techmannih/usbc-charger

index.circuit.tsx

PCB

Schematic

import "tscircuit"
import { enclosure } from "tscircuit"

import { B32922C3104M189 } from "./imports/B32922C3104M189"
import { HLK_20M15C } from "./imports/HLK_20M15C"
import { IP6520StandardNonPps } from "./imports/IP6520"
import { MF72_5D9 } from "./imports/MF72_5D9"
import { MOV_14D471K } from "./imports/MOV_14D471K"
import { PDMTAT068125_220MLU } from "./imports/PDMTAT068125_220MLU"
import { PESD5V0H1BSF } from "./imports/PESD5V0H1BSF"
import { RVE100UF35V67RV0072 } from "./imports/RVE100UF35V67RV0072"
import { RVT1E101M0607 } from "./imports/RVT1E101M0607"
import { SCT1032T2A250V } from "./imports/SCT1032T2A250V"
import { SMBJ13A } from "./imports/SMBJ13A"
import { SMBJ15A } from "./imports/SMBJ15A"
import { TYPE_C_31_M_12 } from "./imports/TYPE_C_31_M_12"
import { WJ500V_5_08_2P } from "./imports/WJ500V_5_08_2P"
import { XRSQ1010_10mH_H } from "./imports/XRSQ1010_10mH_H"

/**
 * Engineering prototype for an 85-265 VAC to USB-C PD wall charger.
 *
 * The encapsulated HLK-20M15C module replaces the former custom flyback,
 * transformer and EMI magnetics. IP6520 converts its isolated 15 V output to
 * negotiated USB-PD source profiles: 5 V / 3 A, 9 V / 2 A and 12 V / 1.5 A
 * (18 W max). The exact standard IP6520 is the non-PPS variant; other IP6520
 * family variants are not approved substitutions.
 *
 * The 15 V / 1.333 A AC/DC module leaves limited conversion and thermal
 * headroom at the 18 W USB rating. Full-load thermal/efficiency testing,
 * including the 15 V to 12 V / 1.5 A operating point, is a hardware release
 * gate.
 * The carrier adds fused surge, inrush and common-mode filtering plus
 * secondary TVS/ESD protection. Physical safety and compliance remain subject
 * to accredited-laboratory testing of the final enclosure and production unit.
 */
export const UsbCPd18WWallCharger = () => (
  <>
    <board
      name="USB_C_PD_18W_WALL_CHARGER"
      title="85-265 VAC to USB-C PD 18 W Engineering Prototype"
      width="110mm"
      height="60mm"
      borderRadius="2mm"
      thickness="1.6mm"
      material="fr4"
      layers={2}
      isViaInPadAllowed
      solderMaskColor="#176b43"
      defaultTraceWidth="0.25mm"
      autorouterVersion="beta_pipeline9"
      autorouterEffortLevel="5x"
      schMaxTraceDistance="3mm"
    >
    <schematicsheet name="mains" displayName="AC Input and Isolated AC/DC Module" sheetIndex={1} />
    <schematicsheet name="pd" displayName="18 W USB-C PD Buck SoC Output" sheetIndex={2} />
    <schematicsection name="ac_input" displayName="Hazardous 85-265 VAC Input" />
    <schematicsection name="mains_filter" displayName="Fused Surge / Inrush / EMI Filter" />
    <schematicsection name="isolated_dc" displayName="Isolated 15 V Supply" />
    <schematicsection name="pd_output" displayName="USB-C PD Output" />

    {/* Four non-plated mounting holes support fixed enclosure standoffs. */}
    <hole name="H1" diameter="3.2mm" pcbX={-50} pcbY={25} />
    <hole name="H2" diameter="3.2mm" pcbX={-50} pcbY={-25} />
    <hole name="H3" diameter="3.2mm" pcbX={50} pcbY={25} />
    <hole name="H4" diameter="3.2mm" pcbX={50} pcbY={-25} />

    {/* The external mains lead must use a rated cable gland and strain relief. */}
    <WJ500V_5_08_2P
      name="J1"
      pcbX={-49}
      pcbY={0}
      pcbRotation={90}
      schSheetName="mains"
      schSectionName="ac_input"
      schX={-10.11}
      schY={1}
      connections={{ L: "net.AC_L", N: "net.AC_N" }}
    >
      <enclosure.cutoutaperture shape="circle" radius="4mm" margin="0.5mm" />
    </WJ500V_5_08_2P>
    <SCT1032T2A250V
      name="F1"
      pcbX={-47}
      pcbY={-13}
      pcbRotation={90}
      schSheetName="mains"
      schSectionName="ac_input"
      schX={-8.08}
      schY={1}
      connections={{ pin1: "net.AC_L", pin2: "net.AC_L_FUSED" }}
    />
    <MOV_14D471K
      name="RV1"
      pcbX={-34}
      pcbY={-25.5}
      schSheetName="mains"
      schSectionName="mains_filter"
      schX={-7}
      schY={-2}
      connections={{ pin1: "net.AC_L_FUSED", pin2: "net.AC_N" }}
    />
    <MF72_5D9
      name="TH1"
      pcbX={-37}
      pcbY={-13}
      schSheetName="mains"
      schSectionName="mains_filter"
      schX={-5.7}
      schY={1}
      connections={{ pin1: "net.AC_L_FUSED", pin2: "net.AC_L_LIMITED" }}
    />
    <XRSQ1010_10mH_H
      name="LCM1"
      pcbX={-23}
      pcbY={-16}
      schSheetName="mains"
      schSectionName="mains_filter"
      schX={-3}
      schY={1}
      connections={{
        pin1: "net.AC_L_LIMITED",
        pin2: "net.AC_L_FILTERED",
        pin3: "net.AC_N_FILTERED",
        pin4: "net.AC_N",
      }}
    />
    <B32922C3104M189
      name="C7"
      maxVoltageRating="305V"
      pcbX={-5}
      pcbY={-16}
      schSheetName="mains"
      schSectionName="mains_filter"
      schX={-1}
      schY={-2}
      connections={{ pin1: "net.AC_L_FILTERED", pin2: "net.AC_N_FILTERED" }}
    />
    {/* Two series 200 V resistors discharge the X2 capacitor C7 while sharing the mains voltage. */}
    <resistor
      name="R3"
      resistance="1Mohm"
      tolerance="1%"
      manufacturerPartNumber="1206W4F1004T5E"
      supplierPartNumbers={{ jlcpcb: ["C17927"] }}
      footprint="res1206"
      pcbX={-8}
      pcbY={-21}
      schSheetName="mains"
      schSectionName="mains_filter"
      schX={1}
      schY={-2.6}
      connections={{ pin1: "net.AC_L_FILTERED", pin2: "net.X_CAP_BLEED_MID" }}
    />
    <resistor
      name="R4"
      resistance="1Mohm"
      tolerance="1%"
      manufacturerPartNumber="1206W4F1004T5E"
      supplierPartNumbers={{ jlcpcb: ["C17927"] }}
      footprint="res1206"
      pcbX={-2}
      pcbY={-21}
      schSheetName="mains"
      schSectionName="mains_filter"
      schX={3}
      schY={-2}
      connections={{ pin1: "net.X_CAP_BLEED_MID", pin2: "net.AC_N_FILTERED" }}
    />
    <HLK_20M15C
      name="U1"
      pcbX={-8}
      pcbY={11}
      schSheetName="mains"
      schSectionName="isolated_dc"
      schX={2}
      schY={1}
      schWidth={1.865}
      schHeight={0.6}
      schPinArrangement={{
        leftSide: { direction: "top-to-bottom", pins: ["AC1", "AC2"] },
        rightSide: { direction: "top-to-bottom", pins: ["VOUT_15V", "GND"] },
      }}
      connections={{
        AC2: "net.AC_N_FILTERED",
        AC1: "net.AC_L_FILTERED",
        VOUT_15V: "net.VIN_15V",
        GND: "net.GND",
      }}
    />

    {/* Standard non-PPS IP6520 reference application: local input bulk and high-frequency bypass. */}
    <RVE100UF35V67RV0072
      name="C1"
      maxVoltageRating="35V"
      polarized
      pcbX={26}
      pcbY={0}
      schSheetName="pd"
      schSectionName="isolated_dc"
      schX={-8}
      schY={2.42}
      connections={{ pin1: "net.VIN_15V", pin2: "net.GND" }}
    />
    <capacitor
      name="C2"
      capacitance="100nF"
      maxVoltageRating="50V"
      manufacturerPartNumber="CC0603KRX7R9BB104"
      supplierPartNumbers={{ jlcpcb: ["C14663"] }}
      footprint="cap0603"
      pcbX={24}
      pcbY={8}
      schOrientation="vertical"
      schSheetName="pd"
      schSectionName="isolated_dc"
      schX={-6}
      schY={3}
      connections={{ pin1: "net.VIN_15V", pin2: "net.GND" }}
    />
    <SMBJ15A
      name="D1"
      pcbX={27}
      pcbY={-14}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="isolated_dc"
      schX={-4}
      schY={-1}
      schWidth={0.6}
      connections={{ C: "net.VIN_15V", A: "net.GND" }}
    />
    <IP6520StandardNonPps
      name="U2"
      pcbX={30}
      pcbY={8}
      pcbRotation={180}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={0}
      schY={1}
      schWidth={1.865}
      schHeight={1}
      schPinArrangement={{
        leftSide: { direction: "top-to-bottom", pins: ["VIN", "BST", "CC1", "CC2"] },
        rightSide: { direction: "top-to-bottom", pins: ["SW", "VOUT", "DP", "DM", "GND"] },
      }}
      connections={{
        VIN: "net.VIN_15V",
        GND: "net.GND",
        SW: "net.SW",
        BST: "net.BST",
        VOUT: "net.VBUS_OUT",
        DM: "net.USB_DM",
        DP: "net.USB_DP",
        CC1: "net.CC1",
        CC2: "net.CC2",
      }}
    />
    <via name="U2_EP_1" pcbX={29.45} pcbY={7.55} connectsTo="net.GND" outerDiameter="0.55mm" holeDiameter="0.25mm" />
    <via name="U2_EP_2" pcbX={30.55} pcbY={7.55} connectsTo="net.GND" outerDiameter="0.55mm" holeDiameter="0.25mm" />
    <via name="U2_EP_3" pcbX={29.45} pcbY={8.45} connectsTo="net.GND" outerDiameter="0.55mm" holeDiameter="0.25mm" />
    <via name="U2_EP_4" pcbX={30.55} pcbY={8.45} connectsTo="net.GND" outerDiameter="0.55mm" holeDiameter="0.25mm" />
    <capacitor
      name="C3"
      capacitance="2.2uF"
      maxVoltageRating="25V"
      manufacturerPartNumber="GRM188Z71E225KE43D"
      supplierPartNumbers={{ jlcpcb: ["C415535"] }}
      footprint="cap0603"
      pcbX={28}
      pcbY={14}
      schOrientation="vertical"
      schSheetName="pd"
      schSectionName="pd_output"
      schX={3}
      schY={3}
      connections={{ pin1: "net.BST", pin2: "net.SW" }}
    />

    {/* Orderable 22 uH / 16 A, 8 mOhm buck inductor. The old EMI chokes were removed with the flyback stage. */}
    <PDMTAT068125_220MLU
      name="L1"
      pcbX={40.5}
      pcbY={8}
      pcbRotation={270}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={4}
      schY={1}
      connections={{ pin1: "net.SW", pin2: "net.VBUS_OUT" }}
    />
    <resistor
      name="R1"
      resistance="2ohm"
      tolerance="1%"
      manufacturerPartNumber="FRC0603F2R00TS"
      supplierPartNumbers={{ jlcpcb: ["C2933191"] }}
      footprint="res0603"
      pcbX={31}
      pcbY={14}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={2}
      schY={-1.42}
      connections={{ pin1: "net.SW", pin2: "net.SNUB" }}
    />
    <capacitor
      name="C6"
      capacitance="1nF"
      maxVoltageRating="50V"
      manufacturerPartNumber="GRM1885C1H102JA01D"
      supplierPartNumbers={{ jlcpcb: ["C77026"] }}
      footprint="cap0603"
      pcbX={31}
      pcbY={17}
      schOrientation="vertical"
      schSheetName="pd"
      schSectionName="pd_output"
      schX={4}
      schY={-2}
      connections={{ pin1: "net.SNUB", pin2: "net.GND" }}
    />

    {/* Output capacitors are rated above the highest 12 V PDO. */}
    <RVT1E101M0607
      name="C4"
      maxVoltageRating="25V"
      polarized
      pcbX={40}
      pcbY={-10}
      pcbRotation={180}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={7}
      schY={2.42}
      connections={{ pin1: "net.VBUS_OUT", pin2: "net.GND" }}
    />
    <resistor
      name="R2"
      resistance="0ohm"
      manufacturerPartNumber="0603WAF0000T5E"
      supplierPartNumbers={{ jlcpcb: ["C21189"] }}
      footprint="res0603"
      pcbX={51}
      pcbY={-15}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={14.5}
      schY={-2}
      schOrientation="vertical"
      connections={{ pin1: "net.USB_SHIELD", pin2: "net.GND" }}
    />
    <capacitor
      name="C5"
      capacitance="100nF"
      maxVoltageRating="50V"
      manufacturerPartNumber="CC0603KRX7R9BB104"
      supplierPartNumbers={{ jlcpcb: ["C14663"] }}
      footprint="cap0603"
      pcbX={49}
      pcbY={8}
      schOrientation="vertical"
      schSheetName="pd"
      schSectionName="pd_output"
      schX={9}
      schY={3}
      connections={{ pin1: "net.VBUS_OUT", pin2: "net.GND" }}
    />
    <SMBJ13A
      name="D2"
      pcbX={46}
      pcbY={-20}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={7}
      schY={-2.6}
      schWidth={0.6}
      connections={{ C: "net.VBUS_OUT", A: "net.GND" }}
    />
    {/* Low-capacitance bidirectional ESD clamps sit next to the exposed port. */}
    <PESD5V0H1BSF
      name="D3"
      pcbX={47.5}
      pcbY={-8.8}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={8.5}
      schY={-2}
      connections={{ pin1: "net.CC1", pin2: "net.GND" }}
    />
    <PESD5V0H1BSF
      name="D4"
      pcbX={46.5}
      pcbY={-10.2}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={9.81}
      schY={-2}
      connections={{ pin1: "net.CC2", pin2: "net.GND" }}
    />
    <PESD5V0H1BSF
      name="D5"
      pcbX={47.5}
      pcbY={-6}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={11.5}
      schY={-2}
      connections={{ pin1: "net.USB_DP", pin2: "net.GND" }}
    />
    <PESD5V0H1BSF
      name="D6"
      pcbX={47.5}
      pcbY={-7.4}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={13.29}
      schY={-2}
      connections={{ pin1: "net.USB_DM", pin2: "net.GND" }}
    />
    <TYPE_C_31_M_12
      name="J2"
      pcbX={51}
      pcbY={0}
      pcbRotation={90}
      schSheetName="pd"
      schSectionName="pd_output"
      schX={13}
      schY={1}
      connections={{
        CC1: "net.CC1",
        CC2: "net.CC2",
        DP1: "net.USB_DP",
        DP2: "net.USB_DP",
        DN1: "net.USB_DM",
        DN2: "net.USB_DM",
        VBUS1: "net.VBUS_OUT",
        VBUS2: "net.VBUS_OUT",
        GND1: "net.GND",
        GND2: "net.GND",
        SH1: "net.USB_SHIELD",
        SH2: "net.USB_SHIELD",
        SH3: "net.USB_SHIELD",
        SH4: "net.USB_SHIELD",
      }}
      noConnect={["SBU1", "SBU2"]}
    >
      <enclosure.cutoutaperture shape="pill" width="10mm" height="4mm" margin="0.25mm" />
    </TYPE_C_31_M_12>

    {/* Ground copper is restricted to the isolated low-voltage side. */}
    <copperpour
      name="ISOLATED_GND_BOTTOM"
      layer="bottom"
      connectsTo="net.GND"
      padMargin="0.2mm"
      traceMargin="0.15mm"
      outline={[{ x: 24, y: -28 }, { x: 54, y: -28 }, { x: 54, y: 28 }, { x: 24, y: 28 }]}
    />
    {/* An 8 mm all-layer copper-free corridor separates primary and SELV copper. */}
    <keepout shape="rect" layers={["top", "bottom"]} pcbX={10} pcbY={0} width="8mm" height="60mm" />
    <fabricationnoterect pcbX={10} pcbY={0} width="8mm" height="58mm" hasStroke isStrokeDashed strokeWidth={0.25} color="#d97706" />
    <fabricationnotetext text="8 mm PRIMARY/SELV COPPER KEEPOUT" pcbX={10} pcbY={0} fontSize="1mm" anchorAlignment="center" color="#d97706" />

    {/* Isolated-side test access for production and compliance measurements. */}
    <testpoint name="TP1" footprintVariant="pad" padShape="circle" padDiameter="1.5mm" pcbX={25} pcbY={-21} schSheetName="pd" schSectionName="isolated_dc" schX={-5} schY={-4} connections={{ pin1: "net.VIN_15V" }} />
    <testpoint name="TP2" footprintVariant="pad" padShape="circle" padDiameter="1.5mm" pcbX={29} pcbY={-24} schSheetName="pd" schSectionName="isolated_dc" schX={-3} schY={-4} connections={{ pin1: "net.GND" }} />
    <testpoint name="TP3" footprintVariant="pad" padShape="circle" padDiameter="1.5mm" pcbX={33} pcbY={-24} schSheetName="pd" schSectionName="pd_output" schX={5} schY={-4} connections={{ pin1: "net.VBUS_OUT" }} />

    <silkscreentext text="DANGER: HAZARDOUS MAINS" pcbX={-41} pcbY={28} fontSize="0.8mm" />
    <silkscreentext text="100-240VAC 50/60Hz" pcbX={-39} pcbY={-29} fontSize="0.65mm" />
    <silkscreentext text="L" pcbX={-52} pcbY={-4} fontSize="0.8mm" />
    <silkscreentext text="N" pcbX={-46} pcbY={-4} fontSize="0.8mm" />
    <silkscreentext text="HLK-20M15C ISOLATED MODULE" pcbX={-8} pcbY={-8} fontSize="0.75mm" />
    <silkscreentext text="ISOLATED 15V" pcbX={28} pcbY={27} fontSize="0.7mm" />
    <silkscreentext text="U2 IP6520 STD / NO PPS" pcbX={34} pcbY={24} fontSize="0.6mm" />
    <silkscreentext text="USB-C PD OUT" pcbX={46} pcbY={-10} fontSize="0.75mm" />
    <silkscreentext text="5V/3A  9V/2A  12V/1.5A" pcbX={42} pcbY={-28} fontSize="0.65mm" />
    </board>
    {/* Fit-check shell only. Production requires a lab-reviewed, flame-retardant enclosure. */}
    <enclosure.fdm.box
      boardRef=".USB_C_PD_18W_WALL_CHARGER"
      width="116mm"
      height="66mm"
      depth="42mm"
      wallThickness="2mm"
    />
  </>
)

export const UsbCPd18WCharger = UsbCPd18WWallCharger
export default UsbCPd18WWallCharger