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Application of Reactor Micro High Avalanche and High Reliability Super junction MOSFET in DJI DJI 100W Dual USB-C Port Gallium Nitride Desktop Charger

Publisher:Reactor Microelectronics


Charging Head Network has obtained a 100W gallium nitride desktop charger launched by DJI. This charger has two USB-C interfaces and supports fast charging of DJI drone batteries and remote controls simultaneously. It also supports PPS and PD fast charging protocols and can charge laptops and phones.

This desktop charger is powered by an eight wire, and different lengths of cables can be replaced according to different usage scenarios, making it convenient and simple to use. The total output power of the charger is 100W, supporting dynamic allocation of 82W+18W power. Below is a disassembly of the DJI gallium nitride charger, let's take a look at the internal design and materials used.

DJI 100W Gallium Nitride Desktop Charger Unpacked

The product packaging box adopts a minimalist style design, with DJI brand, product English name, and appearance printed on the front.

The product name parameters and merchant information are printed on the back.

The packaging includes a power cord, desktop charger body, data cable, and user manual. The power cord adopts a dual pin plug, and the pins are also protected by a plastic case.

The attached data cable is a regular black USB-C to USB-C cable, fixed with rubber rings.

The measured length of the data cable is approximately 102cm.

Using ChargerLAB POWER-Z KM003C, it was measured that the cable has an E-Marker chip, a power transmission capacity of 20V5A, and a data transmission capacity of USB 2.0.

There is corresponding specification information at the cable plug, which supports 6A 250V~input and has passed CCC certification.

The two ends of the power cord are equipped with dual pin national standard and 8-shaped plugs, and both are equipped with protruding teeth for convenient user insertion and removal.

The measured length of the power cord is approximately 1 meter.

The DJI desktop charger features a square shaped design with a frosted anti fingerprint outer shell and chamfered edges on both sides.

The top center design features DJI brand.

The bottom is printed with detailed product specifications.

Product parameter close-up

Model: CDX265-100

Input: 100-240V~50/60Hz 2.5A

USB-C1/C2 output: 5V3A, 9V5A, 12V5A, 15V5A, 20V5A, 5-20V5A

USB-C1/C2 output: 100W Max

USB-C1/C2+USB-C2/C1 output: 82W+18W

Manufacturer: Shenzhen Oulutong Electronics Co., Ltd

The product is authorized for production by Shenzhen DJI Innovation Technology Co., Ltd

The charger has passed certifications such as CCC, KC, CE, EAC, NOM, NYCE, UL, UKCA, etc.

There are also protrusions at the bottom four ends to prevent nameplate information from being worn out.

One end of the body is equipped with an 8-word input port and an independent module design.

On the other end, there are two USB-C interfaces, with chamfered edges and bright surface design, and distinctive markings printed.

The measured length of the fuselage is 73.82mm.

The width is 70.26mm.

The thickness is 32.1mm.

The size of the charger held in your hand is intuitive.

Additionally, its weight was measured to be approximately 275g.

使用充电器LAB POWER-Z KM003C测得USB-C1口支持FCP、SCP、AFC、QC3.0/5、PD3.0、PPS、DCP、Apple2.4A充电协议。

The PDO message shows that the C1 port also has five fixed voltage levels of 5V3A, 9V5A, 12V5A, 15V5A, and 20V5A, as well as a set of PPS voltage levels of 5-20V5A.

The compatibility protocol of USB-C2 port is the same as that of C1 port.

The PDO message is the same, that is, the single port output performance of the two interfaces is the same, supporting power blind insertion.

Disassembly of DJI 100W Gallium Nitride Desktop Charger

After seeing the unboxing and testing of the DJI Gallium Nitride desktop charger, let's take a look at the internal design and materials.

Firstly, cut open the outer shell along the seam on the side of the body, and cover the internal PCBA module with pure copper heat dissipation fins, which are then glued and fixed to the outer shell.

Remove the PCBA module from the casing, and cover the other side of the PCBA module with a pure copper heat sink, which is then glued and fixed to the casing.

The PCBA module is insulated from the heat sink through Mylar sheets and tape, and the heat sink is stamped and recessed for better contact with the heating element.

The length of the PCBA module measured using a vernier caliper is approximately 68.65mm.

The width of the PCBA module is approximately 64.8mm.

The thickness of the PCBA module is approximately 27.3mm.

The pure copper heat sink is fixed to the PCBA module by welding.

The heat sink is fixed by a buckle.

Remove the pure copper heat sink covered by the PCBA module. The PCBA module is wrapped in a Mylar insulation, and the heating element is coated with thermal conductive adhesive for heat dissipation.

The PFC boost inductor and transformer are coated with thermal conductive adhesive to enhance heat dissipation.

On the back, holes are made in the corresponding PFC switch tube, LLC switch tube, and synchronous rectifier tube positions, and thermal conductive adhesive is applied to enhance heat dissipation.

Remove the Mylar sheets covered by the PCBA module and continue with disassembly.

Glue and reinforce the components of the PCBA module to enhance heat dissipation.

The secondary voltage reduction board is isolated from the primary circuit through insulation with a Mylar sheet.

The power input line has a cold pressed terminal and is connected by welding with a heat shrink tubing.

A front view of the PCBA module, with the bottom left corner showing the AC input terminal, soldered fuse, common mode inductor, safety X2 capacitor, and NTC thermistor. The rectifier bridge is equipped with heat dissipation fins, and a small plate is welded on top to weld thin film capacitors and filtering inductors. Welding PFC boost inductor on the right side, welding high-voltage filtering capacitor on the right side of PFC boost inductor.

Weld the resonant inductor and transformer below the high-voltage filtering capacitor, weld the output small board on the right side, and weld the output filtering capacitor in the lower right corner.

Weld a PFC+LLC two in one controller, PFC switch tube, PFC rectifier tube, and LLC switch tube on the back of the PCBA module. Welding feedback optocoupler and two synchronous rectifier tubes on the right side, and welding six SMT Y capacitors on the top.

Through observation of the front and back of the PCBA module, it was found that DJI's 100W gallium nitride charger adopts a PFC+LLC+SR switching power supply architecture design, with PFC performing power factor correction and LLC power supply outputting a fixed voltage. The output is achieved through two independent step-down circuits, achieving independent fast charging of two interfaces. Let's start by understanding the design and materials of the entire charger from the input end.

Overview of PCBA module input terminals, soldered fuses, common mode inductors, safety X2 capacitors, NTC thermistors, rectifier bridges and filtering circuit boards, all inductors wrapped with yellow tape for insulation.

The input fuse specification is 5A 250V.

The first level common mode inductor adopts tape winding to strengthen insulation.

The common mode inductor is wound with enameled wire and insulated wire, and the bottom is welded with an insulated bracket.

The NTC thermistor comes from Shiheng, model 1.5D5, used to suppress surge currents when powered on.

The safety regulation X2 capacitor comes from SCC Shiquan Electronics, with a specification of 0.33 μ F.

The second common mode inductor is also insulated by tape wrapping.

The common mode inductor is wound with flat copper wire, and the bottom is welded with an insulation bracket.

The rectifier bridge is fixed with a pure copper heat sink and coated with silicone grease for thermal conductivity.

The rectifier bridge model is GBP810, with a specification of 8A 1000V.

The side of the PCBA module is welded with a voltage reduction output board, a high-voltage filtering capacitor, a PFC boost inductor, and a filtering capacitor inductor board.

Weld two thin film capacitors and a filtering inductor on the front of the output filtering board.

There are no soldered components on the back.

Both thin film capacitors have a specification of 0.47 μ F400V.

Filter inductor wrapped with tape insulation.

The primary PWM main control chip of the charger adopts NXP NXP TEA2016AAT. One chip is equipped with LLC controller and PFC controller, and digital architecture control, simplifying the design while reducing the number of peripheral components. The chip is equipped with multiple comprehensive protection functions, and the integration is very high.

The filtering capacitor powered by the main control chip comes from Guankun Electronics, with a specification of 47 μ F50V.

The PFC boost inductor adopts ATQ24 magnetic core winding.

The PFC switching transistor adopts gallium future G1N65R240PB, which is a gallium nitride power device with a voltage resistance of 650V, transient voltage resistance of 800V, nominal resistance of 240m Ω, and gate voltage support of ± 20V.

A 75m Ω sampling resistor is used to detect switch tube current.

The PFC rectifier tube is from Ruineng, model BYV29D-600P. It is an ultra fast recovery diode with a voltage resistance of 600V and is packaged in TO252.

Close up of magnetic beads used to suppress high-frequency interference.

The GS3MB diode is used for PFC bypass to charge high-voltage capacitors when the power is turned on.

High voltage filtering capacitors from Chengxing, three pieces with a specification of 18 μ F420V.

There is also a specification of 27 μ F420V.

The LLC switch tube is from Reactor Micro, model RMD65R380SN, NMOS, with a voltage resistance of 650V and a conductivity of 380m Ω. It is packaged in PDFN5 * 6 and connected by two half bridges.

Information on the RMD65R380SN data of Reactor Micro.

The resonant capacitor comes from Xiamen Farad Electronics, with a specification of 0.033 μ F630V.

The resonant inductor adopts ATQ17 magnetic core.

Welding transformers and output filtering capacitors on the side of the PCBA module.

The transformer is tightly wrapped with tape for insulation, using ATQ2716 magnetic core and wrapped with copper foil for shielding.

Six SMT Y capacitors come from Heshengtang, and two are connected in series to enhance the voltage resistance level.

Stick a rubber pad underneath the Y capacitor for support.

Zhaolong CT1018 optocoupler is used for output voltage feedback.

The synchronous rectification controller is from NXP NXP, model TEA1995. It is equipped with two independent synchronous rectification drivers for synchronous rectification of LLC architecture switching power supplies. The peripheral components are simplified and support a working voltage of 38V, which can meet the 28V output of USB PD3.1.

The synchronous rectifier tube is from Weian, model WMB060N06LG2, NMOS, with a voltage resistance of 60V and a conductivity of 4m Ω. It is packaged in PDFN5060-8L.

The other synchronous rectifier tube has the same model.

Welding filter capacitors and step-down small plates on the output side, as well as output filter inductors.

The output filtering capacitor comes from Yunxing, with a specification of 1000 μ F25V.

The output filtering inductor is wound with enameled wire, insulated with tape, and insulated with bakelite board at the bottom.

The front of the output voltage reduction board is welded with a filtering capacitor and a voltage reduction magnetic ring inductor, and the USB-C base is also welded.

The back of the small board is soldered with protocol chips, synchronous voltage reduction controllers, synchronous voltage reduction MOSFETs, and VBUS switching tubes.

The protocol chip comes from Yingjixin, model IP2738, and is a dual protocol chip that supports dual port 18-140W fast charging applications. It has independent feedback control, USB PD control, supports USB PD3.1 28V EPR gear, and supports rich and comprehensive fast charging protocols such as PD3.0/PPS.

The synchronous rectification and voltage reduction controller used for voltage reduction output is from Yingjixin, model IP6550. It is a synchronous voltage reduction controller that supports 36V input, with built-in NMOS transistor driver and two external MOS transistors for efficient synchronous rectification and voltage reduction. Switching frequency 135KHz, input terminal withstand voltage 48V, with built-in comprehensive protection function.

The synchronous step-down tube is from Weian, model WMQ090N04LG2, NMOS, with a voltage resistance of 40V and a conductivity of 5.7m Ω. It is packaged in PDFN3030-8L.

The step-down inductor adopts magnetic ring winding, with two wires wound in parallel.

A 5m Ω sampling resistor is used for output current detection.

The specifications of the input and output filtering capacitors are all 100 μ F25V.

Two screen printed B3006 NMOS transistors are used for USB-C interface VBUS control.

The other route also uses IP6550 for voltage reduction control.

The synchronous pressure reducing tube adopts Weian WMQ090N04LG2.

The step-down inductor adopts magnetic ring winding, with two wires wound in parallel.

The specifications of the input and output filtering capacitors are all 100 μ F25V.

A 5m Ω sampling resistor is used for output current detection.

Two screen printed B3006 NMOS transistors are used for USB-C interface VBUS control.

The USB-C interface is fixed by via welding, and the black rubber core does not expose copper.

The TVS screen printed 2B is used for static protection of CC and DP/DM pins, improving the reliability of the charger.

Take a complete breakdown and take a family photo.

Summary of dismantling the charging head network

This dual port gallium nitride desktop charger from DJI adopts a split cable design, effectively adapting to applications of different lengths. The charger has a 100W output power and supports single port 100W output. Both ports support 100W output power and support automatic power allocation. The actual test charger supports 5-20V 5A PPS fast charging, which not only charges DJI products but also meets the charging needs of mobile phones and laptops well.

According to the disassembly of the Charging Head Network, the 100W GaN charger from DJI adopts a PFC+LLC+DC-DC architecture design. The PFC uses Ga Future GaN power chip combined with Rayleigh diode rectification, and LLC uses sub micron RMD65R380SN MOSFETs to form a half bridge. The output uses two low-voltage MOSFETs for synchronous rectification, and the primary control chip and synchronous rectification controller of the power supply are both from NXP NXP.

The switching power supply adopts a fixed voltage output, and the output adopts a secondary voltage reduction circuit. The two IP6550 synchronous voltage reduction controllers are controlled by the Yingjixin IP2738 protocol chip for voltage reduction output, meeting the requirements of two independent fast charging outputs. The internal electrolytic capacitor of the charger comes from Chengxing, and the output is entirely made of solid-state capacitors, with lower ripple and longer lifespan. The PCBA module of the charger is covered with pure copper heat dissipation fins, and the components are glued and filled to accelerate heat dissipation, meeting the requirements of long-term full load output applications.