TRANSPHORM 100W TPA1001C02-V1.2 Power Adapter User Guide

TRANSPHORM 100W TPA1001C02-V1.2 Power Adapter

Power Adapter Description

This design guide of the Transphorm GaN and Onsemi NCP1623A & NCP1342 controller reference design board describes a 100 W, average efficiency up to 91.93%, with programmable output voltage (5 V/5 A, 9 V/5 A, 15 V/5 A, 20 V/5 A). The power supply uses PFC controller NCP1623A collocation Transphorm GaN TP65H150LSG (650 V SuperGaN FET), Plus the Quasi-Resonant Flyback controller NCP1342 Collocation TP65H300G4LSG (650 V SuperGaN FET). This design shows high power density and efficiency. This document contains the power supply specification, schematic, bill-of-materials, transformer documentation, printed circuit layout, and performance data.

Features

• Integrated Transphorm GaN TP65H150LSG for PFC controller topology
• Integrated Transphorm GaN TP65H300G4LSG for flyback converter topology
• Board-end over 91% Efficiency(90VAC/20V)
• Flat Efficiency Across Universal (90-264 VAC) Input Voltage and Load
• Tight Switching Frequency Regulation for Improved Input EMI Filter Utilization
• Up to 200KHz Switching Frequency Operation
• OTP, UVLO, OPP and OSC Protections
• < 100mW (230Vac) No Load Power Consumption of the IC
• Up to 100W Output Power

Applications

• High-Power-Density USB-PD AC/DC Power Supplies

Warning

1. Caution – High Voltage Operation: Lethal high voltages are present when this evaluation board is powered from AC mains. Improper contact with high voltages could lead to electrical shock, burn and/or fire hazards, risking property damage, personal injury, and death.
2. Evaluation Purpose Only: This evaluation board is intended for evaluation purposes only and not for commercial use. Care must be taken when testing the board, and an isolation transformer should be utilized.
3. Patents: The evaluation board design, along with circuits shown in this test report, may be covered by one or more U.S. and foreign existing/pending patents.

100W Adapter Form Factor

Schematic

Circuit Description

Input Protection
The design incorporates a slow-acting input fuse (F101) as a form of protection in case of destructive failure of any of the downstream components.

EMI Filtering
To meet the target EN55022 conducted EMI specification with sufficient margin with the least number of components and the highest power processing efficiency, the design utilizes an input filter consisting of an X-capacitor (CX101) and a single common- mode choke (LF101,LF102) as well as transformer (T1) construction for better EMI performance.

Fault Protections

Protections

| ****

Behavior

---|---
Input Under Voltage Lockout (UVLO)/ Brown-Out| Auto-Recovery
Internal Over Temp Protection (OTP)| Auto-Recovery
External Over Temp Protection (OTP)| Auto-Recovery
Peak Current Limit (PCL)| Auto-Recovery
Over-Power Protection (OPP)| Auto-Recovery
Output Short Circuit (OSC)| Auto-Recovery

PCB Layout and Bom List

Layout design

Transphorm SuperGan FET

Bill of Materials

PCBA – Main Board| | | | | | | |
---|---|---|---|---|---|---|---|---

No.

| ****

Designator

| ****

Part No.

| ****

Package

| ****

Manufacturer

| ****

Qty

| ****

Value

| ****

Tolerance

| Voltage,

Current, Power

| ****

Remark

| ****

Description

1| F101| office storage| 8.5x4mm| Littelfuse| 1| 3.15A| slow blow| 250Vac| UL&VDE| fuse
2| R101, R118| office storage| 0603| Yageo| 2| 47Ω| 1%| 1/10W| | resistor
3| R102| office storage| 0603| Yageo| 1| 270kΩ| 1%| 1/10W| | resistor
4| R103, R116| office storage| 0603| Yageo| 2| 0Ω| 1%| 1/10W| | resistor
5| R104| office storage| 0603| Yageo| 1| 82Ω| 1%| 1/10W| | resistor
6| R105| office storage| 0603| Yageo| 1| 82kΩ| 1%| 1/10W| | resistor
7| R106| office storage| 0603| Yageo| 1| 10Ω| 1%| 1/10W| | resistor
8| R107, R108| office storage| 0603| Yageo| 2| 22kΩ| 1%| 1/10W| | resistor
9| R109| office storage| 0603| Yageo| 1| 2Ω| 1%| 1/10W| | resistor
10| R110, R164| office storage| 0603| Yageo| 2| 1MΩ| 1%| 1/10W| | resistor
11| R111| office storage| 0603| Yageo| 1| 30kΩ| 1%| 1/10W| | resistor
12| R112| office storage| 0603| Yageo| 1| 20kΩ+17kΩ| 1%| 1/10W| | resistor
13| R113| office storage| 1206| Yageo| 1| 1MΩ| 1%| 1/4W| | resistor
14| R114, R115| office storage| 1206| Yageo| 2| 2.4MΩ| 1%| 1/4W| | resistor
15| R117, R204| office storage| 0603| Yageo| 2| 100Ω| 1%| 1/10W| | resistor
16| R151, R152| office storage| 1206| Yageo| 2| 1kΩ| 1%| 1/4W| | resistor
17| R153| office storage| 1206| Yageo| 1| 2MΩ| 1%| 1/4W| | resistor
18| R154| office storage| 0603| Yageo| 1| 220Ω| 1%| 1/10W| | resistor
19| R155| office storage| 0603| Yageo| 1| 680Ω| 1%| 1/10W| | resistor
20| R156| office storage| 0603| Yageo| 1| 20Ω| 1%| 1/10W| | resistor
21| R157| dismantled| 0603| | 1| 49.9kΩ| 1%| 1/10W| | resistor
22| R158| office storage| 0603| Yageo| 1| 1kΩ| 1%| 1/10W| | resistor
23| R159| office storage| 0603| Yageo| 1| 100kΩ| 1%| 1/10W| | resistor
24| R160| office storage| 0603| Yageo| 1| 1.8kΩ| 1%| 1/10W| | resistor
25| R161| office storage| 0603| Yageo| 1| 200Ω| 1%| 1/10W| | resistor
26| R162| office storage| 0603| Yageo| 1| 110kΩ| 1%| 1/10W| | resistor
27| R163| office storage| 0603| Yageo| 1| 20kΩ| 1%| 1/10W| | resistor
28| R201| office storage| 0603| Yageo| 1| 36kΩ| 1%| 1/10W| | resistor
29| R202, R203| office storage| 1206| Yageo| 2| 10Ω| 1%| 1/4W| | resistor
30| RCS101, RCS102,

RCS103, RCS104

| dismantled| 1206| | 4| 0.47Ω| 1%| 1/2W| | resistor
31| RCS105, RCS106,

RCS107

| dismantled| 1206| | 3| 0.68Ω| 1%| 1/2W| | resistor
32| C101| office storage| 0603| Yageo| 1| 2.2nF| X7R| 50Vdc| | capacitor
33| C102, C161| dismantled| 0603| Yageo| 2| 220nF| X7R| 50Vdc| | capacitor
34| C103, C105| office storage| 0603| Yageo| 2| 2.2uF| | 25Vdc| | capacitor
35| C104| office storage| 0603| Yageo| 1| 10pF| COG| 50Vdc| | capacitor
36| C106| office storage| 0603| Yageo| 1| 680pF| X7R| 50Vdc| | capacitor
37| C107| office storage| 1206| | 1| 47nF| | 630Vdc| | capacitor
38| C151, C151A| office storage| 1210| | 2| 0.1uF| | 630Vdc| | capacitor
39| C152| office storage| 1206| | 1| 10nF| | 630Vdc| | capacitor
40| C153| office storage| 0603| Yageo| 1| 1.5nF| COG| 50Vdc| | capacitor
41| C154, C155| office storage| 0603| Yageo| 2| 1nF| X7R| 50Vdc| | capacitor
42| C156| office storage| 0603| Yageo| 1| 75pF| COG| 50Vdc| | capacitor
43| C157| office storage| 0603| Yageo| 1| 56pF| COG| 50Vdc| | capacitor
44| C158, C158A| office storage| 1206| | 2| 2.2uF| X7S| 100Vdc| | capacitor
45| C159, C160| office storage| 1206| | 2| 4.7uF| X7R| 50Vdc| | capacitor
46| C201| office storage| 0805| | 1| 2.2uF| | 25Vdc| | capacitor
47| C202| MC06KTB251102HF| 1206| Viking| 1| 1nF| | 250Vdc| | capacitor
48| C203| open| 1206| | 1| | | | | capacitor
49| EC101, EC102| HH450M180G20P077S00R| 10x20x5mm| Samxon| 2| 18uF| | 450Vdc| | E-capacitor
50| EC103| EKM396M2WJ20RRS1A1F| 13x20x5mm| Samxon| 1| 39uF| | 450Vdc| | E-capacitor
51| EC201| STAP561M1EE14PDH00J| | | 1| 560uF| | 25Vdc| | E-capacitor
52| EC202| NPXD1601E821Mj| | Ymin| 1| 820uF| | 25Vdc| | E-capacitor
53| CY101| SMD-Y1221K/AC400V| SMD| | 1| 220pF| | 400Vdc| | Y-capacitor
54| CY102| Y5P221K| 10mm| | 1| 220pF| | 500Vac| | Y-capacitor
55| D101, D102,

D103

| EP5J| TO-277| JINAN JINGHENG| 3| 5A/1.2Vf| | 600Vdc| | diode
56| D104, D105,

D158, D159

| 1N4148WS| SOD-123| | 4| 0.15A/1.25Vf| | 75Vdc| | diode
57| D153, D156,

D157

| ES1JFL| SOD-123-2| On-Semiconductor| 3| 1A/1.7Vf| | 600Vdc| | diode
58| D151, D152| RSFML| SOD123| Taiwan Semiconductor| 2| 0.5A/1.3Vf| | 1000Vdc| | diode
59| D154| A7H| | HP| 1| 1A/1Vf| | 1000Vdc| | diode
60| D155| ZHCS400TA| SOD-323-2| Diodes| 1| 0.4A/1.05Vf| | 40Vdc| | diode
61| NTC1| WMFC-0603R104FB4000FRR| 0603| Weilin| 1| 100kΩ| | | | NTC
62| ZD101| MMSZ18VCW| SOD-123| | 1| 18Vz| | | | zener
63| ZD102| MM3Z18VCW| SOD-323| JINAN JINGHENG| 1| 18Vz| | | | zener
64| PH101, PH102| EL1018(TA)-VG| SMD| Everlight| 2| CTR=130-260%| | | | opto- coupler
65| LF101| HF70 T8X4X4| | TDK| 1| 90uH| | | | CM choke
---|---|---|---|---|---|---|---|---|---|---
66| LF201| HF70 T8X4X4| | TDK| 1| 28uH| | | | CM choke
67| L1| Salom offered| RM8| | 1| 200uH| | | | inductor
68| L102| BLM31PG500SN1| 1206| Murata| 2| 3A/50Ω| | | | ferrite bead
69| L104| dismantled| | | 1| 6.8uH| | | | inductor
70| T1| Salom offered| RM10| | 1| 240uH| | | | transformer
71| FB101, FB102,

FB107

| BCMS321611A121 5A| 1206| HongyeX| 3| 5A/120Ω| | | | ferrite bead

72

| FB103, FB106, FB108, FB109,

FB201

| ****

BCAS160808A331

| ****

0603

| ****

HongyeX

| ****

5

| ****

0.2A/330Ω

| | | | ****

ferrite bead

73| U101| NCP1623A| TSOP-6| On-Semiconductor| 1| | | | | PFC controller
74| U102| NCP1342AMDCDD| SOIC-9| On-Semiconductor| 1| | | | | QRF controller
75| U201| MP6908AGJ-Z| TSOT23-6| MPS| 1| | | | | SR controller
76| Q101| TP65H150LSG| 8x8mm PQFN| Transphorm| 1| 150mΩ| | 650Vdc| | GaN
77| Q102| TP65H300G4LSG| 8x8mm PQFN| Transphorm| 1| 240mΩ| | 650Vdc| | GaN
78| Q103| MMBT2222A| SOT-323| On-Semiconductor| 1| 1A| | 40Vdc| | NPN
79| Q104| BSS123| SOT-23| YJ| 1| 0.2A| | 100Vdc| | NPN
80| Q201, Q202| AONS62922| DFN 5x6mm| AOS| 2| 85A, 7mΩ| | 120Vdc| | SR NMOS
| | | | | | | | | |
81| PCB| TPA1001C02 MB-REV.A| 57.5×57.7×1.2mm| | 1| FR4, TG150, 2layers| | Cu 2/2oz| | PCB
| | | | | | | | | |
PCBA – Daughter J Board| | | | | | | |

No.

| ****

Designator

| ****

Part No.

| ****

Package

| ****

Manufacturer

| ****

Qty

| ****

Value

| ****

Tolerance

| Voltage, Current,

Power

| ****

Remark

| ****

Description

1| CX101| JB334K30LAXL2| | | 1| 330nF| | 300Vdc| | X-cap
2| CB101, CB102| UP684KT4LAXV1| | | 2| 680nF| | 450Vdc| | MPP-capacitor
3| L101| T13X8X5| 13x8x5mm| | 1| 124uH| | | | DM choke
4| LF102| T14X7X8| 14x7x8mm| | 1| 20mH| | | | CM choke
5| BD101, BD102| HBS610| HBS| Diodes| 2| 6A/0.96Vf| | 1000Vdc| | bridge diode
| | | | | | | | | |
6| PCB| TPA1001C02 DB1-REV.A| 39.96×27.3×1.2mm| | 1| FR4, TG150, 2layers| | Cu 2/2oz| | PCB
| | | | | | | | | |
PCBA – PD Board| | | | | | | | |

No.

| ****

Designator

| ****

Part No.

| ****

Package

| ****

Manufacturer

| ****

Qty

| ****

Value

| ****

Tolerance

| Voltage,

Current, Power

| ****

Remark

| ****

Description

1| R2| | 0603| Yageo| 1| 1MΩ| 1%| 1/10W| | resistor
2| R15, R15A| LR1206-21R010F4 MA120610FR010FZ| 1206| 旺詮

Everohms

| 2| 10mΩ| 1%| 1/1W| | resistor
3| R26, R29| | 0603| Yageo| 2| 2.2Ω| 1%| 1/10W| | resistor
4| R30| | 0603| Yageo| 1| 5.1kΩ| 1%| 1/10W| | resistor
5| R31, R33| | 0603| Yageo| 2| 22Ω| 1%| 1/10W| | resistor
6| R34| | 0603| Yageo| 1| 47kΩ| 1%| 1/10W| | resistor
7| R36| | 0603| Yageo| 1| 51Ω| 1%| 1/10W| | resistor
8| R39| | 0603| Yageo| 1| 1.5kΩ| 1%| 1/10W| | resistor
9| R40| | 0603| Yageo| 1| 3kΩ| 1%| 1/10W| | resistor
10| R42| | 0603| Yageo| 1| 0Ω| 1%| 1/10W| | resistor
11| R43| open| 0603| | 1| | | | | resistor
12| R44| | 0603| Yageo| 1| 30kΩ| 1%| 1/10W| | resistor
13| R47| | 0603| Yageo| 1| 2kΩ| 1%| 1/10W| | resistor
14| R48| open| 0603| | 1| | | | | resistor
15| C18| | 0603| Yageo| 1| 0.1uF| | 10Vdc| | capacitor
16| C19, C22| | 0603| Yageo| 2| 390pF| | 50Vdc| | capacitor
17| C20| open| 0603| | 1| | | | | capacitor
18| C21| 0805B225K250CTHF| 0805| Walsin| 1| 2.2uF| | 25Vdc| | capacitor
19| C23, C24| | 0603| Yageo| 2| 0.1uF| | 50Vdc| | capacitor
20| C25| open| 0603| | 1| | | | | capacitor
21| C26| open| 0603| | 1| | | | | capacitor
22| C29| 0603X106K100CTHF| 0603| Walsin| 1| 10uF| | 10Vdc| | capacitor
23| C31| open| 0603| | 1| | | | | capacitor
24| D12| 1N4148WS| SOD-123| | 1| 0.15A/1.25Vf| | 75Vdc| | diode
25| ZD1| DESD3Z24WS-HAF| SOD-323| BC| 1| 24Vz| | | | zener
26| ZD2, ZD3| DESD3Z5.0-HAF| SOD-323| BC| 2| 5Vz| | | | zener
27| ZD4, ZD5| DESD3Z8.0C-HAF| SOD-323| BC| 2| 8Vz| | | | zener
28| U202| WT6636F-UG16CWTWT| DFN 5x5mm| Weltrend| 1| | | | | PD controller

29

| ****

Q203

| AON7528

FKBB3016 VS3610AE

| DFN 3.3×3.3mm

DFN 3.3×3.3mm DFN 3.3×3.3mm

| AOS FET

| ****

1

| ****

2mΩ

| | ****

30Vdc

| | ****

PD NMOS

30| Type-C| NAR25-CB5V21| | ACON| 1| | | | | type-C connector
| | | | | | | | | |
31| PCB| CPCB-1203 REV.C| 18.23×27.38×0.8mm| | 1| FR4, TG150, 2layers| | Cu 2/2oz| | PCB

Main Chokes Specification

CM and DM Chokes Specification and Other Configurations

Performance Data

Efficiency Standard
DoE Level VI and CoC Version 5 Tier-2 4-point (25%, 50%, 75%, 100%) average efficiency, along with CoC Version 5 Tier-2 10% load efficiency requirements.

Vout (V)

| ****

Iout

| DoE Level VI 4-PointAverage Efficiency (%)| CoC V5 Tier-2 4-Point Average Efficiency (%)| CoC V5 Tier-2 10%

Efficiency (%)

---|---|---|---|---
5| ****

5

| 84.25| 85.00| 75.47
9| 87.72| 88.85| 78.85
15| 88.00| 89.00| 79.00
20| 88.00| 89.00| 79.00

Efficiency Data
The following efficiency data are averaged from PD 100W boards. The boards are soaked for 5 minutes before measuring the efficiency with output measured after the USB-PD disconnect FET.

Table-3 115Vac Efficiency Data

Vin (Vac)| Vout (V)| Load (%)| Efficiency (%)| Average Efficiency (%)
---|---|---|---|---

115

| ****

5

| 100| 89.26| ****

90.62

75| 91.15
50| 91.42
25| 90.65
10| 88.11|

9

| 100| 91.31| ****

91.22

75| 91.12
50| 90.61
25| 91.85
10| 88.83|

15

| 100| 92.17| ****

91.36

75| 92.09
50| 91.64
25| 89.53
10| 88.42|

20

| 100| 92.31| ****

91.93

75| 92.67
50| 92.25
25| 90.47
10| 86.08|

Table-4 230Vac Efficiency Data

Vin (Vac)| Vout (V)| Load (%)| Efficiency (%)| Average Efficiency (%)
---|---|---|---|---

230

| ****

5

| 100| 86.98| ****

87.87

75| 89.59
50| 88.62
25| 86.30
10| 80.71|

9

| 100| 90.32| ****

89.01

75| 89.57
50| 88.16
25| 87.97
10| 84.78|

15

| 100| 91.95| ****

90.22

75| 91.42
50| 90.47
25| 87.03
10| 82.54|

20

| 100| 92.83| ****

91.10

75| 92.02
50| 91.38
25| 88.18
10| 83.60|

Table-5 Heavy Load Efficiency Data

5

| ****

5

| 88.78| 0.9814
115| 89.26| 0.9558
230| 86.98| 0.7475
264| 87.31| 0.6726
90| ****

9

| 90.65| 0.9919
115| 91.31| 0.9817
230| 90.32| 0.8706
264| 90.58| 0.8146
90| ****

15

| 91.34| 0.9957
115| 92.16| 0.9910
230| 91.91| 0.9365
264| 92.16| 0.9003
90| ****

20

| 91.25| 0.9936
115| 92.29| 0.9934
230| 92.78| 0.9573
264| 93.04| 0.9320

Table-6 No-Load Power Consumption

Efficiency Graphs
The following graphs demonstrate 5 V/ 9 V/ 15 V/ 20 V efficiency results with output measured after the USB- PD disconnect FET.

PPS Protocol Detection

Waveforms and Curves

Switching Waveform
The key waveforms for the worst-case voltage conditions as seen by the primary side GaN Transistor and secondary side MOSFET are shown below.

EMI Scan

Output Voltage Ripple
The output voltage ripple was measured using a voltage probe. Measurement is done at load side using an E-Mark USB cable.

Table-7 Output Voltage Ripple Summary

115

| 5| 0| 22
5| 70
9| 0| 16
5| 58
15| 0| 16
5| 59
20| 0| 15
5| 60

230

| 5| 0| 27
5| 60
9| 0| 24
5| 60
15| 0| 16
5| 63
20| 0| 16
5| 65

Thermal Measurements
The key component temperatures are shown below for 90Vac & 264Vac full load (20V/100W) operating conditions after 1hr bake time.

Component| Part Number| Temp. at 90Vac (°C)| Temp. at 264Vac (°C)
---|---|---|---
BD101| RUBF810| 94.7| 60.4
BD102| RUBF810| 95.9| 63.2
IC101| NCP1623A| 62.3| 58.3
Q101| TP65H150G4LSG| 94.7| 82.8
L1| RM8| 65.6| 62.8
U4| NCP1342AMAACD1R2G| 86.7| 82.3
Q102| TP65H300G4LSG| 92.9| 93.8
T1| PQ23| 93.4| 91.9
IC201| MP6908AGJ-Z| 95.7| 98.5
Q202, Q203| AONS62922| 98.7| 100.6
IC202| WT6636F| 78.7| 88.7
Q201| AON7528| 79.9| 86.9

Hardware Information

Table-9 Equipment List

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