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Charger rôle & specifications
• Model: EP-TA800 / TA-800 • Input: 100-240 V ac, 50/60 Hz, ≤0.7 A
• PDOs: 5 V @ 3 A | 9 V @ 2.77 A
• PPS: 3.3–5.9 V @ 3 A | 3.3–11 V @ 2.25 A
Top-level architecture (isolated fly-back, synchronous output)
(AC) PRIMARY (HV, unsafe) ISOLATION SECONDARY (LV)
Line ── Fuse ─┬─ NTC ─ EMI-L/C ─ Bridge ─ Bulk-C ──────┬───────────────┬──► SR-MOSFET ─ LC-filter ─► VBUS
│ │ │
Neutral ───────┴────────────────────────────────────────┘ Transformer └─► Opto/TL431 ▬▭ feedback
▲ | │
│ └── GP801LS PWM + HCD70R600 MOSFET ◄──┘
▼
USB-PD / PPS controller (AP43771) → VBUS switch (SFTN7422)
⇅ CC1/CC2 negotiation to handsetStage-by-stage explanation
Primary
• EMI filter: fuse, NTC inrush, CM choke, X/Y caps.
• Rectification: GBU-type bridge to ≈325 V dc (on 230 V mains).
• Bulk storage: 22 µF + 15 µF, 400 V electrolytics laid horizontally to save height.
• Power switch: GP801LS (integrated HV start-up, 65–130 kHz) drives HCD70R600 (700 V, 600 mΩ) MOSFET.
• Control: Current-mode PWM with OVP/OTP/OCP; start-up via internal high-voltage regulator, then auxiliary winding.
Isolation & feedback
• Flat, planar transformer for slim profile.
• Everlight optocoupler + TL431 shunt regulator supply precise voltage feedback under USB-PD controller command.
Secondary
• Synchronous rectifier: PDC6986BZ-5 replaces Schottky for ≈95 % peak efficiency.
• Output filter: 600 µF/14 V polymer cap + multiple X7R ceramics for low ESR/ESL.
• Protocol/MCU: AP43771 runs USB-PD 3.0 w/ PPS; measures V/I, negotiates 20 mV PPS steps, supervises protection.
• Load switch: SFTN7422SMP-HAF provides OCP/OTP and disconnects VBUS at fault or no load.
Protection layers
• Primary: fuse, OVP, OCP, hiccup-mode.
• Isolation: ≥4 mm creepage, reinforced tape on core, Y-cap to return-path ground.
• Secondary: VBUS OCP (~3.4 A), OVP (~13 V), SCP shut-down, thermal fold-back.
Known failure modes (field data from repair forums)
• Open start-up resistor → no primary VCC, charger dead.
• Shorted HCD70R600 → blown fuse, zero output.
• Dry polymer output cap → high ripple, phone drops out of PPS.
• Cracked USB-C receptacle pins (especially CC line) → only 5 V legacy charge.
• 2023-2024 chargers in the same power class migrate to GaN integrated fly-back (PI InnoSwitch3-Pro, Navitas NV6xx) offering higher efficiency and smaller size; Samsung kept Si-MOSFET for cost.
• USB-PD 3.1 (up-to 28 V, 140 W) is emerging; TA-800 is limited to PD 3.0/PPS 11 V. Future Samsung adapters (>45 W) adopt PD 3.1 EPR.
• Industry pushes towards high-density planar transformers and co-packaged SR/PWM to shrink wall-warts below 25 cm³.
Why synchronous rectification?
\[
\text{P}_{\text{loss}}^{\text{diode}} = I \times VF,\qquad
\text{P}{\text{loss}}^{\text{SR}} = I^2 \times R_{DS(on)}
\]
At 3 A, V_F ≈ 0.45 V ⇒ 1.35 W vs. SR MOSFET R_DS(on) ≈ 8 mΩ ⇒ 0.072 W; ≈19× less heat.
Partial primary schematic (extracted from GP801LS datasheet, values from teardown)
HV_DC ──+──22µ/400V──+─────+─► T pri
| | |
| RCS 0.2Ω|<─ ISENSE
| | |
+──NTC──Fuse─+── HCD70R600 Drain
GP801LS
VCC ◄─ 10µ/50V aux winding
CS │
FB ◄─ opto• The exact Samsung service schematic is copyright-protected; distributing it without permission infringes IP laws.
• Teardowns and reverse-engineered drawings are legal under fair-use in most jurisdictions, but re-publication of Samsung’s original documents is not.
• Working on mains SMPS poses lethal shock risk; always use isolation transformer, discharge bulk cap, follow IEC 60950/62368 safety.
Obtaining working documentation
Diagnostic workflow
Common component substitutes
• GP801LS ↔ PI InnoSwitch3-CP (if redesigning, not repairing).
• PDC6986BZ-5 ↔ AOZ8661, SRK2001.
Challenges
• Board uses black epoxy “glue-shield” near transformer—must be scraped carefully.
• Horizontal electrolytics are soldered with folded leads; desolder from reverse side.
• Re-engineering to produce clone chargers may violate Samsung patents and regional safety certification (UL, CE).
• The PPS algorithm is firmware inside AP43771; behaviour cannot be altered without IC re-programming.
• Study DIODES Inc. reference design “DER888: 33 W PD/PPS charger using GP801LS + AP43771” (public, schematic included).
• Look up IEC 62368-1 testing requirements (touch current, leakage, creepage) for designing compliant replacements.
• Explore open-source USB-PD projects (USB-C-PD-sink/source by Micropendous, USB-PD PHY on STM32G0) to interface with TA-800 for advanced logging.
An official EP-TA800 schematic is not in the public domain, but detailed teardowns and IC application notes let engineers reconstruct the design: a high-frequency fly-back converter (GP801LS + HCD70R600) with synchronous rectification (PDC6986) and a dedicated USB-PD/PPS controller (AP43771). Armed with teardown photos, datasheets, and standard SMPS know-how, you can trace the board, diagnose faults, or adapt similar reference designs—while observing safety protocols and respecting Samsung’s IP rights.