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Features
Line Voltage Range: 108 to 305 VACrms Output Voltage (VLINK): 460V Rated Pout : 115W Efficiency: 95% @ 115W Spread Spectrum Switching Frequency Integrated Digital Feedback Control Low Component Count General Description The CDB1601-120W board demonstrates the perfor- mance of the CS1601 digital PFC controller as a stand- alone unit. This board is 95% efficient at full load, and has been tailored for use with a resonant second stage to power up to two T5 fluorescent lamps for a maximum output power of 108W. A re sonant second stage driver efficiency of 94% is assumed for this application.
ORDERING INFORMATION
CDB1601-120W Customer Demonstration Board MAR ‘11 DS931DB3
2 DS931DB3
IMPORTANT SAFETY INSTRUCTIONS Read and follow all safety instructions prior to using this demonstration board. /g55/g75/g76/g86/g3/g40/g81/g74/g76/g81/g72/g72/g85/g76/g81/g74/g3/g40/g89/g68/g79/g88/g68/g87/g76/g82/g81/g3/g56/g81/g76/g87/g3/g82/g85/g3/g39/g72/g80/g82/g81/g86/g87/g85/g68/g87/g76/g82/g81/g3/g37/g82/g68/g85/g71/g3/g80/g88/g86/g87/g3/g82/g81/g79/g92/g3/g69/g72/g3/g88/g86/g72/g71/g3/g73/g82/g85/g3/g68/g86/g86/g72/g86/g86/g76/g81/g74/g3/g44/g38/g3/g83/g72/g85/g73/g82/g85/g80/g68/g81/g70/g72/g3/g76/g81/g3/g68/g3 /g79/g68/g69/g82/g85/g68/g87/g82/g85/g92/g3/g86/g72/g87/g87/g76/g81/g74/g17/g3/g55/g75/g76/g86/g3/g83/g85/g82/g71/g88/g70/g87/g3/g76/g86/g3/g81/g82/g87/g3/g76/g81/g87/g72/g81/g71/g72/g71/g3/g73/g82/g85/g3/g68/g81/g92/g3/g82/g87/g75/g72/g85/g3/g88/g86/g72/g3/g82/g85/g3/g76/g81/g70/g82/g85/g83/g82/g85/g68/g87/g76/g82/g81/g3/g76/g81/g87/g82/g3/g83/g85/g82/g71/g88/g70/g87/g86/g3/g73/g82/g85/g3/g86/g68/g79/g72/g17/g3 /g55/g75/g76/g86/g3/g83/g85/g82/g71/g88/g70/g87/g3/g80/g88/g86/g87/g3/g82/g81/g79/g92/g3/g69/g72/g3/g88/g86/g72/g71/g3/g69/g92/g3/g84/g88/g68/g79/g76/g73/g76/g72/g71/g3/g87/g72/g70/g75/g81/g76/g70/g76/g68/g81/g86/g3/g82/g85/g3/g83/g85/g82/g73/g72/g86/g86/g76/g82/g81/g68/g79/g86/g3/g90/g75/g82/g3/g68/g85/g72/g3/g87/g85/g68/g76/g81/g72/g71/g3/g76/g81/g3/g87/g75/g72/g3/g86/g68/g73/g72/g87/g92/g3/g83/g85/g82/g70/g72/g71/g88/g85/g72/g86/g3 /g68/g86/g86/g82/g70/g76/g68/g87/g72/g71/g3/g90/g76/g87/g75/g3/g87/g75/g72/g3/g88/g86/g72/g3/g82/g73/g3/g71/g72/g80/g82/g81/g86/g87/g85/g68/g87/g76/g82/g81/g3/g69/g82/g68/g85/g71/g86/g17/g3/g3 /g3Risk of Electric Shock
- /g3 /g55/g75/g72/g3/g71/g76/g85/g72/g70/g87/g3/g70/g82/g81/g81/g72/g70/g87/g76/g82/g81/g3/g87/g82/g3/g87/g75/g72/g3/g36/g38/g3/g83/g82/g90/g72/g85/g3/g79/g76/g81/g72/g3/g68/g81/g71/g3/g87/g75/g72/g3/g82/g83/g72/g81/g3/g68/g81/g71/g3/g88/g81/g83/g85/g82/g87/g72/g70/g87/g72/g71/g3/g69/g82/g68/g85/g71/g86/g3/g83/g85/g72/g86/g72/g81/g87/g3/g68/g3/g86/g72/g85/g76/g82/g88/g86/g3/g85/g76/g86/g78/g3/g82/g73/g3/g72/g79/g72/g70/g87/g85/g76/g70/g3 /g86/g75/g82/g70/g78/g3/g68/g81/g71/g3/g70/g68/g81/g3/g70/g68/g88/g86/g72/g3/g86/g72/g85/g76/g82/g88/g86/g3/g76/g81/g77/g88/g85/g92/g3/g82/g85/g3/g71/g72/g68/g87/g75/g17/g3/g40/g91/g87/g85/g72/g80/g72/g3/g70/g68/g88/g87/g76/g82/g81/g3/g81/g72/g72/g71/g86/g3/g87/g82/g3/g69/g72/g3/g72/g91/g72/g85/g70/g76/g86/g72/g71/g3/g90/g75/g76/g79/g72/g3/g75/g68/g81/g71/g79/g76/g81/g74/g3/g87/g75/g76/g86/g3/g69/g82/g68/g85/g71/g17/g3
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and near unity power factor over a wide input voltage range (108-305 VAC). for a 460 V, 115 W full load output application. and test points are provided to evaluate the behavior of the IC and the various sections of the design. Figure 1. Board Connections ONLY QUALIFIED PERSONNEL SHOULD HANDLE THE CDB1601-120W. Heatsinking is required for Q4. The end product should use tar pitch or an equivalent compound for this purpose. For lab evaluation purposes, a fan is recommended to provide adequate cooling.
4 DS931DB3
460 VDC
- ALL RESISTOR VALUES ARE IN OHMS.
28 AWG WIRE
1 IFB2 NC3 IAC4 CS 5ZCD
Figure 2. Schematic
- BILL OF MATERIALS /g38/g44/g53/g53/g56/g54/g3/g47/g50/g42/g44/g38 /g38/g39/g37/g20/g25/g19/g20/g16/g20/g21/g19/g58/g66/g53/g72/g89/g66/g38 /g37/g44/g47/g47/g3/g50/g41/g3/g48/g36/g55/g40/g53/g44/g36/g47/g3/g11/g51/g68/g74/g72/g3/g20/g3/g82/g73/g3/g20/g12 /g44/g87/g72/g80 /g38/g76/g85/g85/g88/g86/g3/g51/g18/g49 /g53/g72/g89 /g39/g72/g86/g70/g85/g76/g83/g87/g76/g82/g81 /g52/g87/g92 /g53/g72/g73/g72/g85/g72/g81/g70/g72/g3/g39/g72/g86/g76/g74/g81/g68/g87/g82/g85 /g48/g41/g42 /g48/g41/g42/g3/g51/g18/g49 /g49/g82/g87/g72/g86 1 070-00157-Z1 A DIODE RECT BRIDGE 600V 4A NPb GBU 1 BR1 MICRO COMMERCIAL CO GBU4J-BP 2 011-00042-Z1 A CAP 2200pF ±10% 2000V CER NPb RAD 2 C1 C2 MURATA DEBB33D222KA2B 3 011-00055-Z1 A CAP 0.22uF ±20% 305V PLY FLM NPb TH 0 C3 EPCOS B32923C3224M NO POP 4 011-00040-Z1 A CAP 0.47uF ±20% 305V PLY FLM NPb TH 0 C4 EPCOS B32922C3474M NO POP 5 013-00034-Z1 A CAP 0.33uF ±10% 630V POLY NPb RAD 1 C5 PANASONIC ECQE6334KF 6 012-00186-Z1 A CAP 47UF ±20% 250V ELEC NPb RAD 2 C6 C14 NICHICON UVZ2E470MHD 7 001-05280-Z1 A CAP 33pF ±5% 50V C0G NPb 1206 1 C7 KEMET C1206C330J5GAC 8 001-05783-Z1 A CAP 330pF ±10% 50V C0G NPb 1206 0 C8 KEMET C1206C331K5GAC NO POP 9 001-10233-Z1 A CAP 4.7uF ±20% 25V X7R NPb 1206 1 C9 TDK C3216X7R1E475M 10 001-05542-Z1 A CAP 100pF ±5% 50V C0G NPb 1206 1 C10 KEMET C1206C101J5GAC 11 001-06276-Z1 A CAP 2200pF ±10% 50V X7R NPb 1206 0 C11 C12 KEMET C1206C222K5RAC NO POP 12 011-00064-Z1 A CAP 0.22uF ±20% 330V PLY FLM NPb TH 1 C13 EPCOS B32912B3224M ECO840 13 070-00132-Z1 A DIODE RECT 800V 1A 200mA NPb DO-41 1 D1 DIODES INC 1N4006G-T 14 070-00166-Z1 A DIODE RECT 600V 4A ULT FST NPb SMC 1 D2 ON SEMICONDUCTOR MURS360T3G 15 070-00001-Z1 A DIODE SS 75V 500mW NPb SOD80 1 D4 DIODES INC LL4148 16 180-00022-Z1 A FUSE 3.15A TLAG IEC NPb SHORT TR5 1 F2 LITTLE FUSE 37213150411 17 311-00019-Z1 A HTSNK W LOCK TAB .5" TO220 NPb 1 HS1 AAVID THERMALLOY 6021PBG REQUIRES 1 SCREW, 300-00025-Z1, 1 WASHER, 301- 00013-Z1, 1 NUT, 302-00007-Z1 OR MOUNTING KIT 4880G AAVID 18 115-00014-Z1 A HDR 2x1 ML .1" 062BD ST GLD NPb TH 2 J1 J3 SAMTEC TSW-102-07-G-S 19 110-00301-Z1 A CON 3POS TERM BLK 5.08mm SPR NPb RA 2 J5 J6 WEIDMULLER 1716030000 20 110-00302-Z1 A CON 2POS TERM BLK 5.08mm SPR NPb RA 1 J7 WEIDMULLER 1716020000 21 080-00013-Z1 A WIRE 24 AWG SOLID PVC INS BLK NPb 6.000 JMP1 JMP2 JMP3 JMP4 W2 ALPHA WIRE COMPANY 3050/1 BK005 SEE ASSY DWG FOR LENGT H 22 050-00039-Z1 A XFMR 5mH 1:1 1500Vrms 4PIN NPb TH 1 L1 PREMIER MAGNETICS TSD-2796 23 050-00050-Z1 A XFMR 380uH 10% .265O NPb TH 1 L2 RENCO RLCS-1005 24 040-00127-Z1 A IND 1mH 1.3A ±15% TOR VERT NPb TH 1 L3 BOURNS 2124-V-RC 25 040-00127-Z1 A IND 1mH 1.3A ±15% TOR VERT NPb TH 0 L4 BOURNS 2124-V-RC NO POP 26 050-00039-Z1 A XFMR 5mH 1:1 1500Vrms 4PIN NPb TH 0 L5 PREMIER MAGNETICS TSD-2796 NO POP 27 050-00047-Z1 A XFMR COMMON MODE CHOKE 1.3 A TH NPb 0 L6 L7 RENCO RL-4400-2-4.00 NO POP 28 304-00004-Z1 A SPCR STANDOFF 4-40 THR .500"L NPb 4 MH1 MH2 MH3 MH4 KEYSTONE 2203 REQUIRES SCREW 4-40X5X16" PH STEEL 300-00025- 29 071-00107-Z1 A TRAN MOSFT nCH 11A 600V NPb TO220FP 1 Q4 ST MICROELECTRONICS STF13NM60N 30 020-06337-Z1 A RES 24.9 OHM 1/4W ±1% NPb 1206 FILM 1 R1 DALE CRCW120624R9FKEA 31 020-02502-Z1 A RES 100 OHM 1/4W ±1% NPb 1206 FILM 1 R2 DALE CRCW1206100RFKEA 32 020-02616-Z1 A RES 1k OHM 1/4W ±1% NPb 1206 FILM 0 R3 DALE CRCW12061K00FKEA NO POP 33 020-02273-Z1 A RES 0 OHM 1/4W NPb 1206 FILM 2 R4 R6 DALE CRCW12060000Z0EA 34 020-06390-Z1 A RES 17.8K OHM 1/4W ±1% NPb 1206 1 R5 DALE CRCW120617K8FKEA 35 020-06310-Z1 A RES 20K OHM 1/4W ±1% NPb 1206 FILM 1 R7 DALE CRCW120620K0FKEA 36 030-00091-Z1 A RES 0.1 OHM 2W ±1% WW NPb AXL 0 R8 VISHAY G003R1000FE7080 NO POP 37 030-00091-Z1 A RES 0.1 OHM 2W ±1% WW NPb AXL 1 R9 VISHAY G003R1000FE7080 38 020-06356-Z1 A RES 1.15M OHM 1/4W ±1% NPb 1206 6 R10 R11 R12 R13 R15 R16 DALE CRCW12061M15FKEA 39 020-02616-Z1 A RES 1k OHM 1/4W ±1% NPb 1206 FILM 1 R14 DALE CRCW12061K00FKEA 40 020-06391-Z1 A RES 1.78K OHM 1/4W ±1% NPb 1206 1 R17 DALE CRCW12061K78FKEA 41 020-06372-Z1 A RES 0.24 OHM 1W ±1% NPb 2512 0 R18 R22 PANASONIC ERJ1TRQFR24U NO POP 42 030-00080-Z1 A RES 100K 1W ±5% MTL FLM NPb AXL 2 R19 R20 XICON 294-100K-RC 43 036-00015-Z1 A VARISTOR 470V RMS 14MM NPb RAD 0 RV1 EPCOS S14K300 NO POP 44 110-00045-Z1 A CON TEST PT .1"CTR TIN PLAT NPb BLK 7 TP2 TP3 TP4 TP5 TP6 TP7 TP8 KEYSTONE 5001 45 065-00331-Z3 A2 IC CRUS LPWR FACTOR CORR NPb SOIC8 1 U1 CIRRUS LOGIC CS1601-FSZ/A2 ECO840 46 080-00002-01 A WIRE 28/1 AWG, KYNAR MOD, 500FT 2.000 W1 SQUIRES L 500 UL1422 28/1 BLU ADD LENGTH TO BOM QUANTITY IN INCHES 47 080-00040-Z1 A WIRE 16AWG SOLID PVC INS BLK NPb 4.000 W3 ALPHA WIRE COMPANY 3057/1 BK005 ADD LENGTH TO BOM QUANTITY IN INCHES 48 311-00025-Z1 A HTSNK TO220 MOUNTING KIT NPb 1 XHS1 AAVID THERMALLOY 4880G INCLUDES ALL MOUNTING HARDWARE 49 300-00025-Z1 A SCREW 4-40X5/16" PH MACH SS NPb 4 XMH1MXMH2 XMH3 XMH4 BUILDING FASTENERS PMSSS 440 0031 PH SCREWS FOR STANDOFFS 50 240-00466-Z1 C PCB CDB1601-120W-Z-NPb 1 CIRRUS LOGIC 240-00466-Z1 ECO805/826/840 51 603-00466-Z1 C ASSY DWG CDB1601-120W-Z-NPb REF CIRRUS LOGIC 603-00466-Z1 ECO805/826/840 52 600-00466-Z1 C SCHEM CDB1601-120W-Z-NPb REF CIRRUS LOGIC 600-00466-Z1 ECO805/826/840 53 422-00013-01 C LBL SUBASSY PRODUCT ID AND REV 1 CIRRUS LOGIC 422-00013-01
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Figure 3. Solder Mask (Bottom) Figure 5. Silkscreen (Top) Figure 4. Solder Mask (Top)
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- TYPICAL PERFORMANCE PLOTS
Figure 9. Efficiency vs. Output Power Figure 10. Power Factor vs. Output Power
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Figure 13. Steady State Waveforms — 120 VAC Figure 14. Steady State Waveforms — 230 VAC
Figure 15. Steady State Waveforms — 277 VAC
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Figure 16. Switching Frequency Profile at Peak of AC Line Voltage — 120 VAC Figure 17. Switching Frequency Profile at Peak of AC Line Voltage — 120 VAC (cont.)
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Figure 20. Switching Frequency Profile at Peak of AC Line Voltage — 230 VAC Figure 21. Switching Frequency Profile at Peak of AC Line Voltage — 230 VAC (cont.)
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Figure 24. Switching Frequency Profile at Peak of AC Line Voltage — 277 VAC Figure 25. Switching Frequency Profile at Peak of AC Line Voltage — 277 VAC (cont.)
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Figure 28. Transient — 15W to 115W Load at 10W/ μs, Vin = 120VAC Figure 29. Transient — 15W to 115W Load at 10W/ μs, Vin = 120VAC (cont.)
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Figure 32. Transient — 15W to 115W Load at 10W/ μs, Vin = 277VAC Figure 33. Transient — 15W to 115W Load at 10W/ μs, Vin = 277VAC (cont.)
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Figure 36. Transient — 115W to Zero Load at 10W/ μs, Vin = 230VAC Figure 37. Transient — 115W to Zero Load at 10W/ μs, Vin = 230VAC (cont.)
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- REVISION HISTORY Revision Date Changes DB1 FEB 2011 Initial Release. DB2 FEB 2011 Minor BOM change. DB3 MAR 2011 Updated BOM & Layers to rev C.