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Electronics / Circuits

[Open Source] PD65W GaN Charger (ACF), Based on DK8607AD, IP6538-AC-65W, XPM52CDP65

zeruns
zeruns
2026-03-02 / 0 Comment / 1 Like / 2 Views / 0 words / It is currently checking whether it has been included...

Open source a 65W PD fast charging GaN charger, based on DK8607AD power chip, Active Clamp Flyback (ACF) topology, IP6538-AC-65W + XPM52CDP65.

Download links at the end of the article!

Physical Photos

GaN flyback power supply board front and back and DCDC fast charging board front photos:

DCDC fast charging board back photo:

Project Description

This project consists of GaN flyback power supply board (24V/3A) and 65W fast charging DCDC board;

The fast charging board has two designs:

  • IP6538-AC-65W chip, Buck step-down, built-in MOSFET, A+C ports
  • XPM52CDP65 chip, Buck step-down, built-in MOSFET, single Type-C port

The GaN flyback power supply board solution: The primary side uses Dongke's DK8607AD power chip with two built-in GaN transistors, maximum switching frequency 1MHz, the secondary side uses HBR20200P5 Schottky diode rectification or UCC24612+HSBB15N15S synchronous rectification, designed for either-or soldering.

This project is actually a failed project because the GaN flyback power supply board doesn't work properly, but the 65W fast charging DCDC board tests are normal and fine. I'm posting it to ask for help from experts to see what's wrong.

A total of four power supply boards were soldered, here's a brief description of the issues:

  • Board 1: No startup when powered on, no output, no voltage on auxiliary winding, power input around 0.5W
  • Board 2: DK8607AD chip exploded on power-on, then input short-circuited
  • Board 3: No startup when powered on, power input around 0.5W, no voltage on auxiliary winding, but started when disconnecting mains power, auxiliary winding rectified and filtered to about 15V, dropped after tens of microseconds, and DK8607AD chip exploded
  • Board 4: DK8607AD chip and current sampling resistor exploded immediately on power-on, open circuit after explosion

Photos of boards after chip explosion:

Transformer Parameters and Measured Data

Calculated using SMPSKit software, software download link: https://bbs.eeclub.top/t/smpskit/196

Transformer calculation result screenshot:

Transformer bobbin is PQ2020, primary coil inductance 63uH, winding parameters as follows:

Winding Layer Terminal Wire Specification Turns Winding Method
Layer 1 1-2 Φ0.2mm*7 (Litz wire) 6 Loose winding
Layer 2 5-6 Φ0.2mm*7 (Litz wire) 2 Loose winding
Layer 3 10-12 Φ0.2mm*20 (Litz wire) 3 Loose winding
Layer 4 2-3 Φ0.2mm*7 (Litz wire) 6 Loose winding

Transformer manufacturing specification sheet as follows:

Measured primary coil inductance after transformer winding: 69.576μH.

Transformer primary coil leakage inductance is 1.2μH, slightly larger, the transformer was hand-wound, not well wound.

DCDC Fast Charging Board Testing

XPM52CDP65

XPM52C is an integrated synchronous switching buck converter that supports multiple output fast charging protocols, including USB Type-C and PD protocols, Qualcomm QC 2.0/3.0/3.0+, Huawei FCP/SCP/HVSCP, VOOC 2.0/4.0 protocols, MediaTek PE, Samsung AFC, USB BC1.2 DCP, and Apple 2.4A charging specifications, providing complete solutions for car chargers, various fast charging adapters, smart power strips and other power supply devices. XPM52C has the function of automatically identifying VIN input voltage, and adjusts the output voltage according to the input voltage. XPM52C has built-in power MOS, input working voltage up to 31V, output voltage range from 3.3V to 21V, can provide maximum 65W output power, and can automatically adjust output voltage and current according to the identified fast charging protocol. XPM52C output has CV/CC characteristics, when the output current is less than the set value, output CV mode, output voltage is constant; when the output current is greater than the set value, output CC mode, output voltage decreases. XPM52C's output voltage has line compensation function, the output voltage will be increased accordingly when the output current increases, to compensate for the voltage drop caused by the connection line impedance. XPM52C specially integrates XPD-LINK interconnection communication patented technology. Through XPD-LINK interconnection function, XPM52C can be simply and flexibly applied in charging schemes with multiple Type-C ports. XPM52C supports secondary programming, enabling online upgrade. XPM52C has multiple protection functions, including input overvoltage, undervoltage protection, output short circuit, overcurrent protection, overtemperature protection. XPM52C采用QFN4x4-16L封装.

Fast charging protocol test, actually supported protocols: PD3.0 FIX 65W PPS 63W, QC2 20V, QC3 20V, QC3.0+, QC4+, QC5, FCP 12V, AFC 9V, iP 2.4A.

The USB ammeter used for testing is Ruiken X3: https://s.click.taobao.com/575iCMn

Load test, input voltage 24V, PD decoy output 20V, electronic load set to 3.3A current, actual output power 67.74W, input power 70.8W, conversion efficiency 95.65%, pretty good performance.

Maximum power working thermal image, chip maximum temperature around 90.3℃ (after attaching a small heatsink)

IP6538

IP6538 is an integrated synchronous switching buck converter, supporting 14 output fast charging protocols, supporting Type-C output and USB PD2.0/PD3.0(PPS) protocol dual-port output SOC IC, providing complete solutions for car chargers, fast charging adapters, smart power strips. Support dual USB Type-C, USB Type-C and USB A, or dual USB A output, integrated dual-port automatic plug detection function, any single port can support fast charging output when used alone, when both ports are used simultaneously, both ports output 5V, total power 5V/4.8A. Built-in power MOS, input voltage range from 8.2V to 32V, output voltage range from 3V to 20V

Fast charging protocol test, actually supported protocols: PD3.0 FIX 65W PPS 63W, QC2 20V, QC3 20V, QC4+, QC5, PE1.1, PE2.0, iP 2.4A.

Load test, input voltage 24V, PD decoy output 20V, electronic load set to 2.7A current, actual output power 55.41W, input power 57.35W, conversion efficiency 96.62%.

I don't know if it's my design problem or if there's an issue with this batch of chips, it will trigger protection when the current exceeds 2.7A, but my other project with the same schematic doesn't have this problem. Open source 140W+65W buck-boost PD3.1 fast charging module (2C+1A ports), IP6557+IP6538: https://blog.zeruns.com/archives/801.html

Maximum power working thermal image, chip maximum temperature around 87.6℃, no heatsink.

Schematics

GaN Flyback Power Supply Board

XPM52CDP65 Fast Charging Board

IP6538 Fast Charging Board

PCB

GaN Flyback Power Supply Board

XPM52CDP65 Fast Charging Board

IP6538 Fast Charging Board

Some component purchase links used in this project are here:

It is recommended to purchase components in LCSC: https://activity.szlcsc.com/invite/D03E5B9CEAAE70A4.html

Click "Buy Now" in the BOM table in the LCSC open source link to import all components to the shopping cart with one click.

Materials include: LCSC EDA project files, schematic PDF, SMPSKit software, data sheets of used chips, soldering assistant (interactive BOM), transformer specification sheet, Gerber files, stencil file for 3 boards together (within 10*10, Taobao stencil making around 15 yuan).

▶ Electronics/Single-chip Microcomputer Technical Exchange QQ Group: 2169025065

▶ eeClub-Electronic Engineers Community: https://bbs.eeclub.top/

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Active Clamp Flyback HSBB15N15S HBR20200P5 DK8607AD XPM52CDP65 ACF UCC24612 Flyback Power Electronics GaN SMPS DCDC Power Supply Charger IP6538 Open-Source PD Power

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Copyright Ownership: zeruns
Link to this Article: https://blog.zeruns.top/archives/85.html
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