CDB1601-120W DS931DB4
Transcript of CDB1601-120W DS931DB4
Copyright Cirrus L(All Rights Rewww.cirrus.com
Actual Size:258 mm x 43 mm8.16 in x 1.7 in
CDB1601-120W
CS1601 120W, High-efficiency PFC Demonstration Board
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, andhas been tailored for use with a resonant second stageto power up to two T5 fluorescent lamps for a maximumoutput power of 108W. A resonant second stage driverefficiency of 94% is assumed for this application.
ORDERING INFORMATION
CDB1601-120W-Z Customer Demonstration Board
ogic, Inc. 2011served)
OCT ‘11DS931DB4
CDB1601-120W
IMPORTANT SAFETY INSTRUCTIONS Read and follow all safety instructions prior to using this demonstration board.
Risk of Electric Shock •
•
•
•
•
•
Contacting Cirrus Logic SupportFor all product questions and inquiries contact a Cirrus Logic Sales Representative. To find the one nearest to yougo to www.cirrus.com
IMPORTANT NOTICE
Cirrus Logic, Inc. and its subsidiaries ("Cirrus") believe that the information contained in this document is accurate and reliable. However, the information is subjectto change without notice and is provided "AS IS" without warranty of any kind (express or implied). Customers are advised to obtain the latest version of relevantinformation to verify, before placing orders, that information being relied on is current and complete. All products are sold subject to the terms and conditions of salesupplied at the time of order acknowledgment, including those pertaining to warranty, indemnification, and limitation of liability. No responsibility is assumed by Cirrusfor the use of this information, including use of this information as the basis for manufacture or sale of any items, or for infringement of patents or other rights of thirdparties. This document is the property of Cirrus and by furnishing this information, Cirrus grants no license, express or implied under any patents, mask work rights,copyrights, trademarks, trade secrets or other intellectual property rights. Cirrus owns the copyrights associated with the information contained herein and givesconsent for copies to be made of the information only for use within your organization with respect to Cirrus integrated circuits or other products of Cirrus. This con-sent does not extend to other copying such as copying for general distribution, advertising or promotional purposes, or for creating any work for resale.
CERTAIN APPLICATIONS USING SEMICONDUCTOR PRODUCTS MAY INVOLVE POTENTIAL RISKS OF DEATH, PERSONAL INJURY, OR SEVERE PROP-ERTY OR ENVIRONMENTAL DAMAGE ("CRITICAL APPLICATIONS"). CIRRUS PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR WARRANTED FORUSE IN PRODUCTS SURGICALLY IMPLANTED INTO THE BODY, AUTOMOTIVE SAFETY OR SECURITY DEVICES, LIFE SUPPORT PRODUCTS OR OTHERCRITICAL APPLICATIONS. INCLUSION OF CIRRUS PRODUCTS IN SUCH APPLICATIONS IS UNDERSTOOD TO BE FULLY AT THE CUSTOMER'S RISKAND CIRRUS DISCLAIMS AND MAKES NO WARRANTY, EXPRESS, STATUTORY OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANT-ABILITY AND FITNESS FOR PARTICULAR PURPOSE, WITH REGARD TO ANY CIRRUS PRODUCT THAT IS USED IN SUCH A MANNER. IF THE CUSTOMEROR CUSTOMER'S CUSTOMER USES OR PERMITS THE USE OF CIRRUS PRODUCTS IN CRITICAL APPLICATIONS, CUSTOMER AGREES, BY SUCH USE,TO FULLY INDEMNIFY CIRRUS, ITS OFFICERS, DIRECTORS, EMPLOYEES, DISTRIBUTORS AND OTHER AGENTS FROM ANY AND ALL LIABILITY, IN-CLUDING ATTORNEYS' FEES AND COSTS, THAT MAY RESULT FROM OR ARISE IN CONNECTION WITH THESE USES.
Cirrus Logic, Cirrus, the Cirrus Logic logo designs, EXL Core, and the EXL Core logo design are trademarks of Cirrus Logic, Inc. All other brand andproduct names in this document may be trademarks or service marks of their respective owners.
2 DS931DB4
CDB1601-120W
1. INTRODUCTION
The CS1601 is a high-performance Variable Frequency Discontinuous Conduction Mode (VF-DCM), ac-tive Power Factor Correction (PFC) controller, optimized to deliver the lowest PFC system cost for elec-tronic ballast applications. The CS1601 uses a digital control algorithm that is optimized for high efficiencyand near unity power factor over a wide input voltage range (108-305 VAC).
The CS1601 uses an adaptive digital control algorithm. Both the ON time and the switching frequency arevaried on a cycle-by-cycle basis over the entire AC line to achieve close to unity power factor. The varia-tion in switching frequency also provides a spread frequency spectrum, thus minimizing the conductedEMI filtering requirements.
The feedback loop is closed through an integrated digital control system within the IC. Protection featuressuch as overvoltage, overcurrent, overpower, open circuit, overtemperature, and brownout help protectthe device during abnormal transient conditions. Details of these features are provided in the CS1601 datasheet.
The CDB1601-120W board demonstrates the performance of the CS1601 over a wide input voltage rangeof 108 to 305 VAC, typically seen in universal input ballast applications. This board has been designedfor a 460 V, 115 W full load output application.
Extreme caution needs to be exercised while handling this board. This board is to be powered up bytrained professionals only.
Prior to applying AC power to the CDB1601-120W board, the CS1601 needs to be biased using an exter-nal 13 VDC power supply, applied across pins 1 and 3 of terminal block J5. Terminal block J6 is used toconnect the AC line. The load is connected to J7. As a safety measure, jumper J1 is provided as a meansto apply a small resistive load (200 kminium) to rapidly discharge the output capacitors. Other jumpersand test points are provided to evaluate the behavior of the IC and the various sections of the design.
Figure 1. Board Connections
DANGERHigh Voltage Hazard
ONLY QUALIFIED PERSONNEL SHOULD HANDLE THE CDB1601-120W.
WARNING: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.
J5
J7
J6
J1
AC LineInput
VDD Input
TerminalsOutput
DS931DB4 3
CDB1601-120W
2. SCHEMATIC
REV C
CD
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20W
FO
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Fig
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2.
Sc
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ma
tic
4 DS931DB4
CDB1601-120W
3. BILL OF MATERIALS 1
070-
0015
7-Z1
AD
IOD
E R
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T B
RID
GE
600
V 4
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Pb
GB
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305
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LM N
Pb
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3292
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011-
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1% N
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HM
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10 R
11 R
12 R
13 R
15 R
16D
ALE
CR
CW
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HM
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W ±
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1K78
FKE
A41
020-
0637
2-Z1
AR
ES
0.2
4 O
HM
1W
±1%
NP
b 25
120
R18
R22
PA
NA
SO
NIC
ER
J1TR
QFR
24U
NO
PO
P42
030-
0008
0-Z1
AR
ES
100
K 1
W ±
5% M
TL F
LM N
Pb
AX
L2
R19
R20
XIC
ON
294-
100K
-RC
4303
6-00
015-
Z1A
VA
RIS
TOR
470
V R
MS
14M
M N
Pb
RA
D0
RV
1E
PC
OS
S14
K30
0N
O P
OP
4411
0-00
045-
Z1A
CO
N T
ES
T P
T .1
"CTR
TIN
PLA
T N
Pb
BLK
7TP
2 TP
3 TP
4 TP
5 TP
6 TP
7 TP
8K
EY
STO
NE
5001
4506
5-00
331-
Z3A
2IC
CR
US
LP
WR
FA
CTO
R C
OR
R N
Pb
SO
IC8
1U
1C
IRR
US
LO
GIC
CS
1601
-FS
Z/A
2E
CO
840
4608
0-00
002-
01A
WIR
E 2
8/1
AW
G, K
YN
AR
MO
D, 5
00FT
2.00
0W
1S
QU
IRE
SL
500
UL1
422
28/1
BLU
AD
D L
EN
GTH
TO
BO
M Q
UA
NTI
TY IN
INC
HE
S47
080-
0004
0-Z1
AW
IRE
16A
WG
SO
LID
PV
C IN
S B
LK N
Pb
4.00
0W
3A
LPH
A W
IRE
CO
MP
AN
Y30
57/1
BK
005
AD
D L
EN
GTH
TO
BO
M Q
UA
NTI
TY IN
INC
HE
S48
311-
0002
5-Z1
AH
TSN
K T
O22
0 M
OU
NTI
NG
KIT
NP
b1
XH
S1
AA
VID
TH
ER
MA
LLO
Y48
80G
INC
LUD
ES
ALL
MO
UN
TIN
G H
AR
DW
AR
E49
300-
0002
5-Z1
AS
CR
EW
4-4
0X5/
16" P
H M
AC
H S
S N
Pb
4 X
MH
1MX
MH
2 X
MH
3 X
MH
4B
UIL
DIN
G F
AS
TEN
ER
SP
MS
SS
440
003
1 P
HS
CR
EW
S F
OR
STA
ND
OFF
S50
240-
0046
6-Z1
CP
CB
CD
B16
01-1
20W
-Z-N
Pb
1C
IRR
US
LO
GIC
240-
0046
6-Z1
EC
O80
5/82
6/84
051
603-
0046
6-Z1
CA
SS
Y D
WG
CD
B16
01-1
20W
-Z-N
Pb
RE
FC
IRR
US
LO
GIC
603-
0046
6-Z1
EC
O80
5/82
6/84
052
600-
0046
6-Z1
CS
CH
EM
CD
B16
01-1
20W
-Z-N
Pb
RE
FC
IRR
US
LO
GIC
600-
0046
6-Z1
EC
O80
5/82
6/84
053
422-
0001
3-01
CLB
L S
UB
AS
SY
PR
OD
UC
T ID
AN
D R
EV
1C
IRR
US
LO
GIC
422-
0001
3-01
DS931DB4 5
CDB1601-120W
4. BOARD LAYOUT
Fig
ure
3.
So
lder
Mas
k (B
ott
om
)
Fig
ure
5.
Sil
kscr
een
(T
op
)
Fig
ure
4.
So
lder
Mas
k (T
op
)
6 DS931DB4
CDB1601-120W
Fig
ure
6.
Cir
cu
it R
ou
tin
g (
Bo
tto
m)
Fig
ure
8.
Sil
ks
cre
en (
Bo
tto
m)
Fig
ure
7.
So
lde
r P
ast
e M
ask
(Bo
tto
m)
DS931DB4 7
CDB1601-120W
5. TYPICAL PERFORMANCE PLOTS
50
55
60
65
70
75
80
85
90
95
100
10 20 30 40 50 60 70 80 90 100 110 120
Effic
ienc
y (%
)
Output Power (Watts)
120V
230V
277V
0.80
0.82
0.84
0.86
0.88
0.90
0.92
0.94
0.96
0.98
1.00
20 30 40 50 60 70 80 90 100 110 120
Pow
er F
acto
r
Output Power (Watts)
120V
230V
277V
Figure 9. Efficiency vs. Output Power
Figure 10. Power Factor vs. Output Power
8 DS931DB4
CDB1601-120W
0
5
10
15
20
25
30
35
40
45
50
10 20 30 40 50 60 70 80 90 100 110 120
THD
(%)
Output Power (Watts)
277V
230V
120V
450
452
454
456
458
460
462
464
466
468
470
0 10 20 30 40 50 60 70 80 90 100 110 120
Vlin
k (V
)
Output Power (Watts)
277V230V
120V
Figure 11. THD vs. Output Power
Figure 12. VLink Voltage vs. Output Power
DS931DB4 9
CDB1601-120W
Figure 13. Steady State Waveforms — 120 VAC
Figure 14. Steady State Waveforms — 230 VAC
10 DS931DB4
CDB1601-120W
Figure 15. Steady State Waveforms — 277 VAC
DS931DB4 11
CDB1601-120W
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.)
Ch. 1–VLINK
Ch. 2–VRECT
Ch. 3–Gate
Ch. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
12 DS931DB4
CDB1601-120W
Figure 18. Switching Frequency Profile at Trough of AC Line Voltage —120 VAC
Figure 19. Switching Frequency Profile at Trough of AC Line Voltage — 120 VAC (cont.)
Ch. 1–VLINK
Ch. 2–VRECT
Ch. 3–Gate
Ch. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
DS931DB4 13
CDB1601-120W
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.)
Ch. 1–VLINK
Ch. 2–VRECT
Ch. 3–Gate
Ch. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
14 DS931DB4
CDB1601-120W
Figure 22. Switching Frequency Profile at Trough of AC Line Voltage — 230 VAC
Figure 23. Switching Frequency Profile at Trough of AC Line Voltage — 230 VAC (cont.)
Ch. 1–VLINK
Ch. 2–VRECT
Ch. 3–Gate
Ch. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
DS931DB4 15
CDB1601-120W
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.)
Ch. 1–VLINK
Ch. 2–VRECT
Ch. 3–Gate
Ch. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
16 DS931DB4
CDB1601-120W
Figure 26. Switching Frequency Profile at Trough of AC Line Voltage — 277 VAC
Figure 27. Switching Frequency Profile at Trough of AC Line Voltage — 277 VAC (cont.)
Ch. 1–VLINK
Ch. 2–VRECT
Ch. 3–Gate
Ch. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
DS931DB4 17
CDB1601-120W
Figure 28. Transient — 15W to 115W Load at 10W/s, Vin = 120VAC
Figure 29. Transient — 15W to 115W Load at 10W/s, Vin = 120VAC (cont.)
Ch. 1–VLINKCh. 2–VRECTCh. 3–GateCh. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
18 DS931DB4
CDB1601-120W
Figure 30. Transient — 15W to 115W Load at 10W/s, Vin = 230VAC
Figure 31. Transient — 15W to 115W Load at 10W/s, Vin = 230VAC (cont.)
Ch. 1–VLINKCh. 2–VRECTCh. 3–GateCh. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
DS931DB4 19
CDB1601-120W
Figure 32. Transient — 15W to 115W Load at 10W/s, Vin = 277VAC
Figure 33. Transient — 15W to 115W Load at 10W/s, Vin = 277VAC (cont.)
Ch. 1–VLINKCh. 2–VRECTCh. 3–GateCh. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
20 DS931DB4
CDB1601-120W
Figure 34. Transient — 115W to Zero Load at 10W/s, Vin = 120VAC
Figure 35. Transient — 115W to Zero Load at 10W/s, Vin = 120VAC (cont.)
Ch. 1–VLINKCh. 2–VRECTCh. 3–GateCh. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
DS931DB4 21
CDB1601-120W
Figure 36. Transient — 115W to Zero Load at 10W/s, Vin = 230VAC
Figure 37. Transient — 115W to Zero Load at 10W/s, Vin = 230VAC (cont.)
Ch. 1–VLINKCh. 2–VRECTCh. 3–GateCh. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
22 DS931DB4
CDB1601-120W
Figure 38. Transient — 115W to Zero Load at 10W/s, Vin = 277VAC
Figure 39. Transient — 115W to Zero Load at 10W/s, Vin = 277VAC (cont.)
Ch. 1–VLINKCh. 2–VRECTCh. 3–GateCh. 4–Inductor Current
Ch. 1–VDSCh. 2–VRECTCh. 3–CSCh. 4–ZCD
DS931DB4 23
CDB1601-120W
6. 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.
DB4 OCT 2011 Revised part number to reflect lead free.
24 DS931DB4