Cirrus Logic CDB150x-01 User Manual

Actual Size:

254mm x 44mm

AC Line

Input

Regulated

DC Output

CDB150x-01

CS1501 90W, High-efficiency PFC

Demonstration Board

Features

 Variable On Time, Variable Frequency, DCM PFC

Controller

 Line Voltage Range: 90 to 265 VAC RMS

 Output voltage: 400 V

 Rated Pout: 90 W

 Efficiency: 97% @ 90 W, 230 VAC

 No-load Power Dissipation: <0.3 W

 Low Component Count

 Supports Cirrus Logic Product CS1501

General Description

The CDB150x-01 board demonstrates the performance
of the CS1501 digital PFC controller with a 90 watt out­put at a link voltage of 400 volts.

ORDERING INFORMATION

CDB150x-01-Z PFC Demonstration Board - Supports CS1501

www.cirrus.com

Copyright  Cirrus Logic, Inc. 2011

(All Rights Reserved)

OCT ‘11

DS927DB4

CDB150x-01

Contacting Cirrus Logic Support

For all product questions and inquiries contact a Cirrus Logic Sales Representative. To find the one nearest to you
go 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 subject
to 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 relevant
information 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 sale
supplied at the time of order acknowledgment, including those pertaining to warranty, indemnification, and limitation of liability. No responsibility is assumed by Cirrus
for 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 third
parties. 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 gives
consent 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 con­sent 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 PROP­ERTY OR ENVIRONMENTAL DAMAGE ("CRITICAL APPLICATIONS"). CIRRUS PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR WARRANTED FOR
USE IN PRODUCTS SURGICALLY IMPLANTED INTO THE BODY, AUTOMOTIVE SAFETY OR SECURITY DEVICES, LIFE SUPPORT PRODUCTS OR OTHER
CRITICAL APPLICATIONS. INCLUSION OF CIRRUS PRODUCTS IN SUCH APPLICATIONS IS UNDERSTOOD TO BE FULLY AT THE CUSTOMER'S RISK
AND CIRRUS DISCLAIMS AND MAKES NO WARRANTY, EXPRESS, STATUTORY OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANT­ABILITY AND FITNESS FOR PARTICULAR PURPOSE, WITH REGARD TO ANY CIRRUS PRODUCT THAT IS USED IN SUCH A MANNER. IF THE CUSTOMER
OR 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, IN­CLUDING 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 and
product names in this document may be trademarks or service marks of their respective owners.

IMPORTANT SAFETY INSTRUCTIONS

Read and follow all safety instructions prior to using this demonstration board.

This Engineering Evaluation Unit or Demonstration Board must only be used for assessing IC performance in a
laboratory setting. This product is not intended for any other use or incorporation into products for sale.

This product must only be used by qualified technicians or professionals who are trained in the safety procedures
associated with the use of demonstration boards.

Risk of Electric Shock

• The direct connection to the AC power line and the open and unprotected boards present a serious risk of electric
shock and can cause serious injury or death. Extreme caution needs to be exercised while handling this board.

• Avoid contact with the exposed conductor or terminals of components on the board. High voltage is present on
exposed conductor and it may be present on terminals of any components directly or indirectly connected to the AC
line.

• Dangerous voltages and/or currents may be internally generated and accessible at various points across the board.

• Charged capacitors store high voltage, even after the circuit has been disconnected from the AC line.

• Make sure that the power source is off before wiring any connection. Make sure that all connectors are well

connected before the power source is on.

• Follow all laboratory safety procedures established by your employer and relevant safety regulations and guidelines,
such as the ones listed under, OSHA General Industry Regulations - Subpart S and NFPA 70E.

Suitable eye protection must be worn when working with or around demonstration boards. Always

comply with your employer’s policies regarding the use of personal protective equipment.

All components, heat sinks or metallic parts may be extremely hot to touch when electrically active.

Heatsinking is required for Q1. 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.

2 DS927DB4

CDB150x-01

1. INTRODUCTION

The CS1501 is a high-performance Variable Frequency Discontinuous Conduction Mode (VF-DCM), ac­tive Power Factor Correction (PFC) controller, optimized to deliver the lowest system cost in switched
mode power supply (SMPS) applications. The CS1501 uses a digital control algorithm that is optimized
for high efficiency and near-unity power factor over a wide input voltage range (90-265 VAC).

Using an adaptive digital control algorithm, both the ON time and the switching frequency are varied on a
cycle-by-cycle basis over the entire AC line to achieve close-to-unity power factor. The feedback loop is
closed through an integrated digital control system within the IC.

The variation in switching frequency also provides a spread-frequency spectrum, thus minimizing the con­ducted EMI filtering requirements. Burst mode control minimizes the light-load/standby losses. Protection
features such as overvoltage, overcurrent, overpower, open circuit, overtemperature, and brownout help
protect the device during abnormal transient conditions. Details of these features are provided in the
CS1501 data sheets.

The CDB150x-01 board demonstrates the performance of the CS1501 with input voltage range of 90-265
VAC, typically seen in universal input applications. This board has been designed for 400V V
Watts, full load.

link

, 90

Extreme caution needs to be exercised while handling this board. This board is to be used by trained pro­fessionals only. Prior to applying AC power to the CDB150x-01 board, the CS1501 needs to be biased
using an external 13 VDC power supply.

This document provides the schematic for the board. It includes oscilloscope screen shots that indicate
operating waveforms. Graphs are also provided that document the performance of the board in terms of
Efficiency vs. Load, Total Harmonic Distortion vs. Load, and Power Factor vs. Load for the CS1501 PFC
controller IC.

DS927DB4 3

2. SCHEMATIC

REV B1

12/3/2010

600-00473-Z2

CS1501

SCHEM., CDB150X-01

SHEET TITLE:

ECO# REV DESCRIPTION

INC BY/DATE CHK BY/DATE

OF

ENGINEER

SHEET

1

OF

1

SIZE C

DRAWN BY :

DATE:

PART #:

DESCRIPTIO N:

MUR160

Buss Ba r

NOT ES: UN LE SS OT HER WI SE SP EC IF IE D;

1. AL L RE SIST OR VA LU ES A RE I N O HMS.

Opti on1 @ U2=CS1500:

1. No populate d IC: U1

2. No populate d capacitors: C5, C8, C9, C11

3. No popul ated resis tors: R4,R6,R10,R17, R18,R21,R22

4. Shorted compone nts by #28 wire: L4,NTC2, R9

5. Value _changed capacit ors: C13=C14=C15=1nF

6. Value _changed resis tors: R1=R2=R13=R14=1M,R3=R15=887K

7. Boost inductor L5 has s ame footprint RM10, but diffe rent inductance
Opti on2 @ U1=CS1501:(PIN2=STBY, PIN3=IAC)

1. No populate d IC: U2

2. No populate d capacitors: C5,C8,C9

3. No popul ated resis tors: R4,R10,R17,R21, R22

4. Shorted compone nts by #28 wire: L4,NTC2

5. Value _changed capacit ors: C13=C14=C15=1nF

6. Value _changed resis tors: R1=R2=R13=R14=1M,R3=R15=887K

7. Value _changed resist ors: R6=48.7K,R18=1.74K,R9=0.1/3W

8. Boost inductor L5 has s ame footprint RM10, but diffe rent inductance
Opti on3 @ U1=FAN7529:(PIN2=COMP, PIN3=MOT)

1. No populate d IC: U2

2. No popul ated capaci tors: C5,C11,C14,C15

3. No popul ated resis tors: R1,R2,R3,R10, R18,R20

4. Shorted compone nts by #28 wire: L4,NTC2

6. Value _changed capacit ors: C9=47nF,C8=220nF

7. Value _changed resist ors: R4=820K,R17=10K,R21=56K,R22=12.6K

8. Value _changed resist ors: R6=20K,R13=R14=1M,R9=0.2/1W

9. Boost inductor L5 has s ame footprint RM10, but diffe rent inductance
Opti on4 @ U1=L6562A: (PIN2-COMP, PIN3=MULT)

1. No populate d IC: U2

2. No popul ated capaci tors: C5,C11,C13,C15

3. No popul ated resis tors: R4,R10,R18,R20

4. Shorted compone nts by #28 wire: L4,NTC2

5. Value _changed capacit ors: C9=150nF,C8=2.2uF,C14=10nF

6. Value _changed resist ors: R15=0,R17=22K,R21=15K,R22=12.6K

7. Value _changed resis tors: R1=0,R2=R3=R13=R14=1M,R6=47K,R9=0.3/1W

8. Boost inductor L5 has s ame footprint RM10, but diffe rent inductance
Opti on5 @ U1=NCP1606B:(PIN2=CTRL,PI N3=CT)

1. No populate d IC: U2

2. No popul ated capaci tors: C5,C11,C13,C15

3. No popul ated resis tors: R1,R2,R3,R10, R18,R20,R4,R21

4. Shorted compone nts by #28 wire: L4,NTC2

5. Value _changed capacit ors: C9=100nF,C8=390nF,C14=1.5nF

6. Value _changed resist ors: R13=R14=1M,R15=2M,R17=54.9K,R22=24.9K

7. Value _changed resist ors: R6=100K,R9=0.12/1W

5. Shorted compone nts by 0K resis tor: C13

8. Boost inductor L5 has s ame footprint RM10, but diffe rent inductance

A

INITIAL RELEASE

9/17/10 9/17/10

B CHANGED L5 TO NEW FOOTPRINT

12/9/10

ECO806

B1 CHANGED R6 FROM 17.8K TO 48.7K

01/05/11

ECO819

F1

4A

t

NTC1

30

NO POP - SHORT WITH 28 AWG WIRE

C1

2200pF

C2

2200pF

C3

0.22uF

C4

0.22uF

+

-

BR1

GBU4J-BP

600V

C5

NO POP

D1

C6

0.33uF

D2

MUR460G

600V

t

NTC2

30

NO POP, SHORT WITH AWG28 WIRE

R8 20K

1

2

CON2

TERM BLK

123

CON1

TERM BLK

R3

1M

MH1

SCREW-PHILIPS-4-40THR-PH-5/16-L -Z

ASSY DW G-

603-00473-Z1

PCB DWG-

240-00473-Z1

SCH DWG-

600-00473-Z2

MH3

MH4MH2

1

FD1

1

FD2

1

FD3

R20

1K

R6

48.7K

R2

1M

R13

1M

R18

1.78K

VZ

V300LA20AP

300V

E1

1PAD-H78P108

E2

1PAD-H78P108

1

2

3

4

L1

IND-5MH-TSD-2796

5mH

NO POP, SHORT PIN 1-2 & PI N 3-4 with 28 AWG wire

L2

IND-5MH-TSD-2796

5mH

123

CON3

TERM BLK

A1

1PAD-H78P108

A2

1PAD-H78P108

R19 100

C7

100uF

ELEC

R12

0

R11

1K

C10

4.7uF

1

VBIAS22STBY3IRECT4ILINK

5

GND

6GD7

VDD

8

VBIAS1

U2

CS1500-FSZ

NO POP

HS1

12.5W

C12

100pF

S

D

G

Q1

STP12NM50FP

L3

L4

NO POP, SHORT WITH AWG28 WIRE

L5

380uH

RLCS-1007

R17

NO POP

C8

NO POP

C9

NO POP

R21

NO POP

R22

NO POP

R4

NO POP

R10

NO POP

D3

LL4148

1

IFB2NC3IAC4CS

5

ZCD

6

GND

7GD8

VDD

U1

CS1501-FSZ

C11

33pF

R14

1M

R7

4.7 OHM

TP8

TP2

TP3

TP4

TP5

TP6

TP7

R5

NO POP

R16 0

R23

0

R15

1M

JP1

0.800" WIRE JUMPER

C14

1000pF

X7R

NO POP

C13

1000pF

X7R

C15

1000pF

X7R

NO POP

R1

1M

R9

0.1

1W

TO220-INSUL-MOUNT-HEATSINK-KIT

XHS1

LBL SU BASSY PR OD ID AN D REV

LBL SU BASSY PR OD NUMBE R

Figure 1. Schematic

CDB150x-01

4 DS927DB4

3. BILL OF MATERIALS

&,5586/2*,&

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%,//2)0$7(5,$/3DJHRI

,WHP &LUUXV31 5HY 'HVFULSWLRQ 4W\ 5HIHUHQFH'HVLJQDWRU 0)* 0)*31 1RWHV

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 DO NOT POPULATE

4 011-00064-Z1 A CAP 0.22uF ±20% 330V PLY FLM NPb TH 1 C4 EPCOS B32912B3224M ECO0841

5 011-00040-Z1 A CAP 0.47uF ±20% 305V PLY FLM NPb TH 0 C5 EPCOS B32922C3474M DO NOT POPULATE

6 013-00034-Z1 A CAP 0.33uF ±10% 630V POLY NPb RAD 1 C6 PANASONIC ECQE6334KF

7 012-00191-Z1 A CAP 100UF ±20% 450V ELEC NPb RAD 1 C7 NICHICON UVZ2W101MRD

8 000-00009-Z1 A NO POP CAP NPb 1206 0 C8 C9 NO POP NP-CAP-1206 DO NOT POPULATE

9 001-10233-Z1 A CAP 4.7uF ±20% 25V X7R NPb 1206 1 C10 TDK C3216X7R1E475M

10 001-05280-Z1 A CAP 33pF ±5% 50V C0G NPb 1206 1 C11 KEMET C1206C330J5GAC

11 001-05542-Z1 A CAP 100pF ±5% 50V C0G NPb 1206 1 C12 KEMET C1206C101J5GAC

12 001-06035-Z1 A CAP 1000pF ±5% 50V X7R NPb 1206 1 C13 KEMET C1206C102J5RAC

13 001-06035-Z1 A CAP 1000pF ±5% 50V X7R NPb 1206 0 C14 C15 KEMET C1206C102J5RAC DO NOT POPULATE

14 110-00301-Z1 A CON 3POS TERM BLK 5.08mm SPR NPb RA 2 CON1 CON3 WEIDMULLER 1716030000

15 110-00302-Z1 A CON 2POS TERM BLK 5.08mm SPR NPb RA 1 CON2 WEIDMULLER 1716020000

16 070-00132-Z1 A DIODE RECT 800V 1A 200mA NPb DO-41 1 D1 DIODES INC 1N4006G-T

17 070-00154-Z1 A DIODE RECT 600V 4A NPb DO-201AD TH 1 D2 ON SEMICONDUCTOR MUR460G

18 070-00001-Z1 A DIODE SS 75V 500mW NPb SOD80 1 D3 DIODES INC LL4148

19 180-00025-Z1 A FUSE 4A SLO BLO 250V NPb RAD 1 F1 BELFUSE RST 4

20 311-00019-Z1 A HTSNK W LOCK TAB .5" TO220 NPb 1 HS1 AAVID THERMALLOY 6021BG REQUIRES 1 SCREW, 300-00025-

Z1, 1 WASHER, 301-00013-Z1, 1

NUT, 302-00007-Z1

21 080-00013-Z1 A WIRE 24 AWG SOLID PVC INS BLK NPb 1 JP1 ALPHA WIRE

COMPANY

3050/1 BK005 SEE ASSY DWG FOR LENGTH

22 050-00039-Z1 A XFMR 5mH 1:1 1500Vrms 4PIN NPb TH 0 L1 PREMIER MAGNETICS TSD-2796 DO NOT POPULATE, SHORT PIN 1-

2 & PIN 3-4 with 28 AWG wire

23 050-00039-Z1 A XFMR 5mH 1:1 1500Vrms 4PIN NPb TH 1 L2 PREMIER MAGNETICS TSD-2796

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 DO NOT POPULATE, SHORT WITH

AWG28 WIRE

26 050-00051-Z1 A XFMR 380uH 10:1 PFC BOOST NPb TH 1 L5 RENCO RLCS-1007 ECO806

27 304-00004-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-Z1

28 036-00008-Z1 A THERM 30 OHM 1.5A 5% NPb RAD 0 NTC1 GE SENSING CL-210 DO NOT POPULATE, SHORT WITH

28 AWG WIRE

29 036-00008-Z1 A THERM 30 OHM 1.5A 5% NPb RAD 0 NTC2 GE SENSING CL-210 DO NOT POPULATE, SHORT WITH

AWG28 WIRE

30 071-00083-Z1 A TRAN MOSFET nCH 12A 500V NPb TO220 1 Q1 ST

MICROELECTRONICS

STP12NM50FP

31 020-06374-Z1 A RES 1M OHM 1/4W ±1% NPb 1206 6 R1 R2 R3 R13 R14 R15 DALE CRCW12061M00FKEA

32 000-00004-Z1 A NO POP RES NPb 1206 0 R4 R5 R17 R21 R22 NO POP NP-RES-1206 DO NOT POPULATE

33 020-06376-Z1 A RES 48.7K OHM 1/4W ±1% NPb 1206 1 R6 DALE CRCW120648K7FKEA ECO819

34 020-06389-Z1 A RES 4.7 OHM 1/4W ±1% NPb 1206 1 R7 DALE CRCW12064R70FKEA ECO805

35 020-06310-Z1 A RES 20K OHM 1/4W ±1% NPb 1206 FILM 1 R8 DALE CRCW120620K0FKEA

36 030-00092-Z1 A RES 0.1 OHM 3W ±1% WW ISEN NPb AXL 1 R9 OHMITE 13FR100E

37 021-01186-Z1 A RES 1 OHM 1W ±5% NPb 2512 FILM 0 R10 DALE CRCW25121R00JNEG DO NOT POPULATE

38 020-02616-Z1 A RES 1k OHM 1/4W ±1% NPb 1206 FILM 2 R11 R20 DALE CRCW12061K00FKEA

39 020-02273-Z1 A RES 0 OHM 1/4W NPb 1206 FILM 3 R12 R16 R23 DALE CRCW12060000Z0EA

40 020-06391-Z1 A RES 1.78K OHM 1/4W ±1% NPb 1206 1 R18 DALE CRCW12061K78FKEA

CDB150x-01

DS927DB4 5