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copyright ? cirrus logic, inc. 2011 (all rights reserved) www.cirrus.com actual size: 254mm x 44mm ac line input regulated dc output cdb150x-01 cs1501 90w, high-efficiency pfc demonstration board features ? variable on time, variab le 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 out- put at a link voltage of 400 volts. ordering in formation cdb150x-01 pfc demonstration board - supports cs1501 mar ?11 ds927db3
cdb150x-01 2 ds927db3 contacting cirrus logic support for all product questions and inquiries contact a cirrus lo gic 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 reli able. 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 ob tain the latest version of relevant information to verify, before placing orders, that information be ing relied on is current and complete. all products are sold s ubject to the terms and conditions of sale supplied at the time of order acknowledgment, including those pertaining to warranty, indemnification, and limitation of liabil ity. 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 in fringement of patents or other rights of third parties. this document is the property of cirrus and by furnishi ng this information, cirrus grants no license, express or impli ed under any patents, mask work rights, copyrights, trademarks, trade secrets or other intellectual property rights. cirrus owns the copyrights associated with the inf ormation contained herein and gives consent for copies to be made of the information only for use within your organization with respect to cirrus integrated circui ts 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 cre ating 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"). cir rus 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. in clusion 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 merchant- ability and fitness for particular purpose, with regard to any ci rrus 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, in- cluding attorneys' fees and costs, that may result from or arise in connection with these uses. cirrus logic, cirrus, and the cirrus logic logo designs 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 genera l 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.
cdb150x-01 ds927db3 3 1. introduction the cs1501 is a high-performance variable frequenc y discontinuous conducti on mode (vf-dcm), ac- tive power factor correction (pfc) controller, optimiz ed to deliver the lowest system cost in switched mode power supply (smps) appl ications. the cs1501 uses a digital c ontrol 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 con- ducted emi filtering requirements. burst mode cont rol minimizes the light-load /standby losses. protection features such as overvoltage, overcurrent, over power, open circuit, overtem perature, 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 boar d has been designed for 400v v link , 90 watts, full load. extreme caution needs to be exercis ed while handling this board. this board is to be used by trained pro- fessionals 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.
cdb150x-01 4 ds927db3 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 #: description: mur160 buss bar notes: unless otherwise specified; 1. all resistor values are in ohms. option1 @ u2=cs1500: 1. no populated ic: u1 2. no populated capacitors: c5, c8, c9, c11 3. no populated resistors: r4,r6,r10,r17,r18,r21,r22 4. shorted components by #28 wire: l4,ntc2,r9 5. value_changed capacitors: c13=c14=c15=1nf 6. value_changed resistors: r1=r2=r13=r14=1m,r3=r15=887k 7. boost inductor l5 has same footprint rm10, but different inductance option2 @ u1=cs1501:(pin2=stby,pin3=iac) 1. no populated ic: u2 2. no populated capacitors: c5,c8,c9 3. no populated resistors: r4,r10,r17,r21,r22 4. shorted components by #28 wire: l4,ntc2 5. value_changed capacitors: c13=c14=c15=1nf 6. value_changed resistors: r1=r2=r13=r14=1m,r3=r15=887k 7. value_changed resistors: r6=48.7k,r18=1.74k,r9=0.1/3w 8. boost inductor l5 has same footprint rm10, but different inductance option3 @ u1=fan7529:(pin2=comp, pin3=mot) 1. no populated ic: u2 2. no populated capacitors: c5,c11,c14,c15 3. no populated resistors: r1,r2,r3,r10,r18,r20 4. shorted components by #28 wire: l4,ntc2 6. value_changed capacitors: c9=47nf,c8=220nf 7. value_changed resistors: r4=820k,r17=10k,r21=56k,r22=12.6k 8. value_changed resistors: r6=20k,r13=r14=1m,r9=0.2/1w 9. boost inductor l5 has same footprint rm10, but different inductance option4 @ u1=l6562a: (pin2-comp, pin3=mult) 1. no populated ic: u2 2. no populated capacitors: c5,c11,c13,c15 3. no populated resistors: r4,r10,r18,r20 4. shorted components by #28 wire: l4,ntc2 5. value_changed capacitors: c9=150nf,c8=2.2uf,c14=10nf 6. value_changed resistors: r15=0,r17=22k,r21=15k,r22=12.6k 7. value_changed resistors: r1=0,r2=r3=r13=r14=1m,r6=47k,r9=0.3/1w 8. boost inductor l5 has same footprint rm10, but different inductance option5 @ u1=ncp1606b:(pin2=ctrl,pin3=ct) 1. no populated ic: u2 2. no populated capacitors: c5,c11,c13,c15 3. no populated resistors: r1,r2,r3,r10,r18,r20,r4,r21 4. shorted components by #28 wire: l4,ntc2 5. value_changed capacitors: c9=100nf,c8=390nf,c14=1.5nf 6. value_changed resistors: r13=r14=1m,r15=2m,r17=54.9k,r22=24.9k 7. value_changed resistors: r6=100k,r9=0.12/1w 5. shorted components by 0k resistor: c13 8. boost inductor l5 has same footprint rm10, but different 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 1 2 3 con1 term blk r3 1m mh1 screw-philips-4-40thr-ph-5/16-l-z assy dwg- 603-00473-z1 pcb dwg- 240-00473-z1 sch dwg- 600-00473-Z2 mh3 mh4 mh2 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 & pin 3-4 with 28 awg wire l2 ind-5mh-tsd-2796 5mh 1 2 3 con3 term blk a1 1pad-h78p108 a2 1pad-h78p108 r19 100 c7 100uf elec r12 0 r11 1k c10 4.7uf 1 vbias2 2 stby 3 irect 4 ilink 5 gnd 6 gd 7 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 ifb 2 nc 3 iac 4 cs 5 zcd 6 gnd 7 gd 8 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 subassy prod id and rev lbl subassy prod number figure 1. schematic
cdb150x-01 ds927db3 5 3. bill of materials
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() )"' 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 6 ds927db3 cirrus logic cdb150x-01_rev_c bill of material (page 2 of 2) item cirrus p/n rev description qty reference designator mfg mfg p/n notes 41 020-02502-z1 a res 100 ohm 1/4w 1% npb 1206 film 1 r19 dale crcw1206100rfkea 42 110-00025-z1 a con test pt .1" tin plate wht npb 7 tp2 tp3 tp4 tp5 tp6 tp7 tp8 keystone 5002 43 065-00328-z3 a2 ic crus lpwr factor corr npb soic8 1 u1 cirrus logic cs1501-fsz/a2 eco0841 44 065-00276-z5 c1 ic crus lpwr factor corr npb soic8 0 u2 cirrus logic cs1500-fsz/c1 do not populate 45 036-00006-z1 a varistor 300v 400pf 14mm npb rad 1 vz littelfuse v300la20ap 46 311-00025-z1 a htsnk to220 mounting kit npb 1 xhs1 aavid thermalloy 4880g includes all mounting hardware 47 300-00025-z1 a screw 4-40x5/16" ph mach ss npb 4 xmh1 xmh2 xmh3 xmh4 building fasteners pmsss 440 0031 ph 48 422-00013-01 c lbl subassy product id and rev 1 cirrus logic 422-00013-01 49 422-00037-01 c lbl subassy product number 1 cirrus logic 422-00037-01 see assydwg for label placement 50 603-00473-z1 c assy dwg cdb150x-0x-z-npb ref cirrus logic 603-00473-z1 eco805/eco824/eco0841 51 240-00473-z1 c pcb cdb150x-0x-z-npb 1 cirrus logic 240-00473-z1 eco805/eco824/eco0841 52 600-00473-Z2 c schem cdb150x-01-z-npb ref cirrus logic 600-00473-Z2 eco819/ec o0841 080-00036-z1 a wire 22awg 19/34 str blk 105c np 1 alpha wire company 5855 bk005 eco824, see assy dwg 080-00002-01 a wire 28/1 awg, kynar mod, 500ft 1 squires l 500 ul1422 28/1 blu eco824, see assy dwg
cdb150x-01 ds927db3 7 4. board layout figure 2. top silkscreen
cdb150x-01 8 ds927db3 figure 3. bottom routing figure 4. bottom silkscreen figure 5. bottom solder paste mask
cdb150x-01 ds927db3 9 5. performance plots 0 2 4 6 8 10 12 14 16 18 20 10 13.5 18 27 36 45 63 90 94.5 thd(%) output power (w) vin=110 vin=220 85 87 89 91 93 95 97 99 567891013.518273645639094.5 efficiency(%) output power (w) vin=110 vin=220 figure 6. efficiency vs. load at 110 vac, 220 vac figure 7. distortion vs. load at 110 vac, 220 vac
cdb150x-01 10 ds927db3 0.7 0.75 0.8 0.85 0.9 0.95 1 10 13.5 18 27 36 45 63 90 94.5 power factor output power (w) vin=110 vin=220 390 392 394 396 398 400 402 404 406 408 410 1234567891013.518273645639094.5 v link (v) output power (w) vin=110 vin=220 figure 8. power factor vs. load at 110 vac, 220 vac figure 9. v link vs. output power at 110 vac, 220 vac
cdb150x-01 ds927db3 11 figure 10. steady state waveforms ? 110 vac figure 11. switching frequency profile at peak of ac line voltage ? 110 vac
cdb150x-01 12 ds927db3 figure 12. switching frequency profile at trough of ac line voltage ? 110 vac figure 13. steady state waveforms ? 220 vac
cdb150x-01 ds927db3 13 figure 14. switching frequency profile at peak of ac line voltage ? 220 vac figure 15. switching frequency profile at trough of ac line voltage ? 220 vac
cdb150x-01 14 ds927db3 figure 16. load transient ? 9 w to 90 w, 1 w/us, 110 vac figure 17. load transient ? 90 w to 9 w, 1 w/us, 110 vac
cdb150x-01 ds927db3 15 figure 18. load transient ? 9 w to 90 w, 1 w/us, 220 vac figure 19. load transient ? 90 w to 9 w, 1 w/us, 220 vac
cdb150x-01 16 ds927db3 6. revision history revision date changes db1 feb 2011 initial release. db2 feb 2011 updated efficiency vs. load plot with more current data. db3 mar 2011 updated bom & layers to rev c.

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