DIODES EV1 SSR Premium Charger Board User Guide

DIODES EV1 SSR Premium Charger Board

Specifications

• Power Output: 18W
• Quick Charge Version: QC3.0
• Topology: SSR (Solid State Relay)
• Efficiency Standards: DOE6, CoC Tier 2

Product Information

Chapter 1. Summary
General Description: The 18W QC3.0 SSR Premium Charger EV1 Board is designed for efficient and accurate charging with constant voltage and current control.

Key Features
System Key Features
Implementing SSR Topology with Opto-coupler for precise voltage and current control.

1. AP3302 Key Features: Detailed features of the AP3302 component.
2. APR34509 Key Features: Detailed features of the APR34509 component.
3. AP43331N Key Feature: Detailed feature of the AP43331N component.

FAQ
Q: What is the power output of the charger?
A: The power output of the charger is 18W.

Chapter 1. Summary

General Description
The 18W QC 3.0 charger Evaluation Board EV1 is composed of three main parts, AP3302 offers the QR/DCM PWM switching, APR34509 is an N-Mosfet SO-8EP co- packaged Synchronous Rectification Switcher, and the AP43331N performs QC 3.0 class A decoding function. Based on monitoring D+ & D- signals in USB Type A port, the AP43331N interprets desired voltage and current setting and provides real-time feedback information to the primary side AP3302 controller for voltage regulation. The 18W QC3.0 quick charger reference design exemplifies the cost-effective performance-optimized QC3.0 charging solution.

Key Features
System Key Features

• SSR Topology Implementation with an Opto-coupler for Accurate Step Constant Voltage and Current Control
• QC 3.0 Compliance
• Meet DOE6 and CoC Tier 2 Efficiency Requirements
• <75mW No-Load Standby Power

AP3302 Key Features

• Quasi-resonant operation with Valley Lock under all Lines and Load Conditions
• Switching Frequency: 22kHz-120kHz
• Non-audible-noise QR Controlling
• Soft Start Process during the Start-up Turn-on Moment
• During the burst mode operation and Low start-up operating quiescent currents, 75mW standby power can be achieved
• Built-in Jittering Frequency Function which is the EMI emission can be improved
• Internal Auto Recovery OCP, OVP, OLP, OTP Power Protection, cycle by cycle current limit, also with DC polarity & transformer short and Brown out protection

APR34509 Key Features

• Co-package (SO-8EP) N-Mosfet and synchronous rectification controller IC
• Synchronous Rectification supporting the DCM,CCM mode and QR Flyback
• Eliminate Resonant Ringing Interference
• Fewest External Components used & the total SR space reduced.

AP43331N Key Feature

• Supporting Qualcomm QC 3.0 and QC2.0

• Built in Shunt Regulator for Constant Voltage and Constant Current
  Programmable OVP/UVP/OCP/OTP

• Internal Discharge MOS

• Certified Qualcomm QC3.0 protocol spec (UL Report

• Number – 4787662260-1, 3/22/2017)

• Output cable voltage compensation

Applications

• 18W QC3.0 Quick Charge

Main Power Specifications (CV & CC Mode)

Input standby

power

| < 75mW
Main Output Vo / Io| QC2.0: 5V/3A, 9V/2A, 12V/1.5A, QC3.0: 3.6V ~12V, Io <3A,
Efficiency| 87.5%
Voltage step| + / – 0.2V
Total constant

Output Power

| <= 18W
Protections| OVP, UVP, OLP, BNO, FOCP, SSCP, OTP
XYZ Dimension| 37 x 39 x 20 mm
ROHS

Compliance

| Yes

Evaluation Board Pictures

Chapter 2. Power Supply Specification

Specification and Test Results

Compliance

Chapter 3. Schematic

EV1 Board Schematic

Bill of Material (BOM)

Vds=700VDC, Rds_on =0.9ohm

| TO-251| 1| DMJ70H900HJ
Designator| Comment| Footprint| Quantity| Remark
---|---|---|---|---
Q2| MMBT3904| SOT-23| 1|
R1A, R1B, R1C| 2.2M ohm| 0805| 3|
R2| 270K| 1206| 1|
R3| 20R| 1206| 1|
R4| 2.4R| 0805| 1|
R5 , R11| 15K| 0603| 2|
R6| 300K| 0603| 1|
R7| 33K| 0603| 1|
R8A,R8B| 1.2R| 0805| 2|
R9| 560R| 0603| 1|
R10| 120 ohm| 0603| 1|
R15| 20 ohm| 0603| 1|
R12, R19| 1K| 0603| 2|
R13, R14, R24| 20R| 0603| 3|
R16| 75K| 0603| 1|
R17A，R17B| 45 mohm| 1206| 2|
R18| 39K| 0603| 1|
R20, R22, R26| 4.7K| 0603| 3|
R21, R28| 56K| 0603| 2|
U1| AP3302| SOT26| 1|
U3| TCLT1006| OP817-SOD| 1| Or PIC817
U4| AP43331N| SO-8| 1|
U5| APR34509| SO-8EP| 1|
ZD1| MMSZ5251B,24V Zener Doide| SOD123| 1|
USB| USB CLASS A Connector| USB-A| 1|
T1| PQ2016             Low             Height Bobin,H=12mm| PQ2016D| 1|
PCB| 37mm*39mm double-side| | 1|

Transformer design

PQ2016 **Ae=64mm2 ****Height=12mm**

NO| NAME| TERMINAL NO.| WINDING
START| FINISH| WIRE| TURNS| Layers
1| Np1| 8| 7|  0.23*1| 45| 3
2| Na| 3| 4（GND）|  0.18*1| 18| 1
3| Shield| 4（GND）| *** NC|  0.131| |

4| Ns| * 5| 6|  0.65 TIW 1| **

6

| 2
5| Shield| 4（GND）| NC|  0.13*1| Full| 1
6| Np2| 7| 2（VBUS）| * .231| ** 20|
Primary Inductance| Pin 8-2,all other windings open, measured at 1kHz, 0.4VRMS| 950uH,±5%
---|---|---
Primary Leakage Inductance| Pin 8-2, all other windings shorted, measured at 10kHz, 0.4VRMS| 20 uH (Max.)

Schematics Description

AC Input Circuit & Differential Filter
There are three components in the section. The Fuse F1 protects against over- current conditions which occur when some main components fail. The line filter consists of L1, L2 & two bulk caps CE1 & CE2, it will block the switching noise back to AC line. The BD1 is a rectifier and basically converts alternating current & voltage into direct current & voltage.

AP3302 PWM Controller
The AP3302 PWM controller U1 & Opto-Coupler U3 and Q1 are the power converting core components. The R1A, R1B, R1C resistor path will provide start-up voltage and current during starting up through Vcc (Pin 5). The subsequent VCC power will be provided by voltage feedback from the auxiliary winding through D2, D3, Q2, R4, R5, ZD1 regulator circuit. This design is to accommodate with the required wide voltage range to support QC3.0 various protocols from 3.6V to 12V.
Based on the feedback of the secondary side from Pin 3 of AP43331N Decoder to primary side FB pin of AP3302 through Opto-coupler U3, the AP3302 PWM controller will switch Q1 ON and Off by a certain duty cycle to regulate the desired voltage and current on the secondary side.

APR34509 Mosfet Co-packaged Synchronous Rectification (SR) Switcher
APR34509 operates in DCM mode in this design and drive the internal MOSFET based on the secondary side transformer on/off duty cycle.

3.4.4 AP43331N QC3.0 Decoder Interface to Power Devices
AP43331N is highly integrated secondary side constant voltage (CV) and constant current (CC) controller with QC3.0 decoder.

1. D+ & D- (Pin 7, 8): D+ & D- pin voltage are defined by QC3.0 spec to provide the channel communication link between the power AC source and sink devices.

2. Constant Voltage (CV): The CV is implemented by sensing the ratio of R20 & R18 voltage (pin 5) and comparing with an internal reference voltage to generate a CV compensation signal on pin 3. There is a voltage loop compensation circuit C11 & R21 between Pin5 & Pin3, the fast voltage response can be obtained by adjusting their value. The output voltages can be adjusted by firmware programming.
   Constant Current (CC): The CC is implemented by sensing the voltage across the current sense resistor (R17A & R18B) and current sense amplifier, then comparing with internal programmable reference voltage to generate a compensation signal on the pin3.

3. CC Loop Compensation: between Pin3 & Pin1’s C12, R22 are for the current loop compensation circuit.

4. Vout Pin 3: It is the key interface link from the secondary decoder (AP43331N) to the primary regulation circuit (AP3302). It is connected to an Opto-coupler through U3 for feedback information based all sensed D+ & D- voltage status for getting desired output charging voltage & current.

Chapter 4. The Evaluation Board (EVB) Connections

EVB PCB Layout
The thickness for both sides of PCB board trace cooper is 2 Oz.

Quick Start Guide Before Connection

1. Before starting the 18W QC3.0 EVB test, the end user needs to prepare the following tool. For details,

   • Test Kit: Diodes 18W QC3.0 & 2.0 Test Kit

2. Prepare a one-foot USB 3.0 – Micro B cable and a one side cut USB-3.0 Cable to the E-load.

3. Connect the sample input AC L & N wires to AC power supply output “L and N “wires.

4. Ensure that the AC source is switched OFF or disconnected before the connection steps.

5. Use 2 banana jack cables, one port of the cables are connected to E-load + & – terminals while the other port Of the cables

6. Or use a smart phone instead of E-load to connected with A Standard-A to Micro-B cable output

System Setup
QC 3.0 sample load connection + Test Kit

QC3.0 test Kit test procedures

• The charger output default setting is 5V when was turned on
• Chose mode of QC2.0 or QC3.0 by pushing the O button
• If in QC2.0 mode, the charger output will be increased

To 9V or 12V when push the “+” button once time from 5V And the charger voltage will be decreased to 9V then to 5V from 12V when push the “-” button once time

• If in QC3.0 mode, the charger voltage will be increased by 200mV/per step when push the “+” button once time until from 3.6V to 12V
• If in QC3.0 mode, the charger voltage will be decreased by 200mV/per step when push the “-” button once time from 12V to 3.6V

Figure 11: The Test Kit test Buttons

Chapter 5. Testing the Evaluation Board

Input & Output Characteristics
Input Standby Power

5.1.2 Power Conversion Efficiency at Different AC Line Input Voltage (PCB End)

Vin| Vo| 25%| 50%| 75%| **100%| ****Average Efficiency| Energy Star Level VI| 10% load efficiency**
---|---|---|---|---|---|---|---|---
115VAC/60HZ| 5.0V| 87.67| 87.5| 86.02| 84.47| 86.42| >81.39%| 86.83
230VAC/60HZ| 5.0V| 86.88| 87.56| 86.66| 85.94| 86.76| 83.17
115VAC/60HZ| 9.0V| 88.07| 88.2| 87.82| 87.34| 87.85| >85.00%| 85.84
230VAC/60HZ| 9.0V| 87.82| 88.8| 88.96| 88.78| 88.59| 83.4
115VAC/60HZ| 12.0V| 87.06| 88.09| 87.95| 87.85| 87.74| >85.00%| 81.17
230VAC/60HZ| 12.0V| 86.91| 88.79| 89.14| 89.28| 88.53| 79.29

Output I – V Curve @ Board End

Key Performance Waveforms
18W QC3.0 System Start-up Time & Hold-up Time

Q1 and AP34509 Main Switching MOSFET Stress on at 12V/ 1.5A Loading @264Vac

System Output Ripple & Noise with @ 1.2m Cable End

Output Voltage Transition Time

Dynamic load: The test condition
5V Dynamic loading between 10% ~ 90% of 3A, Fd = 250mA /us 50% duty Tr =1mS

5V Dynamic Load

9V Dynamic Load

Loading| 10ms- 10ms| 100ms- 100ms| 200ms- 200ms
---|---|---|---
Vo_min| Vo_max| Vo_min| Vo_max| Vo_min| Vo_max
0– >100%| 8.85| 9.38| 8.97| 9.39| 8.95| 9.39
0– >50%| 8.91| 9.24| 8.98| 9.27| 8.95| 9.25
10– >90%| 8.89| 9.35| 8.9| 9.33| 8.89| 9.32

12V Dynamic Load

Thermal Testing
Test Condition: Vin=90Vac & 264Vac Vo=9.0V Io=2.0A Open Frame

Primary Switching

MOSFET

|

℃

| 71.1
Secondary Rectifier| ℃| 73.1
Ambient Temp| ℃| 25
Test Items| Unit| Temperature
---|---|---
Transformer wire| ℃| 59.8
Transformer core| ℃| 57.8
Primary Switching

MOSFET

|

℃

| 73.4
Secondary Rectifier| ℃| 79.5
Ambient Temp| ℃| 25

EMI (CE) Conductive Emission Testing
Test Condition: Vin=230Vac, Vo=12V, Io=1.5A

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