Preface
NOT LONG AGO, THE CHARGING HEAD NETWORK DISASSEMBLED THE DJI POWER 1000 POWER STATION, AND THIS ISSUE OF DISMANTLING BRINGS ANOTHER DJI POWER 500 POWER STATION WITH A SMALLER CAPACITY. This power station has a built-in 512Wh lithium iron phosphate battery, weighs about 7.2kg, and has a handle on the side for easy carrying.
THE DJI POWER 500 POWER STATION SUPPORTS 1000W OUTPUT POWER AND HAS A UPS FUNCTION. The power station supports 540W fast charging mode and 270W normal mode charging, and also supports USB-C port and SDC port charging. Both USB-C ports can charge the outdoor power supply, with a single port input power of 100W and two ports charging input power of 200W.
The USB-C port supports 100W fast charging output, and the USB-A port supports 24W fast charging output, and each interface is designed independently. The SDC Lite connector supports a 300W charge input and a 240W discharge output. The body screen has input and output power display, battery percentage display and remaining time display. LET'S TAKE A TEARDOWN OF THE DJI POWER 500 POWER STATION, LET'S TAKE A LOOK AT THE INTERNAL MATERIALS AND DESIGN.
DJI Power 500 unboxing
The product is packaged in a kraft cardboard box with DJI POWER 500 printed on the front and a sketch of the product's appearance.
There are product parameter stickers on the side, and we will introduce the details to the product physical display.
The power station continues the same design language as the DJI POWER 1000, but the size is smaller, and the top handle is single-sided, which also has its own unique identity.
There is an integrated carrying handle on the top side of the fuselage, which is convenient for users to handle.
The top center is designed with the DJI brand.
The two-in-one design of the switch key and indicator light in the lower right corner of the top surface is convenient for users to intuitively understand whether the product is started or not.
The front end of the fuselage is equipped with a digital display screen, 2A2C four USB ports, two sets of 3+2 new national standard AC AC jacks, SDC Lite and AC charging interfaces.
The digital display screen can display the remaining power, input and output power in real time, and the AC output function module is equipped with an independent on/off key, and each group of AC jacks is equipped with corresponding indicator lights for easy observation. The SDC Lite and AC charging ports are covered with protective covers, and the AC input supports 540W and 270W charging modes and can be switched flexibly.
The other end is designed with an inclined plane above the grille and a grille heat dissipation hole.
The lower casing is affixed with a product nameplate
AC输出(x2)：CN：220V-，50/60Hz，1000W max；
EU：230V-，50/60Hz，1000W max；
UK：230V-，50/60Hz，1000W max；
AU：230V-，50/60Hz，1000W max；
AC输出(旁路)(x2)：220-240V-，50/60Hz，1000W max（total）；
USB-A输出(x2):5V3A、9V2A、12V2A 24W max;
USB· C输出(x2)：5/9/12/15/20V5A，100W max；
AC输入：220-240V-，50/60Hz，5A max；
SDC Lite输入：22.4-29.2V，10A max，300W max；
USB-C输入：5/9/12/15/20V5A，100W max；
SDC Lite输出：9-27V，240W max；
额定容量：20Ah，25.6V，512Wh；
Discharge ambient temperature: -10-45°C
Charging ambient temperature: 0-45°C
Manufacturer: Shenzhen DJI Technology Co., Ltd
产品通过了CCC、CE、EAC、UKCA、KC认证。
There are anti-slip pads on both sides of the bottom to play the role of anti-slip and cushion protection products.
The length of the body of the outdoor power station is about 31.5cm.
The height is about 17cm.
The thickness is about 20.5cm.
The overall weight of the product is about 7.195kg.
使用ChargerLAB POWER-Z KM003C测得USB-C口支持SCP、QC3.0、PD3.0、PPS、QC5、DCP、Apple 2.4A充电协议。
PDO报文显示USB-C口还具备5V5A、9V5A、12V5A、15V5A、20V5A五组固定电压档位,以及3.3-21V5A一组PPS电压档位。
测得USB-A口支持Apple 2.4A、Samsung 5V2A、DCP、QC2.0/3.0、SCP充电协议。
The AC output jack voltage was measured to be 219.5V.
The output frequency is 50Hz.
Use the 570W fast charging mode to charge the outdoor power station, and the input power is 593W through the display.
Use the 270W standard charging mode to charge the outdoor power station, and the input power is 293W through the display.
A single charger is used to quickly charge the product through the USB-C port of the outdoor power station, and the input power is measured to be 91W.
Using two chargers to charge simultaneously through two USB-C ports, the power can be stacked, and the input power is 179W.
DJI Power 500 disassembly
AFTER READING THE UNBOXING AND DISPLAY OF THE DJI POWER 500 POWER STATION, LET'S TEAR IT DOWN AND TAKE A LOOK AT THE INTERNAL DESIGN AND MATERIALS.
On the side of the fuselage there is a ventilation grille.
Remove the ventilation grille, set up a dust filter on the grille, and use the cooling fan inside.
Unscrew the set screws on the sides of the fuselage.
Remove the side cover of the fuselage.
There are air outlets on the side cover and are equipped with dust filters.
The other side of the cover is also equipped with an air outlet.
The body of the outdoor power station is the upper and lower shells, which are fixed by screws.
Close-up of the screws securing the upper and lower housings, with tamper-evident labels.
Remove the upper cover, and inside is a bidirectional inverter module.
Foam cushioning is applied to the inside of the housing.
A copper foil shield is pasted in the middle of the foam.
The inside of the fuselage is at a glance, with the battery pack at the bottom, the bidirectional inverter module at the top, and the fast charging panel on the right.
A metal nut is embedded in the housing.
Unscrew the fixing screws and remove the connecting cables between the battery pack and the inverter module.
The AC output and input line of the inverter module are directly welded and connected, and the wire solder joints are glued and reinforced.
The side panel is removed, and the input and output sockets are connected by wires.
Remove the cooling fan from the inside of the fuselage.
The cooling fan is from AVC, model DS06025B12UPT02, specification is 12V0.7A, and ball bearings are used. There are rubber pads on the top and bottom of the fan to play the role of buffer sealing.
The bidirectional inverter module is screwed to the housing.
Unscrew the fixing screws to remove the inverter module, and the supporting aluminum plate is below.
Unscrew the set screws of the battery pack.
Remove the battery pack from the case.
The side of the battery pack is provided with a protection plate, the protection plate is insulated with white glue as a whole, and the protection plate is connected and fixed by screws.
The other side of the battery pack is covered with white glue and equipped with a wiring connector.
The side of the battery pack is equipped with wiring for battery cell voltage detection.
Remove the aluminum alloy cover on the front of the battery pack and observe the battery pack cells.
The built-in lithium iron phosphate battery of the outdoor power station is from Penghui, model GPHN IFR40135-20AH, the battery voltage is 3.2V, the capacity is 20Ah, and the energy is 64Wh.
The battery pack voltage was measured at 26.3V using a multimeter.
The battery protection plate is connected to the battery by a binding post.
The front of the battery protection plate is glued and sealed as a whole to protect the components. On both sides is the battery pack connection terminal, the middle terminal is used to connect the bidirectional inverter module, and the upper right corner is connected to the wire for the fast charging panel.
Clean off the sealant, and on the top left side of the protection board is the current sampling resistor, the lower part is the battery protection chip, and the lower part is the battery equalization resistor. The middle position is the main control MCU, and the right side is equipped with the driver chip, memory, battery protection tube and fuse.
The main control MCU of GD32L233RCT6 the protection board is a Cortex-M23 low-power 32-bit processor with built-in 256KB FLASH and 32KB SRAM, with two UART interfaces, two USART interfaces, one LPUART interface, three I2C interfaces, two SPI interfaces and one I2S interface.
The battery protection chip from Texas Instruments, model BQ7695202, is a high-precision monitor and protector that supports 3-16 string batteries, supporting lithium-ion batteries, lithium-polymer batteries and lithium iron phosphate battery applications.
The battery protection tube is from Xinjie Neng, model NCEP40T15GU, NMOS, withstand voltage 40V, conduction resistance 1.09mΩ, using DFN5*6-8L package, using four in parallel, opposite series series, a total of eight, for battery output control.
Eight 47 ohm resistors are used for eight strings of cell balancing.
The 0.5mΩ sampling resistor is used for battery pack current sensing.
Two 60A chip fuses are connected in parallel for overcurrent protection.
Close-up of the terminal block connecting the inverter.
The memory is from Winbond, model number W25Q128JVSQ, with a capacity of 16MB, and the battery protection tube drive on the right.
The MOS tube driver is from TI Texas Instruments, model BQ76200, for battery protection tube drives.
MOS管来自新洁能，型号NCEP40T15GU，NMOS，耐压40V，导阻1.09mΩ，采用DFN5*6-8L封装。
The chip fuse specification is 6.3A.
There is a patch button on the protection board.
There is also a buzzer welded to the protection plate.
Close-up of key contacts reserved for the protection board.
The back of the protective plate is likewise covered with white glue.
The front of the bidirectional inverter module is at a glance, the left side of the bottom is the DC terminal, the filter inductor is welded, the filter capacitor is welded on the right, the main control MCU is welded on the top, and the resonant inductor and heat sink are provided on the right side. The step-up switch tube is fixed on the heat sink, and a transformer and resonant capacitor are arranged below the heat sink.
The middle position is equipped with a heat sink for the heat dissipation of the high-voltage switch tube, and above the inverter module are high-voltage filter capacitors, filter inductors, thin film filter capacitors, relays and varistors and other components.
Solder the current sense resistor, isolate the driver chip, isolate the communication chip and the current sense chip on the back of the PCBA module.
The specifications of the two filter capacitors at the input end are 35V220μF.
The input filter capacitor is from Fengbin, which is a PD series solid-state capacitor with a specification of 220μF 35V and uses eight in parallel.
Two 0.5mΩ resistors are connected in parallel to detect the DC current of the inverter.
The main control chip comes from SPINTROL, the model is SPC1168APE48, the chip has a built-in Cortex-M4 high-performance CPU with a frequency of 200MHz, 128KB Flash and 64KB SRAM, a built-in 16-channel 14-bit ADC, a built-in programmable gain amplifier, and an analog comparator.
SPC1168APE48 has 12 PWM signal outputs, and waveform generation supports phase leading/hysteresis control. It has 40 GPIO pins, UART interface, SPI interface. I2C interface and a SIO interface, which can be configured as a CAN, SPI, I2C or UART interface.
The primary switch tube plate is welded with four switch tubes and drivers, which are screwed to the heat sink.
Fill the PCB with a pink thermal gel between the heatsink.
The primary switch is from AOS Semiconductor, model AOTL66610, NMOS, withstand voltage 60V, conduction resistance 1mΩ, and is in TOLLA package.
The half-bridge driver from Infineon, model number IRS21867, is a 600V half-bridge driver that supports logic voltage input and is available in an SOIC-8 package.
The resonant inductor is wound with litz wire.
There is a transformer under the heat sink.
The resonant capacitor is welded to a small vertical plate.
The other main control chip is also a spin SPC1168APE48.
The heat sink is flanked on both sides of the switch and the thermistor.
两颗MOS管来自新洁能,型号NCE65TF099T,NMOS,耐压650V,导阻89mΩ,采用TO-247封装。
On the other side, there are four IGBTs, also from Xinjieneng, model NCE60TD65BT, with a specification of 650V 60A, in a TO-247 package, for inverter output modulation.
The thermistor is fixed by screws and is used to detect the heat sink temperature.
The high-voltage filter capacitor is from Fengbin and has a specification of 330μF 500V.
The capacitor specification of the film is 1μF 630V.
Close-up of two magnetic ring inductors.
The thin-film filter capacitor is from TDK and is specified at 9μF 310VAC.
There is a relay on the side of the filter capacitor.
Close-up of the filter inductor at the output.
The film capacitor specification is 0.68μF.
The relay comes from Hongfa, model HF152F /012-1ZT, which is an ultra-small high-power relay with a coil voltage of 12V and a set of built-in conversion contacts.
One relay information is obscured.
Two cement resistors are glued and fixed, one of which is 10W75Ω.
The AC input fuse is 10A.
A blue varistor is used for input surge protection.
The common mode inductor is magnetically surrounded, and the inside is insulated by a bakelite board.
The safety X2 capacitor specification is 2.2μF.
SCT2A22 The synchronous step-down converter is a 100V input voltage synchronous step-down converter with an output current of 1A, the chip adopts constant on-time control, and adopts ESOP8 package.
The chip electrolytic capacitor is from Panasonic and is rated at 100μF 50V.
The RS485 transceiver from SRP is a TPT75176H model with 15kV ESD protection, 10Mbps transmission rate and full fault protection.
The auxiliary power filter capacitor is from Man Yu.
The capacitance specification is 10μF 550V.
Close-up of auxiliary power transformer.
The isolated communication chip from NOVOSENSE, model NSi8262, is a high-reliability six-channel digital isolator with four built-in forward channels and two reverse channels, and is packaged in SOW16.
The isolation amplifier is from TI Texas Instruments, model TLA7312, and is used for current signal sampling amplification.
Close-up of another NOVOSENSE NSi8262 digital isolation chip.
The four tantalum polymer capacitors are rated at 100μF 20V.
The isolation driver is from Shuming Semiconductor, model SLMI8233BD, which is an isolation driver with 5kVRMS isolation capability, with a peak output current of 4A and an isolation voltage of 1500V between the two drivers built into the chip. The on-chip driver supports a 40V input voltage and a 3-18V operating voltage.
Close-up of another SLMi8233 driver.
The Hall current sampling chip is from MagnTek, model MT9522, which is a high-precision low-temperature drift current sensor chip with 4800Vrms withstand voltage, and adopts SOP-16W package.
Close-up of another MT9522 current sampling chip.
The dual op amp from SRP, model TP2412, is a low noise dual op amp that supports rail-to-rail input and output.
Attach buffer tape to the back of the PCB of the bidirectional inverter module.
Another close-up of cushioning pads.
Inside the side panel, fix the fast charging panel, AC input and output socket, SDC Lite socket and indicator button small board.
Remove the fast charging panel, and below is the screen module.
Two blue Y capacitors are welded to the inverter output board.
Disassemble and remove the buttons, SDC Lite connector, indicator light and button board.
The power switch button is equipped with foam buffer, and the inside is designed to transmit light.
Close-up of the SDC Lite socket with positive and negative poles on both sides and communication pins in the middle.
Close-up of the AC output button and indicator panel.
Close-up of the small board of the charging mode toggle switch.
Close-up of the power button board on the top of the fuselage.
Close-up of the internal damping mechanism of the slide switch.
The power input socket is connected via a connector.
On the back of the fast charging panel, an aluminum heat sink is provided for the heat dissipation of the switch tube, and a filter inductor, a filter capacitor, a buck-boost inductor and a step-down inductor are set around the periphery, and a protocol chip and a switch tube are also provided under the glue.
The back components are also covered with glue, and there are MCUs, memories, synchronous buck controllers, MOS tubes, and other components.
The fast charging panel is connected to the battery pack using an XT60 connector.
The 10A chip fuse is used for overcurrent protection of the USB-C interface.
The main control MCU is from GigaDevice, model GD32F305VCT6, is an MCU with a main frequency of 120MHz, built-in Cortex-M4 core, with 256KB FLASH and 96KB SRAM, with 3 USART, 2 UART, 3 SPI, 2 I2C, 2 I2S, 2 CAN2.0B and 1 SDIO interface.
The memory is soldered to the back of the MCU, from Winbond, model number W25N02KVZEIR, and is a 256MB SLC memory.
NOVOSENSE NSi8262 is used for fast charging panel communication.
The outdoor power station uses three Nanxin SC8815A two-way synchronous buck-boost controllers, two of which are used for two-way fast charging of USB-C interface and one for SDC Lite interface.
SC8815 is a bidirectional synchronous buck-boost controller with integrated I2C interface, supporting 2.5-36V input and output voltage ranges, supporting battery charging, in which the battery charging current and voltage, reverse discharge output voltage, input and output current limit can be controlled by the I2C bus, the chip has under-voltage protection, over-voltage protection and over-current protection, and supports short-circuit protection and over-thermal shutdown protection.
According to the dismantling of the charging head network, Nanxin's fast charging solution is widely used in mobile power supplies, chargers, car chargers and other fields, and has been used by Anker PowerHouse II 400 outdoor power supply, Empire 300W portable energy storage power supply, Zimi 20 200W PD fast charging power bank, Zhengtuo 100W bidirectional fast charging mobile bank SuperTank Pro, Samsung 10000mAh 25W PD fast charging power bank, Xiaomi 20000mAh mobile power bank 50W super flash charging version and other dozens of products.
The four MOS transistors for the synchronous buck-boost of the USB-C interface are from Wanguo Semiconductor, model AON6264E, NMOS, withstand voltage 60V, conduction resistance 7.7mΩ, and DFN5*6 package.
Close-up of two 4.7μH alloy chokes and the corresponding filter capacitors.
The USB-C interface fast charging protocol chip adopts Nanxin SC2151A, which has obtained USB-IF PD3.0 certification, TID: 4869. Presented in a 16-pin QFN 4*4mm package, it is a controller that supports PD and DP/DM fast charging protocols, with an integrated feedback loop, supports the latest Type-C and PD3.0 standards, and also supports proprietary fast charging protocols, making it suitable for various adapter applications.
Nanxin SC2151A integrates a 32-bit high-performance MCU core with 24kB single programming memory and 2kB RAM. The controller integrates USB PD physical layer, Type-C detection, DP/DM fast charging protocol physical layer for various fast charging protocols, and VCONN power supply.
Charging head network learned that Nanxin's SC2151A protocol chip has also been used in dozens of products of well-known brands such as Greenlink 30W PD fast-charging gallium nitride charger, Gushi Technology 30W PD fast-charging gallium nitride charger, Anker 30W mini gallium nitride fast charger, Nubia 30W gallium nitride fast charging charger, etc., and the product quality has been unanimously recognized by customers.
The two Nanxin Technology SC2021A correspond to two USB-C interfaces.
The VBUS switch for the two USB-C interfaces is from AOS, model AON7140, NMOS, withstand voltage 40V, conduction resistance 1.9mΩ, and comes in DFN3.3*3.3 package.
The USB-C receptacle is secured by via soldering.
用于SDC Lite接口同步升降压的四颗MOS管来自英飞凌，型号BSC066N06NS，NMOS，耐压60V，导阻6.6mΩ，采用SuperSO8封装。
Close-up of the XT30 connector connected to the SDC Lite interface.
两颗PMOS来自威兆半导体，型号VSP007P06MS，PMOS，耐压60V，导阻7.5mΩ，采用PDFN5060X封装。
威兆半导体 VSP007P06MS 资料信息。
The controller of the USB-A interface buck output is from Nanxin Technology, model SC8002, which is a synchronous buck controller, which can be configured as dual output or single output. The SC8002 regulates the output voltage to a 5V or other voltage by setting a voltage divider resistor. High-accuracy output current limiting is also provided. When either of the two output channels reaches the set current limit, the SC8002 enters constant current (CC) mode. The total output power can be set by the resistor, which is convenient for constant power control.
The SC8002 can be set to the frequency and select the PWM or PFM operation mode. With the smallest BOM, maximum functionality can be achieved for the user's different applications. The SC8002 also supports full-featured protection, including under-voltage protection, over-voltage protection, short-circuit protection, auto-restart, and over-temperature protection. SC8002 is mainly used in on-board chargers, multi-group interface adapters, hubs, industrial voltage conversion, etc.
Through the dismantling of the charging head network, it was learned that Nanxin Technology SC8002 was also used by vivo X Fold original 80W dual-C-port gallium nitride flash charging, Akasis 300W portable energy storage power supply, Kexun 65W 1A1C gallium nitride fast charging, Aukey 100W gallium nitride fast charging, Momis 65W 2C1A gallium nitride fast charging and other products.
The MOS transistor for synchronous step-down is AON7140 by AOS and Wanguo Semiconductor.
The USB-A receptacle uses an orange rubber core, and the positive and negative poles are widened to support high-current fast charging.
A list of all dismantling and a family photo.
Summary of the dismantling of the charging head network
Finally, a list of DJI power 500 core components is attached for your convenience.
The DJI POWER 500 comes with a low-profile gray-black housing with a single-sided handle, making it easy to carry and store on a daily basis. There is a display panel and connection interface on the side of the outdoor power supply, and there are exhaust vents on both sides of the fuselage to cooperate with fans to dissipate heat for the inverter module. The outdoor power station has a built-in 512Wh lithium iron phosphate battery, the bidirectional inverter module supports 1000W output power, the USB-C interface supports 100W charging and discharging, and the SDC interface supports 300W charging.
Through the dismantling of the charging head network, it is learned that the interior of this outdoor power station is modular, which is composed of a fast charging panel, a battery protection board, a battery pack and a bidirectional inverter module. The bidirectional inverter module is fixed to the plastic frame of the battery pack using an aluminum plate, and is equipped with a cooling fan to dissipate heat from the heating elements. The fast charging panel is equipped with a synchronous buck-boost circuit, which supports charging and discharging of USB-C interface and SDC interface.
The outdoor power station has a built-in 8-string lithium iron phosphate battery and is fixed by an insulated frame. The battery protection board adopts Texas Instruments protection chip, with GigaDevice main control chip, and is equipped with a fuse for overcurrent protection. The bidirectional inverter module uses the main control chip of Xuanzhi, and the display panel uses the Nanxin synchronous buck-boost controller and protocol chip for fast charging output. The internal PCBA module is coated with thermally conductive adhesive and conformal coating to prevent damage caused by foreign objects. The internal components are all well-known brands, and the overall workmanship materials are reliable.