Infineon EZ-PD PAG2S-2P User manual

User guide

Please read the sections “Important notice” and “Warnings” at the end of this document

002-39511 Rev. **

www.infineon.com

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active

clamp flyback charger and adapter solution

user guide

REF_65W_HFACF_PAG2

About this document

Scope and purpose

This document provides instructions and a quick start guide for the EZ-PD™PAG2S-2P controller-based Type-C

charger and adapter solution (REF_65W_HFACF_PAG2).

Intended audience

This document is primarily intended for EZ-PD™PAG2S-2P high-frequency active clamp flyback (ACF) charger

and adapter solution developers.

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Table of contents

About this document....................................................................................................................... 1

Table of contents............................................................................................................................ 2

1Introduction .......................................................................................................................... 3

2Specifications........................................................................................................................ 5

3Board overview...................................................................................................................... 6

4Test setup ............................................................................................................................. 9

4.1 Test equipment .......................................................................................................................................9

4.2 Power adapter tester (PAT)...................................................................................................................10

5Quick steps for demo.............................................................................................................11

References....................................................................................................................................12

Revision history.............................................................................................................................13

Disclaimer.....................................................................................................................................14

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Introduction

1Introduction

The Active Clamp Flyback (ACF) converter is a popular flyback topology that offers ZVS for the FETs. This topology

is suitable for higher frequency operation than the QR flyback because of the ZVS operation. There is also a

complete energy recovery in transformer leakage inductance, which is dissipated in the QR flyback RCD clamp.

ACF also has good electromagnetic interference (EMI) performance regarding ZVS operation and clamping of the

primary FET voltage through the clamp capacitor.

There are two types of ACF control modes: Complementary (CP) and noncomplementary (NCP). In the CP mode,

the main flyback and clamp switches are turned on/off alternatively to complement each otherin every switching

cycle, and the transformer current waveform is sinusoidal. Both the main flyback and clamp switches are under

ZVS switching. In the CP mode, the switching frequency rises with load decrease. This may have an impact on

light load and standby efficiency as well as EMI. Additionally, the full resonant current in the resonant tank

increases the conduction loss in the transformer.

To overcome the increased conduction loss and improve the light-load efficiency, use the noncomplementary

mode. This mode operates the active clamp FET so that it only turns on to accumulate enough magnetic energy

to ensure the main FET ZVS operation. This way, the circulating clampcapacitor currents are mitigated to output.

A few analog ACF controllers exist in the market. Some of them can only support either CP or NCP, but not both

types of operation.

Secondary Side

Isolation Barrier

Primary Side

EMI

Filter

Full-bridge

Rectifier

VCC

USB Type-C Connector

CC1

CC2

DP_GPIO

DM_GPIO

VBUS_TypeC

EZ-PDPAG2S

SR_DRV

SR_SEN

PWM_DRV

SR_CPP

SR_CPN

VBUS_IN

VBUS_CTRL

CSN

CSP

VBUS_C

VDDD

VCCD

VBUS_IN

Temperature

Sensor

GPIO

CC_COMP_GPIO

EA_OUT

AC input

GND

EZ-PD

PAG2P

PULSEIN

Driver

GDH

VCC

GND

Vbst

BSW

SR_CAP

Rext

SR_DRAIN

Figure 1 High-level block diagram of EZ-PD™PAG2S-2P REF_65W_HFACF_PAG2 Solution

Infineon provides a comprehensive solution for ACF-based flyback adapters. Specifically, for AC-DC conversion,

Infineon’s EZ-PD™PAG2x-based solution offers two chip solutions:

•EZ-PD™PAG2P primary side startup controller with high and low side PWM drive

•EZ-PD™PAG2S USB PD power adapter secondary side controller with synchronous rectification (SR)

EZ-PD™PAG2S-2P based 65W active clamp flyback charger and adapter demonstrates this highly efficient

topology.

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Introduction

Table 1 Critical components bill of materials (BOM)

Designator

Description

Part number

Manufacturer

EZ-PD™PAG2P primary side

startup controller

CYPAP212A1-14SXQ

Infineon Technologies

EZ-PD™PAG2S USB PD power

adapter secondary side

controller

CYPAS212A1-32LQXQ

Infineon Technologies

High-side gate driver IC non-

inverting

IRS25752LTRPBF

Infineon Technologies

OptiMOS™N-channel 30 V 19 A

BSZ0902NS

Infineon Technologies

OptiMOS™6 N-channel 120 V

3.04 mΩ

ISC030N12NM6

Infineon Technologies

Q2, Q3

700 V 150 mΩ E-mode GaN

transistor

GS-065-009-6S-L

Infineon Technologies

118 µH ATQ23.7 power

transformer

EF-239002

Better Magnetics Corp

Pulse edge transformer

ALTWR-C33TF

Infineon Technologies

C2, C3, C4, C5

Capacitor ALUM 33 µF 400 V 8x25

Radial

KCX 33 µF 400 V 8X25

Sh-ymin

C9, C48

Aluminium organic polymer

capacitors 560 µF 25 V (6.3x10)

NPX 560 µF 25 V 6.3x10

Sh-ymin

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Specifications

2Specifications

Table 2 Test specifications

Parameter

Value

Input voltage and frequency

100 to 240 V AC, 47 to 63 Hz

Max output power

65 W, 20 V to 3.25 A max

Output voltage

Fixed PDOs: 5.0 V / 3.0 A, 9.0 V / 3.0 A, 15.0 V / 3.0 A, 20.0 V / 3.25 A

PPS: 5 V to 11 V, 3.0 A; 5 V to 16 V, 3.0 A; 5 V to 21.0 V, 3.25 A with PPS power

limit

Peak efficiency

> 94%

Protections

1. Input overvoltage protection

2. Input undervoltage protection

3. VBUS_C overvoltage protection (OVP)

4. VBUS_C undervoltage protection (UVP)

5. Overcurrent protection (OCP)

6. Short-circuit protection (SCP)

7. Over-temperature protection (OTP)

8. VBUS_C to CC short protection

Charging standards

supported

1. USB-C PD v3.1 including programmable power supply (PPS) mode

2. Apple Charging 2.4 A

3. Qualcomm QC 2.0, 3.0, 4.0, 5.0

4. Samsung AFC

5. USB BC 1.2

EMI/EMC

1. Conducted emissions, CISPR32 CLASS B, 4 dB margin at 115/220 V AC

2. ESD, IEC61000-4-2, ±8 kV contact, ±16 kV air, Criteria A

3. Surge, IEC61000-4-5, ±1 kV DM and ±2 kV CM, Criteria B

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Board overview

3Board overview

The EZ-PD™PAG2S-2P based 65 W active clamp flyback USB PD charger and adapter solution

(REF_65W_HFACF_PAG2) shown in Figure 2 solution board is designed to meet the specifications shown in

Table 2.

Figure 2 REF_65W_HFACF_PAG2 solution board

In this solution, the EZ-PD™PAG2x operates with an optimal frequency of 150 kHz and functions as a

secondary-side flyback, ACF controller, and SR controller. Additionally, a high-side driver is used externally to

drive the ACF/high-side GaN FET. This solution board consists of three boards:

•Baseboard being primary board with EZ-PD™PAG2P and other power components

•EMI Board with filters and bulk capacitors

•Secondary board with EZ-PD™PAG2S, SR MOSFET, and Type-C connector

Figure 3 shows the schematic of EZ-PD™PAG2S-2P based 65 W high frequency active clamp flyback charger and

adapter solution.

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Board overview

Figure 3 EZ-PD™PAG2S-2P REF_65W_HFACF_PAG2 Schematic

EZ-PD™PAG2S uses PSoC™MiniProg4 (CY8CKIT-005) to program the EZ-PD™controllers. The EZ-PD™PAG2S-

based board uses a PSoC™MiniProg4 five-pin connection and a JTAG to Type-C connector board. In this way,

one can simply program the EZ-PD™PAG2S-2P based 65 W active clamp flyback charger and adapter board

using a Type-C connector.

Figure 4 PSoC™MiniProg4 (CY8CKIT-005) Programmer Kit

Programming interface and settings

The PSoC™Programmer software is used as a programming interface to program the firmware (.hex file) in an

EZ-PD™PAG2S-based board. For programming, select the “CCGx” platform and update the settings as shown in

Figure 5.

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Board overview

Figure 5 Programming interface to program EZ-PD™PAG2S board

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Test setup

4Test setup

Figure 6 shows the test setup to capture the electrical data of the DUT. The following is the optimal setup to

capture efficiency by capturing:

•Input power using a power meter

•Output power using high-resolution output multimeters

Figure 6 Test equipment connected to the standalone REF_65W_HFACF_PAG2 board

4.1 Test equipment

Table 3 shows the test equipment to measure performance parameters such as efficiency, ripple, regulation,

and transient response.

Table 3 Test equipment details

Test setup

Description

Programmable AC source

Chroma 61501

AC power meter

Yokogawa WT310E

PAT tester

USBCEE PAT

Electronic load

Chroma 63102A

Multimeters

Keysight 34465A

User guide

002-39511 Rev. **

2024-02-15

EZ-PD™PAG2S-2P 65 W high-frequency active clamp flyback

charger and adapter solution user guide

Test setup

4.2 Power adapter tester (PAT)

Connect the DUT to a USB-C power adapter tester (PAT) using a USB Type-C cable. After the connection is

established, the PAT UI does a PDO discovery and displays the results.

The EZ-PD™PAG2S-2P based 65 W active clamp flyback charger and adapter solution is pre-configured with

seven PDOs:

•Fixed PDOs: 5.0 V / 3.0 A; 9.0 V / 3.0 A; 15.0 V / 3.0 A; 20.0 V / 3.25 A

•PPS: 5 V to 11 V, 3.0 A; 5 V to 15.0 V, 3.0 A; 5 V to 21.0 V, 3.25 A (PPS power limited)

Choose a suitable pre-configured PDO or configure a new one using the EZ-PD™Configuration Utility. Tests in

the following sections use pre-configured PDOs.

To know more about the PAT tester, see USBCEE.

Figure 7 PAT tester and user interface

Table of contents

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