6n60c

AP1661 2*36W ballast Demo Board Manual

PROPRIETARY & CONFIDENTIAL

BCD Semi Ltd Co.

Content:

1. Description

2. Specifications

3. Schematics of the Demo Board

4. PCB Layout

5. Photo View of the Demo Board

6. PCB Dimensions

7. BOM

ADVANCED ANALOG CIRCUITS CORPORATION PAGE 1 OF 9

8. Test Result



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1 Description: The AP1661 is an active power factor control IC which is designed mainly for use as

pre-converter in electronic ballast and off-line power supply applications. This Demo manual

provides a design example of 2*36W lamps ballast using AP1661 for power factor correction

circuit and evaluates the demo board performance.

2 Specifications


AC Input Voltage 184VAC~265VAC

Rated input power Typ Pin = 80W

Rated Lamp current Typ Ila=320mA

PFC output regulated voltage Typ Vo = 395V

Power factor Min PF>0.96

Total harmonic distortion Max THD



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3 Schematic of the Demo Board

Figure 1. Demo board schematic

4 PCB Layout of the Demo Board

Figure 2. demo board PCB and components ( Top view, real size1 275mm26mm )

Figure 3. demo board PCB layout( Bottom view, real size 275mm26mm)




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5 Photo View of the Demo Board

Figure 4. photo view of the demo board

6 PCB Dimensions

7 BOM


Part Type Designator Part Type Designator X-CAP 220nF/275V C11 C12 MOSFET 6N60C Q21 Y-CAP 3.3nF/250V C13 TRANSISTOR 13005 Q31 Q32 220nF/630V C21 TRANSISTOR 9014 Q33 Q34 22uF/450V C22 BT169 Q51 220pF/50V C23 1M R10 1uF/16V C24 680K R11 22uF/50V C25 C51 C52 10K R12 R54 220nF/400V C31 C32 180K R14 R15 100n/250V C33 68K R20

2.7nF/1600V C41 C42 1ohm R21 470pF/1KV C61 20 ohm R23 10nF/50V C62 1Kohm R22

100nF/25V C63 120ohm R24



BCD Semi Ltd Co. 1N4007 D1 D2 D3 D4

D54 820K R26

FR107 D21 D31 D32 D35

470K R27

1N4148 D22 D33 D34 D51 D52 D53

D54 D61

8.2K R28

DB3 DB3 0.33ohm R31 R32

Fuse 3A/250V F1 220K R311 R53

CONNECTOR-3P J1 150K R33 R34

CONNECTOR-7P J2 6.8ohm R35 R37

1mH L11 51ohm R36 R38

18mH L12 10ohm R39 R310

1.5mH L21 39K R51 R52 R55 10uH L31 L32 RING CORE 2:2:2 T1 1.8mH L41 L42 ZENER 15V Z1

PTC P1 P2 ZENER 27V Z2

8 Test Results To evaluate the performance of the ballast demo board, the following parameters have been

measured: Pin (Input Power), Pla (Lamp Power), (Efficiency), VBus (PFC output DC bus voltage), VBus (PFC output DC bus voltage ripple), PF (Power Factor), THD (Current Total Harmonic Distortion), Ila (Lamp current), CF (Lamp Current Crest Factor). The demo board evaluation results are as below:

8.1 Performance test results at full load


Vinrms(V)

Pin(W)

Pla(W)

(%)

VBus(V)

VBus(V)

PF THD

(%)

Ila (mA)

CF

184 79.7 70.5 88.5 394 24 0.9981 5.8 323 1.52

196 79.2 71.0 89.6 394 24 0.9976 5.49 324 1.53

220 78.6 71.2 90.6 394 24 0.9960 5.65 324 1.54

240 78.4 71.3 90.9 394 24 0.9938 6.17 324 1.54

264 78.3 71.2 90.9 394 24 0.9907 8.75 324 1.53



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8.2 Input Current waveform

Figure 5. input voltage(Ch1) and input current(Ch2) waveform at 220V AC input

8.3 PFC inductor current waveform

Figure 6. PFC inductor current waveform and zoom

The PFC inductor works in DCM boundary conduction mode. The inductor current envelop is

sine wave. This insures good power factor correction.




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8.4 PFC Output DC BUS Voltage Ripple

Figure 7. PFC output DC bus voltage ripple waveform

8.5 Vds and Vgs waveform of PFC MOSFET


Figure 8. Vds(Ch1) and Vgs(Ch2) of MOSFET at 220V ac input



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8.6 Start up waveform

Figure 9. Ch1: PFC output DC bus voltage at start up Ch2: input current at start up

8.7 Lamp current waveform


Figure 10. lamp current waveform



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8.8 Half bridge voltage and current waveform

Figure 11. Half bridge midpoint voltage and current waveform

The half bridge works in inductive mode. There is enough phase margin to ensure Zero Voltage Switching of the half bridge switches.

8.9 Characterization Results Summary

Test Item Specification Test result

input power 80W 78-79W

Power factor PF>0.96 PF>0.99

Total harmonic distortion THD

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