors have been prepared to allow easy component selection.
The HFB is based on a half-bridge structure as shown above. The main winding of transformer T200 is connected to the half-bridge switching node at one end and to the resonant capacitors (C201 to C223) at the other end. Shunt resistors (R211, R212) are used to sense the current through the main winding of the transformer for HFB peak current regulation. For precise switching timing, a signal from the auxiliary winding (Vaux1) is used. It uses devices R205, R206, R204 and a small filter capacitor C203 to generate a ZCD signal. Resistors R200, R201, R202 and R203 are used for PFC voltage sensing. Both voltages from the auxiliary windings Aux1 and Aux2 are supplied to the VCC daughter board via connector M200.The JP200 connector is used for parameter configuration via UART communication.
The following figure shows the schematic of the half-bridge, including the gate RC network driving the GaN switch.
On the secondary side, the output voltage is rectified by a synchronous rectifier circuit, while the USB PD daughter board controls the reference voltage of the shunt regulator (D202) and thus the output voltage.The schematic diagram of the SR daughter board is shown in the following figure.
To keep the system cost low, all boards use a two-layer PCB. the following two diagrams show the PCB layout of the motherboard.
2.2 VCC Power Board
At cold start, the VCC supply is provided through a resistor connected to the HV pin. The charging current is controlled by the starting battery. During normal operation, the VCC supply is ensured by the VCC daughter board. The following figure shows the schematic of the VCC board.
The VCC supply circuit is based on the charge pump concept. According to this concept, the IC supply is coupled to the HFB input voltage but independent of the wide range output voltage. Two auxiliary windings are implemented for efficient VCC generation. At high HFB input voltage, energy is transferred from Vaux1, while at low HFB input voltage, Vaux2 is used.The PCB design of the board is shown below.
2.3 EPR boards
The EPR board is based on the EZ-PD ™controller CYPD3175, as shown below
A linear regulator (G1) is used to generate the required supply voltage for the controller CYPD3175. A circuit consisting of Q2, Q2A, D2, D3, R3 and R11 provides the required voltage on the communication lines CC1 and CC2. The controller CYPD3175 senses the input voltage Vco (VBUS_IN from the perspective of the EPR board) and the output voltage (VBUS_OUT), where the output voltage of the Type-C connector is "on" or "off" controlled by the load switch Q6. The output current of the Type-C connector is sensed by shunt resistors R17 and R18, filtered by elements R19 and C7, and then sent to the PD controller IC. The controller CYPD3175 communicates with the end device via communication lines CC1 and CC2, sets the output voltage level of the HFB accordingly via the signal PDFB, and controls the supply to the end device via load switch Q6. device. For output voltage drop transitions, the PD controller may activate the bus discharge paths (R4, Q3 and R2, Q5) before and after the safety switch. The PCB layout of the EPR board is shown in the figure below.
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Show LessThis series presents details of a 140-watt USB PD reference design that utilizes a novel XDP ™digital power supply, the XDPS2221, for Power Factor Correction (PFC) plus Hybrid Flyback (HFB), with a CoolGaN ™device IGLD60R190D1 as the main switch, and EZ-PD ™ CCG3PA CYPD3175 for USB PD Extended Power Range (EPR) control. The series contains key waveforms and performance data.
XDP ™ XDPS2221 Overview
The XDPS2221 controller is a highly integrated device that includes a valley-switching power factor correction (PFC) controller, an asymmetrical half-bridge (HFB) controller, and three gate drivers for the main switch. internal collaboration between the PFC and HFB controllers, as well as adaptive bus voltage settings, make this controller ideal for applications that require a wide AC input and wide output voltage range, such as USB PD adapters and battery chargers. The internal collaboration between the PFC and HFB controllers and the adaptive bus voltage setting make this controller ideal for applications requiring wide AC input and wide output voltage ranges, such as USB PD adapters and battery chargers. To learn more about this control IC, see the datasheet [1]. The following is a brief summary of product highlights, key features, IC pinouts, and key benefits to customers.
1 Product Highlights
- PFC and HFB digital combo controller integrated in DSO-14 (150 mil) package
- Innovative Zero Voltage Switching (ZVS) HFB Topology Designed for Ultra-High System Efficiency
- Integrated gate driver supporting GaN and Si switches
- 600V high-voltage starter unit for fast VCC charging
- Burst mode operation for minimum no-load standby power
- Adaptive PFC bus voltage and PFC enable/disable control to maximize average and light load efficiency
- Configurable protection modes and system performance parameters
- Pb-free lead plating, halogen-free (according to IEC 61249-2-21), RoHS compliant
2 Power Factor Correction (PFC) Control Characteristics
- Configurable PFC QRM operation for improved average efficiency
- Pulse skip function for light load efficiency improvement
- Automatic disabling/enabling of PFC control based on operating conditions
- Adaptive PFC bus voltage level according to operating conditions
3 Hybrid Flyback (HFB) Control Characteristics
- Peak current mode control for stable and fast input and load control
- Zero voltage switching (ZVS) operation of high-side and low-side switches and ZVS pulse insertion in discontinuous conduction mode (DCM)
- Configurable multi-mode operation for increased average and light load efficiency
4 Controller Pinout
5 Highlights to attract customers
5.1 Low material costs
- PFC + HFB Gate Drive Control in 14-pin DSO Package
- Integrated gate driver for direct drive of CoolMOS ™and CoolGaN ™
- Integrated starter unit for initial VCC charging
- Better for reducing transformer size than other flyback topologies
5.2 High system performance
- High system efficiency
- High power density design
- Low standby power
5.3 Unique controllers on the market
- Ideal for applications with wide AC input and wide output voltage ranges, such as USB PD EPR adapters and battery chargers
- Embedded digital core supports configurable parameters for optimal system performance
- Design simplicity by using one controller for multiple designs and applications, supporting a platform design approach
XDPS2221 Control IC Firmware
REF_XDPS2221_140W The XDP ™ XDPS2221 on the board has been upgraded to the new firmware version 3.1.4. Earlier firmware versions are no longer supported. xdp ™ The date code on the XDPS2221 indicates the firmware version used. Figure 2 illustrates the date code.
Note: If the date code for the XDP ™ XDPS2221 on the REF_XDPS2221_140W board is 2252, upgrade the board.
Upgrading the XDP using firmware version 3.1.4 ™ Steps for the REF_XDPS2221_140W1 board of the XDPS2221:
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Order samples of the new XDP ™ XDPS2221. Contact your local Infineon salesperson or contact Infineon Support.
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Replace the existing XDP ™ on the REF_XDPS2221_140W board with a new sample (with firmware version 3.1.4) XDPS2221.
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Add discharge resistors. Since the new firmware version 3.1.4 does not support active X-cap discharging, you must add discharging resistors to the inputs; RX100 and RX101 (1.2 each). (MEG) is shown in Figure 3
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If you want to upgrade the XDP ™ XDPS2221 on the REF_XDPS2221_140W1 board to firmware version 3.1.4, you first need to order the new XDP ™ XDPS2221 Sample. You can accomplish this step by contacting your local Infineon salesperson or Infineon support.
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Upon receipt of the new XDP ™ XDPS2221 sample, replace it with the existing XDP ™ XDPS2221 on the REF_XDPS2221_140W board.This requires some knowledge of electronics, may require the use of soldering equipment, and adherence to safe practices.
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The new firmware version 3.1.4 does not support active X-cap discharging, so you will have to add discharging resistors to the inputs. This means that you need to solder two discharge resistors, type RX100 and RX101, each with a resistance value of 1.2, in the corresponding places on the board. MEG.
Left: Old REF_XDPS2221_140W board: XDP ™ XDPS2221 with firmware version 3.1.1, no discharge resistor.
Right: New REF_XDPS2221_140W board: XDP ™ XDPS2221 with firmware version 3.1.4, with discharge resistor
By using the XDP ™ XDPS2221 with a date code of 2312, the REF_XDPS2221_140W board will run firmware version 3.1.4 with the latest fine-tuned parameter set included.
Note: (Optional) Update the parameter file
If the REF_XDPS2221_140W board with firmware version 3.1.1 is used for certain test purposes After replacing the control IC with firmware version 3.1.4, the parameter values have changed and you need to use your customized parameters based on the .csv file of firmware version 3.1.4.
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Show LessHi Infineon team,
Good day to you all, I'm working on a 2.5KW (Output - 58V 40A) Battery charger for EV Application. I've taken the 2Kw Li-ion charger for reference.
https://www.infineon.com/cms/en/product/evaluation-boards/eval_2kw_48v_char_p7/
Converter is working fine but I'm facing some heating issues in Output diodes. Kindly Advice me to solve this issue.
Output Diode specs : Vr - 200V, If - 45A, Vf - 0.86V output diode link - MBR90200WT
Here I'm attaching my primary transformer current waveform and output side diode current waveform for your reference
Show LessMy academic project involves implementing a wireless charger using the WLC1115 chip, which will perform authentication to ensure that the transmitter (Tx) can only be used with a specific receiver (Rx), and vice versa. To achieve this, I plan to use the OPTIGA Trust M chip. I have some specific questions related to this process and would greatly appreciate it if you could help me address them.
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Which of the two methods for programming the WLC1115 chip do you recommend that is more easily accessible in the market and that can fully program the chip or modify its firmware?
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Can I use the configuration tool provided by you for the basic configuration of the chip with the miprog4?
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Can I use the chip without the Optiga trust charge but with the Optiga trust M?
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Can I achieve a power greater than 10W without the Optiga trust charge?
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What could I do if I want to transmit data between Tx and Rx?
- How can I program the Optiga Trust M?
Good day. I am developing an academic application which involves the development and implementation of a wireless charger with authentication. However, the authentication part mostly involves customizing the wireless charger for a single receiver (device). Initially, I relied on the WLC1115_68LQXQ chip, but the issue with this chip is that it is Qi 1.3 compliant, including authentication via Optiga, and I'm not sure if Optiga allows the authentication I require. I would like to know what ideas or recommendations you have for implementing the authentication of the wireless charger I need, or what other charging chip you would recommend.
Thank you.
Show LessMy name is Dexaca, and I am reaching out to inquire about the WLC1150 chip. I am looking to integrate this chip into a wireless charger for a project, and I require additional information regarding the corresponding receiver chip.
Furthermore, I am in need of the transmitter and receiver chip for authentication purposes during the charging process. If you could provide detailed specifications, compatibility, and pricing information, it would greatly assist in my decision-making process.
Additionally, I am interested in exploring other wireless charging chip options that adhere to the Qi 1.3 protocol for both transmission and reception of wireless charging. If you have any other product recommendations or references that meet these criteria, I would appreciate the information.
Thank you for your attention to this matter. I anticipate your prompt response and would be grateful for any assistance you can provide.
Show LessHi Infineon,
I am working on a 2.5KW battery charger and I have gone through the Application note of the Evaluation Board (2KW EVAL_2kW_48V_CHAR_P7) a Lead-acid/Li-ion battery charger of Infineon.
Here are my queries.
There is a resistor (R200) across the capacitor (C90) in the schematic but in the evaluation board that resistor is not present. But when I checked the current version of the schematic the capacitor C90 is not present. Can you explain this variation in schematics?
Show Less