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copyright ? cirrus logic, inc. 2011 (all rights reserved) www.cirrus.com actual size: 356 mm x 27 mm 14.0 in x 1.07 in CRD1601-120W cs1601 120w, high-efficien cy pfc + fluorescent lamp driver reference design features ? line voltage range: 108 to 305 vacrms ? output voltage (v link ): 460v ? rated maximum p in : 120w ? spread spectrum s witching frequency ? integrated digita l feedback control ? low component count general description the CRD1601-120W board demonstrates the perfor- mance of the cs1601 digital pfc controller in an electronic ballast application. the crd1601 uses a res- onant second stage driver to power up to two t5 fluorescent lamps. the crd1601 has been designed to fit into a slimline t5 fluorescent electronic ballast form- factor. ordering in formation CRD1601-120W pfc custom er reference design mar ?11 ds931rd3
CRD1601-120W 2 ds931rd3 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 q4 & q5. 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. 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.
CRD1601-120W ds931rd3 3 1. introduction the cs1601 is a high-performance variable frequenc y discontinuous conducti on mode (vf-dcm), ac- tive power factor correction (pfc) controller, optimize d to deliver the lowest pfc system cost for elec- tronic ballast applications . the cs1601 uses a digital control algorithm that is optimized for high efficiency and near unity power factor over a wide input voltage range (108-305 vac). the cs1601 uses an adaptive digital control algorith m. 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 varia- tion in switching frequency also provides a spread frequency spectrum, thus minimizing the conducted emi filtering requirements. the feedback loop is closed through an integrated digital control system within the ic. protection features such as overvoltage, overcurrent, overpower, open circuit, overtemperature, and brownout help protect the device during abnormal transient conditions. detail s of these features are provided in the cs1601 data sheet. the CRD1601-120W board demonstrates the performanc e of the cs1601 over a wide input voltage range. this board has been designed to generate 460v from the pfc stage, which is then processed by the resonant driver, to power up to two t5 lamps connected in series, for a total output of 108w. extreme caution needs to be exercised while hand ling this board. this board should be energized by trained professionals only. terminal block j1 is used to connect the ac line. the lamp is connected to terminal j2 as shown in the schematic. figure 1. board connections danger high voltage hazard only qualified personnel shou ld handle the CRD1601-120W. warning: heatsinking is required for q4 & q5. 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. j2 j1 ac line input terminals output
CRD1601-120W 4 ds931rd3 2. schematic rev c 01/07/2010 CRD1601-120W pfc for fluorescent ballast schematic CRD1601-120W-z 2 gp gp 1 chk by/date inc by/date description rev eco# size b of sheet part # description: drawn by: date: engineer: sheet title: typical vlink 460v max dc load 120 w danger! high voltage! 460 volt notes: unless otherwise specified; 1. all resistor values are in ohms. a initial design gp gp 08/10/2010 08/10/2010 hardware and documentation for use by trained professionals only 600-00467-z1 108-305 vac 45 - 65 hz line neutral ground b layout change to eliminate flicker eco807 a. garza gp 12/1/10 12/1/10 b1 schematic change to improve performance eco820 gp gp 01/14/11 01/14/11 eco825 b2 chgd r32 to 499 ohms a. garza 01/28/11 gp 01/28/11 eco839 c replace obsolete part c13 with 011-00048-z1 darren b. 03/15/11 colin lambert 03/15/11 chgd cirrus device from a1 to a2 assy dwg- 603-00467-z1 pcb dwg- 240-00467-z1 1 fd1 1 fd2 1 fd3 lbl subassy prod id and rev 422-00013-01 schematic dwg 600-00467-z1 mh1 mh3 mh4 mh2 f2 3.15a 1 2 3 4 l3 5mh c27 2200pf cer no pop c29 2200pf cer no pop 12 l5 1mh c31 0.33uf plyflm 1 + 3 4 - 2 d3 gbu4j-bp 600v r28 75 no pop r29 75 no pop 1 2 3 j6 term blk 1 2 3 4 l6 4mh no pop 1 2 rv1 s14k300 1 2 d1 1n4006g-t 1 2 d2 murs360t3g 600v r2 20k r4 24.9 r10 17.8k r12 1.15m 12 d4 ll4148 75v r13 1.78k g d s 1 3 2 q1 stb13nm60n 1 ifb 2 stby 3 iac 4 cs 5 zcd 6 gnd 7 gd 8 vdd u1 cs1601-fsz c10 1000pf cog c11 2200pf x7r r14 20 r24 0 c2 33pf cog c4 2200pf x7r r32 499 c5 4.7uf x7r jmp6 1.5" jumper 6 9 12 10 l2 380uh r33 1.15m r34 1.15m r35 1.15m r36 1.15m r37 1.15m c6 47uf 250v c17 47uf elec 250v r38 0.1 2w r40 0.24 1w no pop r41 0.24 1w no pop c8 0.22uf jmp2 0.800" wire jumper c30 2200pf cer c33 2200pf cer r39 0.1 2w no pop standoff-adhesive-rubber-375x250-z sj61a3 jmp8 1.6" jumper jmp9 1.5" jumper jmp10 1.0" wire jumper r1 1k c32 330pf c0g chgnd gnd chgnd gnd gnd vlink_jmp [2] gnd vdd_jmp [2] chgnd gnd
CRD1601-120W ds931rd3 5 rev c 01/07/2010 2 2 pfc for fluorescent ballast 600-00467-z1 sheet title: size b of sheet part # date: typical vlink 460v max dc load 120 w danger! high voltage! 460 volt for use by trained professionals only 1 ct 3 cf 2 csw 4 iref 5 gnd 6 gl 7 vdd 9 fvdd 8 pcs 10 gh 11 sh 12 acm 13 lvs 14 vref 15 csp 16 csn u2 uba2014t_n1-518_soic16-z c1 0.33uf x7r c3 0.33uf x7r 7 2 95 6 3 10 t1 tsd-2709 c9 5600pf x7r c13 270pf cer c16 0.1uf poly r11 2 r16 8.25k c18 0.068uf x7r r17 61.9k r18 8.25k c20 0.022uf x7r c22 0.22uf x7r c21 100pf cog r19 33.2k r20 221k r21 8.06k c23 0.056uf x7r c24 6800pf x7r c25 0.33uf x7r g d s 1 3 2 q4 spp04n60c3 g d s 1 3 2 q5 spp04n60c3 r22 3 r23 3 r25 2 r26 49.9 r27 150 c26 0.10uf x7r c19 1000pf x7r 1 2 z13 es1d 200v 12 z14 1n4148w c28 4.7nf b32612 1 2 z16 bzv55-b15-115 15v r3 2 r7 330k r8 330k c7 0.15uf plyflm c12 0.15uf plyflm c14 0.15uf plyflm c15 330pf cer 12 z9 1n4148w jmp3 0.750" wire jumper jmp4 1.3" jumper jmp5 0.750" wire jumper jmp1 2.7" wire jumper 1 2 3 4 5 6 j2 6 pos trmblk jmp7 1.25" wire jumper 1 2 z1 1n4148w 1 2 z2 1n4148w 1 2 z3 1n5244b 14v r5 33 r30 0 tp1 test-point-black-z no pop tp2 test-point-black-z no pop vcc gnd gnd gnd gnd gnd gnd gnd gnd gnd gnd_jmp gnd gnd gnd_jmp gnd_jmp gnd gnd_jmp gnd_jmp vdd_jmp [1] gnd gnd_jmp vlink [2] vlink_jmp [1] vlink [2] gnd
CRD1601-120W 6 ds931rd3 3. bill of materials cirrus logic CRD1601-120W_rev_ c bill of material (page 1 of 2) item cirrus p/n rev description qty reference designator mfg mfg p/n notes 1 001-10235-z1 a cap 0.33uf 10% 50v x7r npb 1206 3 c1 c3 c25 kemet c1206c334k5rac 2 001-05280-z1 a cap 33pf 5% 50v c0g npb 1206 1 c2 kemet c1206c330j5gac 3 001-06276-z1 a cap 2200pf 10% 50v x7r npb 1206 2 c4 c11 kemet c1206c222k5rac 4 001-10233-z1 a cap 4.7uf 20% 25v x7r npb 1206 1 c5 tdk c3216x7r1e475m 5 012-00186-z1 a cap 47uf 20% 250v elec npb rad 2 c6 c17 nichicon uvz2e470mhd 6 013-00037-z1 a cap 0.15uf 10% 250v poly npb rad 3 c7 c12 c14 epcos b32529c3154k 7 011-00064-z1 a cap 0.22uf 20% 330v ply flm npb th 1 c8 epcos b32912b3224m eco0839 8 001-06516-z1 a cap 5600pf 10% 50v x7r npb 1206 1 c9 kemet c1206c562k5rac 9 001-06036-z1 a cap 1000pf 10% 50v c0g npb 1206 1 c10 kemet c1206c102k5gac 10 011-00048-z1 a cap 270pf 10% 1kv cer npb rad 1 c13 tdk ck45-r3ad271k-nr eco0839 11 011-00046-z1 a cap 330pf 10% 2kv cer npb rad 1 c15 tdk ck45-r3dd331k-nr 12 013-00027-z1 a cap 0.1uf 10% 630v poly npb rad 1 c16 panasonic ecqe6104kf 13 001-06838-z1 a cap 0.068uf 10% 50v x7r npb 1206 1 c18 kemet c1206c683k5rac 14 011-00045-z1 a cap 1000pf 10% 500v x7r npb rad 1 c19 vishay/sprague 562r5tsd10 15 001-06709-z1 a cap 0.022uf 5% 50v x7r npb 1206 1 c20 kemet c1206c223j5rac 16 001-05542-z1 a cap 100pf 5% 50v c0g npb 1206 1 c21 kemet c1206c101j5gac 17 001-06948-z1 a cap 0.22uf 10% 50v x7r npb 1206 1 c22 kemet c1206c224k5rac 18 001-06821-z1 a cap 0.056uf 10% 50v x7r npb 1206 1 c23 kemet c1206c563k5rac 19 001-06548-z1 a cap 6800pf 10% 50v x7r npb 1206 1 c24 kemet c1206c682k5rac 20 001-10225-z1 a cap 0.10uf 10% 25v x7rlesr npb 0603 1 c26 murata grm188r71e104ka01d 21 011-00049-z1 a cap 2200pf 20% disc 500v rad npb 0 c27 c29 vishay vy1222m47y5uq63v0 no pop 22 013-00026-z1 a cap 4.7nf 5% 1600v poly npb rad 1 c28 epcos b32612a1472j008 23 011-00049-z1 a cap 2200pf 20% disc 500v rad npb 2 c30 c33 vishay vy1222m47y5uq63v0 24 013-00034-z1 a cap 0.33uf 10% 630v poly npb rad 1 c31 panasonic ecqe6334kf 25 011-00059-z1 a cap 330pf 5% 100v c0g c315 npb th 1 c32 kemet c315c331j1g5ca form leads to match layout 26 070-00132-z1 a diode rect 800v 1a 200ma npb do-41 1 d1 diodes inc 1n4006g-t 27 070-00166-z1 a diode rect 600v 4a ult fst npb smc 1 d2 on semiconductor murs360t3g 28 070-00157-z1 a diode rect bridge 600v 4a npb gbu 1 d3 micro commercial co gbu4j-bp 29 070-00001-z1 a diode ss 75v 500mw npb sod80 1 d4 diodes inc ll4148 30 180-00022-z1 a fuse 3.15a tlag iec npb short tr5 1 f2 little fuse 37213150411 31 110-00321-z1 a con term blk 6x1 fml ra grn npb th 1 j2 phoenix contact 1727052 32 110-00301-z1 a con 3pos term blk 5.08mm spr npb ra 1 j6 weidmuller 1716030000 33 080-00013-z1 a wire 24 awg solid pvc ins blk npb 10 jmp1 jmp2 jmp3 jmp4 jmp5 jmp6 jmp7 jmp8 jmp9 jmp1 0 alpha wire company 3050/1 bk005 see assy dwg for length 34 050-00050-z1 a xfmr 380uh 10% .265o npb th 1 l2 renco rlcs-1005 35 050-00039-z1 a xfmr 5mh 1:1 1500vrms 4pin npb th 1 l3 premier magnetics tsd-2796 36 040-00127-z1 a ind 1mh 1.3a 15% tor vert npb th 1 l5 bourns 2124-v-rc 37 050-00047-z1 a xfmr common mode choke 1.3 a th npb 0 l6 renco rl-4400-2-4.00 no pop 38 304-00001-z1 a spcr standoff 4-40 thr .875l al npb 0 mh1 mh2 mh3 mh4 keystone 1809 install rubber feet sj61a3 39 071-00108-z1 a tran mosfet nch 11a 600v npb d2pak 1 q1 st microelectronics stb13nm60n 40 071-00082-z1 a tran mosfet nch 69w npb to220-3 2 q4 q5 infineon spp04n60c3 41 030-00010-z1 a res 1k 1/4w 1% metal film npb axl 1 r1 vishay ccf551k00fke36 42 020-06310-z1 a res 20k ohm 1/4w 1% npb 1206 film 1 r2 dale crcw120620k0fkea 43 020-06347-z1 a res 2.00 ohm 1/4w 1% npb 1206 3 r3 r11 r25 dale crcw12062r00fkea 44 020-06337-z1 a res 24.9 ohm 1/4w 1% npb 1206 film 1 r4 dale crcw120624r9fkea 45 021-00544-z1 a res 33 ohm 1/4w 5% npb 1206 film 1 r5 dale crcw120633r0jnea 46 031-00052-z1 a res 330k ohm 1/4w 5% carfl npb axl 2 r7 r8 panasonic erd-s2tj334v 47 020-06390-z1 a res 17.8k ohm 1/4w 1% npb 1206 1 r10 dale crcw120617k8fkea 48 020-06356-z1 a res 1.15m ohm 1/4w 1% npb 1206 6 r12 r33 r34 r35 r36 r37 dale crcw12061m15fkea 49 020-06391-z1 a res 1.78k ohm 1/4w 1% npb 1206 1 r13 dale crcw12061k78fkea 50 020-06324-z1 a res 20 ohm 1/4w 1% npb 1206 film 1 r14 dale crcw120620r0fkea 51 020-06343-z1 a res 8.25k ohm 1/4w 1% npb 1206 2 r16 r18 dale crcw12068k25fkea 52 020-06345-z1 a res 61.9k ohm 1/4w 1% npb 1206 1 r17 dale crcw120661k9fkea 53 020-06346-z1 a res 33.2k ohm 1/4w 1% npb 1206 1 r19 dale crcw120633k2fkea 54 020-06342-z1 a res 221k ohm 1/4w 1% npb 1206 film 1 r20 dale crcw1206221kfkea 55 020-06344-z1 a res 8.06k ohm 1/4w 1% npb 1206 1 r21 dale crcw12068k06fkea 56 021-06319-z1 a res 3 ohm 1/2w 5% npb 1210 film 2 r22 r23 panasonic erj14yj3r0u 57 020-02273-z1 a res 0 ohm 1/4w npb 1206 film 2 r24 r30 dale crcw12060000z0ea 58 020-02467-z1 a res 49.9 ohm 1/4w 1% npb 1206 film 1 r26 dale crcw120649r9fkea
CRD1601-120W ds931rd3 7 cirrus logic CRD1601-120W_rev_ c bill of material (page 2 of 2) item cirrus p/n rev description qty reference designator mfg mfg p/n notes 59 020-02520-z1 a res 150 ohm 1/4w 1% npb 1206 film 1 r27 dale crcw1206150rfkea 60 020-02488-z1 a res 75 ohm 1/4w 1% npb 1206 film 0 r28 r29 dale crcw120675r0fkea no pop 61 020-02581-z1 a res 499 ohm 1/4w 1% npb 1206 film 1 r32 dale crcw1206499rfkea eco0825 62 030-00091-z1 a res 0.1 ohm 2w 1% ww npb axl 1 r38 vishay g003r1000fe7080 63 030-00091-z1 a res 0.1 ohm 2w 1% ww npb axl 0 r39 vishay g003r1000fe7080 no pop 64 020-06372-z1 a res 0.24 ohm 1w 1% npb 2512 0 r40 r41 panasonic erj1trqfr24u no pop 65 036-00015-z1 a varistor 470v rms 14mm npb rad 1 rv1 epcos s14k300 66 050-00042-z1 a xfmr 1.3mh 2000vac 10pin npb th 1 t1 premeir tsd-2709 67 110-00045-z1 a con test pt .1"ctr tin plat npb blk 0 tp1 tp2 keystone 5001 no pop 68 065-00331-z3 a2 ic crus lpwr factor corr npb soic8 1 u1 cirrus logic cs1601-fsz/a2 eco0839 69 060-00477-z1 a ic cntl ballast 600v npb soic16 1 u2 nxp uba2014t/n1,518 70 305-00005-z1 a feet prot adh back .375x.25 blk npb 4 xmh1 xmh2 xmh3 xmh4 3m sj61a3 see assembly drawing 71 070-00007-z1 a diode fast sw 75v 350mw npb sod123 4 z1 z2 z9 z14 diodes inc 1n4148w-7-f 72 070-00194-z1 a diode zen 14v 15ohm 500mw npb do-35 1 z3 fairchild semiconductor 1n5244b 73 070-00196-z1 a diode rect 200v 1a sma npb do-214ac 1 z13 taiwan semiconductor es1d 74 070-00195-z1 a diode zener 500mw 15v 8.5ma minimlf 1 z16 nxp bzv55-b15,115 75 603-00467-z1 c assy dwg CRD1601-120W-z-npb ref cirrus logic 603-00467-z1 76 422-00013-01 c lbl subassy product id and rev 1 cirrus logic 422-00013-01 77 240-00467-z1 c pcb CRD1601-120W-z-npb ref cirrus logic 240-00467-z1 78 600-00467-z1 c schem CRD1601-120W-z-npb ref cirrus logic 600-00467-z1 eco0820/0825/0839
CRD1601-120W 8 ds931rd3 4. board layout figure 3. silkscreen (top) figure 2. solder mask (top)
CRD1601-120W ds931rd3 9 figure 4. circuit routing (bottom) figure 7. solder mask (bottom) figure 5. solder paste mask (bottom) figure 6. silkscreen (bottom)
CRD1601-120W 10 ds931rd3 5. performance plots .95 .96 .97 .98 .99 1.00 100 120 140 160 180 200 220 240 260 280 300 power factor input voltage (vac) 0% 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% 100 120 140 160 180 200 220 240 260 280 300 thd input voltage (vac) figure 8. power factor vs. ac input voltage figure 9. thd vs. ac input voltage
CRD1601-120W ds931rd3 11 100 102 104 106 108 110 112 114 116 118 120 100 120 140 160 180 200 220 240 260 280 300 input power (w) input voltage (vac) figure 10. input power vs. ac input voltage
CRD1601-120W 12 ds931rd3 6. revision history revision date changes rd1 feb 2011 initial release. rd2 feb 2011 minor bom & schematic change to eliminate possible flicker. rd3 mar 2011 updated bom, schematic, and la yers to rev c (rev a2 cirrus device).

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