Open-source 140W+65W buck-boost PD3.1 fast charging module (2C+1A ports), IP6557+IP6538, 205W desktop charger

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Open-source 205W buck-boost fast charging module based on IP6557 and IP6538 chips (140W+65W), featuring one Type-C port supporting PD3.1 protocol with maximum output of 28V5A, and another combination of Type-A and Type-C ports with maximum output of 65W (20V3.25A). When paired with a 24V10A switching power supply, it forms a low-cost 205W fast charger! Maximum conversion efficiency of 96.7%

This design is not perfect, experts please don’t flame. If you have any suggestions for improvement, feel free to leave comments below. Friendly communication is welcome.

Complete documentation provided, fully replicable. Download link at the end of this article!

Video demonstration: https://www.bilibili.com/video/BV1HM4m1U7Hc/

LCSC Open-source Platform Link: https://url.zeruns.com/99439

Electronics/MCU Technical Exchange QQ Group: 2169025065

Introduction

This fast charging module combined with a 24V10A power supply forms a low-cost 205W dual-port fast charger! (24V10A power supply costs around ¥30)

Using a cigarette lighter to DC male/XT30 adapter can convert it into a car charger, creating a 140W+65W automotive fast charging solution!

The module has two input interfaces: XT30 and DC5.5 (these two input interfaces cannot be used simultaneously, they are connected in parallel!)

Input voltage range: 8.2~31V

C1 port is buck-boost capable (output voltage can be higher than input), while C2 and A ports are buck-only (output voltage must be lower than input)

Regarding IP6557 chips: I purchased 8 pieces and soldered them all, but 4 were defective (various failure symptoms). Only 4 worked properly. Not sure if this was chip quality/control issue or my soldering problem (heating platform temperature set at 230°C, no cold soldering detected). All IP6538 chips worked perfectly without issues. Both chips were purchased from the same store.

I’ve made several finished units. Those interested in purchasing ready-made modules can contact me through the QQ group.

Specifications and Details

C1 Port (IP6557)

The first Type-C power chip is INJOINIC’s IP6557-C, delivering maximum output power of 140W with 28V/5A (actual maximum可达6A) output.

Input Voltage Range: 5~31V

This buck-boost chip allows output voltage higher than input voltage.

Supported Fast Charging Protocols:

  • PD3.1/PPS/ERP28V
  • BC1.2 and APPLE
  • QC2.0/QC3.0/QC3+/QC4+/QC5
  • FCP and HSCP
  • AFC
  • MTK
  • UFCS (Unified Fast Charging)

Supports output voltages: 5V, 9V, 12V, 15V, 20V, 28V

PPS supports 3.3V-21V voltage output with 10mV/step adjustment.

C2 and A1 Ports (IP6538)

The second Type-C and Type-A ports use IP6538-AC-65W chip, delivering maximum 20V/3.25A (65W) when using single Type-C port, and 5V/4.8A total output when both ports are used simultaneously.

Input Voltage Range: 8.2V~32V (both chips share same input, so maximum remains 31V)

This chip is buck-only, so output voltage cannot exceed input voltage. To achieve 65W output, input voltage must be above 21V

Note: IP6538 has two versions (45W and 65W). Those without “-65W” suffix are 45W version! (The documentation below provides datasheets for 45W version, no datasheet available for 65W version)

Supported Fast Charging Protocols:

  • PD2.0 / PD3.0(PPS), Type-A port does NOT support PD protocol
  • BC1.2, Apple, Samsung protocols
  • QC2.0 and QC3.0
  • MTK PE+1.1 and MTK PE+2.0
  • Huawei FCP/SCP
  • Samsung AFC
  • Spreadtrum SFCP
  • OPPO VOOC / Super VOOC (65W version appears to NOT support OPPO fast charging protocol, 45W version untested. May require original charging cable to trigger)

Supports output voltages: 5V, 9V, 12V, 15V, 20V

PPS supports 3.3V~11V voltage output with 20mV/step adjustment.

Physical Photos

Front view of PCB

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Back view of PCB. The flying wires in the photo below were caused by misinterpretation of the official application schematic in the IP6557 datasheet (missing connection dots at crossing lines). This issue has been fixed in the schematic and PCB files I released.

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Side view of PCB

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After installing the aluminum alloy enclosure (enclosure purchased separately, front/back covers 3D printed by myself)

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Review of Bambu Lab P1SC 3D printer: https://blog.zeruns.com/archives/770.html

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Close-up of soldered IP6557 chips

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Close-up of soldered IP6538 chips

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Testing with colorful silkscreen printing

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Usage Instructions & Notes

1. To achieve 28V/5A output, you must use a data cable with E-Marker chip that supports PD3.1 protocol, as shown below.

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2. The input current sampling resistor (current sensing resistor) R2 on this board is 5mΩ. The IP6557 chip’s input current limit is set at 10A. When input voltage is 12V, achieving 140W output requires minimum input current of 12A, exceeding the limit and causing voltage drop. To resolve this, replace R2 with smaller resistance (e.g., 2.5mΩ by paralleling two 5mΩ resistors) to enable full power output at 12V input. However, this will significantly increase MOSFET heat dissipation, requiring proper heatsinking!

The two images below show: one before modifying the current sensing resistor (input current limited to <10A), and one after modification (input current exceeds 10A). The 28V/5A output at 12V input was tested at 14V input due to my adjustable power supply’s maximum output of 12A being insufficient.

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3. When selecting alternative MOSFETs, note that the Ciss parameter must be <1000pF. The IP6557 operates at 250kHz switching frequency, which requires strict input capacitance control. Excessive Ciss will affect MOSFET switching times.

Protocol Support Testing

C1 port protocol support shown below:

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C1 port also supports UFCS protocol, but limited to 33W.

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C2 port protocol support shown below:

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A port protocol support shown below:

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Load Testing

C1 port testing: XT30 input at 24V, output set to 28V with electronic load set to 5.3A current.

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C2 port testing

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A port testing

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Dual-port full load testing

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Testing equipment used:

Conversion Efficiency Testing

Efficiency tested at various input/output voltage combinations for both C1 and C2 ports.

IP6557

Maximum conversion efficiency: 95.468%

Input Voltage(V) Input Current(A) Input Power(W) Output Voltage(V) Output Current(A) Output Power(W) Conversion Efficiency(%)
23.997 6.459 154.997 27.592 5.323 146.872 94.758
11.999 9.598 115.166 19.980 5.345 106.793 92.729
8.299 8.897 73.836 20.030 3.336 66.820 90.498
23.997 4.686 112.450 20.100 5.341 107.354 95.468
23.997 1.764 42.331 12.001 3.337 40.047 94.606

IP6538

Maximum conversion efficiency: 96.719%

Input Voltage(V) Input Current(A) Input Power(W) Output Voltage(V) Output Current(A) Output Power(W) Conversion Efficiency(%)
24.008 0.795 19.086 5.165 3.315 17.122 89.708
24.008 1.265 30.370 12.217 2.335 28.527 93.930
24.008 2.910 69.863 20.243 3.338 67.571 96.719
24.008 0.933 22.399 9.084 2.245 20.394 91.045

Thermal Imaging

Thermal imaging of C1 port PCB after 5 minutes of 140W full load output. MOSFETs reach temperatures above 111°C. Heatsinks or aluminum enclosure with thermal pads are mandatory for full load operation.

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Thermal imaging of C2 port PCB after 10 minutes of 65W full load output. IP6538 chip reaches about 75°C. Full load operation possible without heatsink.

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Thermal imaging of aluminum enclosure after 10 minutes of dual-port full load output. Maximum enclosure temperature about 65°C. Due to the split enclosure design with gaps in the middle, heat mainly concentrates in the bottom half.

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Ripple Testing

Ripple rate calculation formula:

Ripple Rate = \frac{(Ripple Peak - Ripple Valley)/2}{Output Average Voltage} \times 100\%

C1 port output at 28V (actual 27.6V) shows ~33mV peak-to-peak ripple, resulting in 0.059% ripple rate.

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C1 port output at 28V5.2A shows ~178mV peak-to-peak ripple, resulting in 0.323% ripple rate.

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C2 port output at 20V no-load shows ~25mV peak-to-peak ripple, resulting in 0.062% ripple rate.

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C2 port output at 20V3.3A shows ~54mV peak-to-peak ripple, resulting in 0.133% ripple rate.

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Ripple performance is quite good.

Schematic Diagram

IP6557:

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IP6538:

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PCB Layout

Top Layer:

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Bottom Layer:

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Component Purchase Links

Here are the purchase links for most of the components used in this project:

Recommended to purchase components at LCSC Mall: https://activity.szlcsc.com/invite/D03E5B9CEAAE70A4.html

Click “Immediate Order” in the BOM table from the LCSC open-source link to import required components into your shopping cart with one click.

Download Links

The following links include: LCEDA project files, schematic PDFs, datasheets for used chips, and enclosure 3D models.

Baidu Cloud Disk: https://pan.baidu.com/s/1RJNC_v2P1YijWpv1sFXowQ?pwd=89hi (Password: 89hi)

123 Cloud Disk: https://www.123pan.com/s/2Y9Djv-BItvH.html (Password: 0nEm)

If you find this helpful, please consider donating through the 123 Cloud Disk link above. If this is from a WeChat article (Official Account: zeruns-gzh), you can also click “Like Author” at the bottom of the article to donate. Thank you.

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