USER MANUAL

Air Conditioner Reference Manual

1 Introduction
The Development Board is intended to aid the user in the rapid evaluation and development of a wide variety of dual or single
motor control applications. This development system is targeted to control Brushless DC (BLDC) motors, Permanent Magnet Syn-
chronous Motors (PMSM) in sensor-less operation.

The system has Front end Interleaved Boost convertor for the Power factor correction. The boost convertor also helps to regu-
late the DC Bus over a wide input range. Two motor loads can be controlled simultaneously with the demo board. three-phase
IPM inverter that can drive high powered motor and separate discrete gate driver’s & IGBT circuitry intended to drive ODU. The
circuit drives a BLDC, PMSM or ACIM motor using different control techniques independent of additional hardware. It also has Power
Factor Correction (PFC) circuitry in order to provide efficient performance at light loads.

This development board is designed to target the Air-conditioner application primarily where control of Compressor & ODU is
possible simultaneously along with power factor control Stage to meet the regulations. The board is intended for approximately
1.8KW output when running from a 160V to 265V single-phase input voltage range. The Demo board supports 1.34KW compressor
and up to 120W ODU Condenser Fan. Additional Features like Sensors for temperature monitoring, Stepper motor control for EEV,
and relays for ac loads have been implemented in the demo board to support Air-conditioner design requirements.

The demo board can also be considered for other high-power applications like HVAC, Textile machines, water pumps, indus-
trial motors with slight modifications.

FIGURE 1 : BLOCK DIAGRAM OF CONTROL BOARD

 USER MANUAL

2 Board Image

Compressor
ODU

MCU

&

Current Sense

Amplifers

Interleaved PFC

EMI Filter and Bridge

FIGURE 2 : BOTTOM VIEW

FIGURE 3 : TOP VIEW

 USER MANUAL

3 Design Specifications
The below table shows the specification of the EVK Board.

RSI-B-0039 REV 1.0 Board Specifications

Description Symbol MIN TYP MAX Unit

Input Voltage VIN 160 220 265 Vac

Frequency FLINE 60 Hz

DC Bus Voltage VOUT 378 380 385 V

Output Ripple Voltage VRIPPLE <2 V

Output Current IOUT 5 A

PFC: 64
Switching frequency Fsw kHz
Motor: 4Khz ~ 16Khz

Input Power PIN (max) 1800 W

Efficiency @ Full Load, 230Vac ŋ ➢ 92 %

Ambient temperature Max TAMB 65 oC

Line/Load Regulation <3 %

Power factor 0.99

Standby Power 1.5 to 3.5 W

Assembled PCB Size 190 x 300 x 85 mm

 4
1 2 3 4 5 6

F101 PFC :Low Side driver

AC V+
ACV ACV+
250VAC/ 25A
6.99m m x 32.7m m
CY101 U105
RV102
RV100 470 0pF PF C_EN ABLE A 1 8PF C_EN ABLE B
14mm 13 m m D ia 2 L100 3 PFC_ENABLEA EN_A EN_B PFC_ENABLEB
14mm 510V
510V
CX100 440VAC CY100 R125 R122
1uF,X-Typ e 470 0pF PF C_PWM A_G 2 7 PF C_G ATEA
470K PFC_PWM A_G INA OUTA PFC_GATEA
TH_26.5x11x20m m_22.5P 1 4 13 m m D ia 0R
A L CY102 (2512 ) A
310VAC 440VAC (0805 ) 3 6
L 4.5mH CX101 GND VDD
470 0pF
13 m m D ia
1uF,X-Typ e RV103 R123
N 310VAC PF C_PWM B_G 4 5 PF C_G ATEB
N 440VAC 14mm PFC_PWM B_G INB OUTB PFC_GATEB
510V 0R
E (0805 ) MCP14E4 +15V
Schematic

E
RV101 R157 R158 R160
N 14mm R124 10K 10K 10K
510V
(0805 ) (0805 ) (0805 )

160 V AC - 285 V AC
G100 470K DGND R161
(2512 ) + C110
1 2 C111 10K
CY103 10uF (0805 )
50V 0.1uF
470 0pF 25V
GDT 13 m m D ia (0805 )
8 x15m m 440VAC
AC V- DGND
ACV-
DGND
E MI Component Placeholders

+12V ACV RT1

Inrush Lim it F100 +12V +15V
AVDD DVDD
ACV +

K
+t o 1
D106 1
2
US1M 2
3
1000 V 3 -
4 PGND 3
4
B 1A 4 B
5 VDC
SM A 5

A
J100 6
2 1
J101

R159 RLY100
RE LA Y_INR USH _CTR L RE LAY_I NRU SH_CT RL AGND DGND
0R SFK-112DMP-F
(0805 )

Test Points
R213 R205
TP100
0R 0R PFC_PWM A_G
(Net Tie) (Net Tie) PFC_PWM A

AGND DGND PGND

TP101
D101 PFC_PWM B_G
L102 PFC_PWM B
DC V+ 12 1 A K
900uH TP102
RFUH30TS6S PFC_GATEA
600V
TO247
PFC_GATEA
C C
D100 VDC
L101 VDC TP103
12 1 A K
PFC_GATEB
900uH PFC_GATEB
RFUH30TS6S
AC V-
600V DCV+

1
ACV- C102 D102 R101 D103 R102 TO247 DC V+
K A K A
BR1 1uF RGTH80TS65 RGTH80TS65

+
K
TH - 26.5x10x18.5_22.5P 1SS355VM
0R 1SS355VM 0R
2 GBJ250 8-F SO D-323FL (0805 ) SO D-323FL (0805 )

K
4-SIP, G BJ 630VD C DCV-
3 90V 2 Q100 90V 2 D104
R104 D105 R105 DNP
PF C_G ATEA 1 PF C_G ATEB 1 Q101 + C103 + C104

-
PFC_GATEA 650V DNP PFC_GATEB 650V 1000 V 680uF 680uF
AC V+ 10R C136 10R C137
ACV+ TO247 1000 V TO247 SM A 500V 500V DCV-
(0805 ) 100 0pF R106 3 (0805 ) 100 0pF R107 3

4
25V 25V
A

(0805 ) 10K (0805 ) 10K

SM A

A
DNP (0805 ) DNP (0805 )

R109 R110 Heatsink Ho les Fiducial Pad Mounting Holes

PF C_I A_P PF C_I B_P
PFC_IA_P PFC_IB_P
0R 0R MH9 MH10 MH11 MH12 MH1 MH2 MH3 MH4
(0805 ) R111 R112 FD1 FD2 FD3
(0805 )

FIGURE 4 INPUT AC & PFC STAGE SCHEMATIC (SHEET 1 OF 10)

1
1
1
1
1
1
1
1

25mR 25mR
1
1
1

R114 Strip R115 Strip

PF C_I A_N PF C_I B_N MH16
PFC_IA_N PFC_IB_N MH13 MH14 MH15
0R 0R PGND FD4 FD5 FD6 MH5 MH6 MH7 MH8
R118
1

(0805 ) (0805 )
1
1
1
1
1
1
1
1
1
1

10mR
D DCV- Strip D
PGND
R120 Title
PF C_I DC_P
PFC_IDC_P Airco nditioner - 1.8KW
0R
(0805 )
Size: Numb er: Revision:
R121
PF C_I DC_N
PFC_IDC_N B RSI-B-0039 REV 1.0
0R
(0805 ) Date: 31-01-201 9 Tim e: 08:48:08 Sheet1 of To talpage s
File:
1 2 3 4 5 6
USER MANUAL
 1 2 3 4 5 6

C200 C201
R200

100R
VDC _PS 2.2nF_YCAP (0805 )
220PF
8m m D ia 100V
4m m x 2.5m m
D200 +15V_PS
L200
5 6 A K

A
6.8uH Current
A MBRS2H100T3G SL V ol tage Regulation A
R201
D201 100V 2A +12V_PS
+ C202 R202 1K
P6KE200A C203 SM B
10uF DNP C204 (1206 )

K
DO -204AC DNP R203
450V 2W + + R204
TH
C205 C206
1KV 4 1) 15V 500mA 1%

K
100R 330uF 100uF 3K
220PF

A
7 (0805 ) 35V 25V (1206 )
D203 100V LD200
4m m x 2.5m m + C207
US1M D202 RED

K
1000 V
470uF (0805 )
PGND_PS A K 25V
2) 12V 500mA 5%
SM A

A
C208 3 MBRS2H100T3G
47pF 100V 2A DGND_PS
1KV 8 SM B 3) 3.3V 500mA 5%
5.5m m x 4m m
D204 +4V_PS DGND_PS
L201
U200 9 A K
Vbias D205 6.8uH
2 7 R206 K A 2
NC DRAIN MBRS2H100T3G
Vbias 100V 2A Test Points For Main Board
100R SM B
5 6 (0805 ) MBRS2H100T3G + C209 + C210
VCC DRAIN 100V 2A
+ C212 680uF 330uF
C211 1 SM B
SOURCE 10uF 25V 25V Test Points For Aux PS Board
0.1uF 63V R207 R208

GND
FB
25V 1 10 +15V
(0805 ) 1.2K 75K +15V
(0805 ) (0805 )

3
TR1

4
B PGND_PS TP213 B
BM2P014 1.1mH +4V_PS
PGND_PS DGND_PS
+12V
+12V
RS200 +15V_PS
820mR ISO200 +15V_PS DVDD
1W C213 4 1 R209
(2512 ) 100 0pF 2.7K
25V 3 2 (0805 )
(0805 ) +12V_PS DVDD1
C214 +12V_PS DVDD
EL357N-G R210
PGND_PS 80V
10K
(0805 )
0.1uF

2
PGND_PS 25V DVDD_PS AVDD
(0805 ) DVDD_PS AVDD
C215 1
2.2uF R211
25V TL V431A-D

3
(0805 ) 15K AVDD_PS PGND1
U201 (0805 )
AVDD_PS

PGND PGND2
DGND_PS PGND_PS

PGND3

C PGND_PS C
DGND
+4V_PS DVDD_PS AVDD_PS DGND_PS
MIC371 00-3.3WS-CT-ND
U202 DGND1
R212 AVDD_PS DVDD_PS +12V_PS +15V_PS DGND
1 3
VIN VOUT DGND_PS
GND GND 0R
(1206 ) 1 AGND_PS DGND2
1
2 4 2
PGND_PS 2
3
3 DGND3
+ C218 + C219 4
C217 C220 VDC_PS 4 AGND_PS
47uF 22uF 5
10uF 0.1uF 5
10V 10V J200 6
25V 120 6) CASEA(120 6) 25V VDC _PS AGND
(0805 ) (0805 ) VDC_PS
J201

AGND AGND1
DGND_PS DGND_PS DGND_PS AGND_PS AGND_PS DGND_PS

FIGURE 5 AUXILIARY POWER STAGE SCHEMATIC (SHEET 2 OF 10)

AGND2

D D

Title
Airco nditioner - 1.8KW
NOTE : PGND_DS & DGND_DS are sh orted wit h a Net tie in the m ain Board.
Size: Numb er: Revision:
B RSI-B-0039 REV 1.0
Date: 1/29/201 9 Tim e: 10:32:56 AM Sheet2 of To talpage s
File:
USER MANUAL

1 2 3 4 5 6
 1 2 3 4 5 6

+ C300
C301 MC1_ B EMF sensing
47uF
35V
0.1uF D303 AVDD
25V 2 M C1_U
(0805 ) MC1_U
M C1_VU 3
MC1_VU
+ C302 1 R300
C303 100K
47uF DAN217UM
35V
0.1uF (1206 )
25V SO T-323FL
(0805 )
A C305 D304 A
+ C304 R301
0.1uF 2 100K
47uF 25V
35V M C1_VV 3 (1206 )
(0805 ) MC1_VV
1
R302
DAN217UM
SO T-323FL 100K
U300 (1206 )
VDC R303
D305 M C1_VU
MC1_VU
2 24 2 300 R
VBU P [VDC]
M C1_VW 3 R304 (0805 )
C308 MC1_VW C307
3 1 2.2K
VBV 1uF 4.7nF
(0805 )
4 630VD C DAN217UM 25V
VBW TH - 26.5x10x18.5_22.5P SO T-323FL (0805 )
MC1_U
23 M C1_U PGND
U
AGND PGND
R306
M C1_PWM UH
MC1_PWM UH MC1_U
M C1_W M C1_V
100R MC1_W MC1_V
(0805 ) 5 R322 R305
HINU
R307 High Side MC1_V MC1_V 100K 100K
M C1_PWM VH 6 Gate Driver 22 M C1_V (1206 ) (1206 )
MC1_PWM VH HINV V
100R (HVI C)
(0805 ) 7 R323 R308
HINW
+15V 100K 100K
B R309 8 B
M C1_PWM WH (1206 ) (1206 )
MC1_PWM WH HVCC MC1_W

K
100R R310 R311 R312 + C309 C310 MC1_W
Z302
(0805 ) 10K 10K 10K 220uF 0.1uF 21 M C1_W R327 R313
18V W
(0805 ) (0805 ) (0805 ) 35V 25V SO D-323F 9 100K 100K
GND
(0805 )

A
(1206 ) (1206 )
R316 R331 R314
M C1_PWM UL M C1_VW M C1_VV
MC1_PWM UL MC1_VW MC1_VV
100R 300 R 300 R
(0805 ) DGND DGND 10 R332 (0805 ) R315 (0805 )
LINU C314 C311
R317 2.2K 2.2K
M C1_PWM VL 11 (0805 ) 4.7nF (0805 ) 4.7nF
MC1_PWM VL LINV 25V 25V
100R (0805 ) (0805 )
(0805 ) 12 20
LINW NU
+15V
R318 13 PGND PGND
M C1_PWM WL R319 R320 R321
MC1_PWM WL LVCC
10K 10K 10K

K
100R Z301
(0805 ) (0805 ) (0805 ) (0805 ) + C312
C313 18V Low Side
SO D-323F
220uF Gate Driver Test Points
35V
0.1uF 14 19
FO NV

A
25V (HVI C) TP300
(0805 ) MC1_PWM UH
DGND DVDD MC1_PWM UH

R324 15
CIN R325 R326 TP301
5.6K DGND M C1_I V_P M C1_I U_P
MC1_IV_P MC1_IU_P MC1_PWM VH
C M C1_FA ULT (0805 ) 18 40.2R 40.2R MC1_PWM VH C
MC1_FAULT NW
(0805 ) (0805 )
16
GND TP302
R329 R330 MC1_PWM WH
10mR 10mR MC1_PWM WH
DGND (2512 ) (2512 )
CI N 17
CIN VOT TP303
MC1_PWM UL
R333 R334 MC1_PWM UL
M C1_I V_N M C1_I U_N
MC1_IV_N MC1_IU_N
BM639 67 40.2R 40.2R TP304
(0805 ) (0805 ) MC1_PWM VL
MC1_PWM VL
R336
M C1_I DC_N
R335 MC1_IDC_N TP305
M C1_I PM_TE MP
MC1_IPM_TEMP 40.2R MC1_PWM WL
470R (0805 ) MC1_PWM WL
R338

K
R339 (0805 )
TP306
Z300 470R 10mR M C1_IPM _TEM P
3.3V (0805 ) (2512 ) MC1_IPM_TEMP
SO D-323F
R341

A
M C1_I DC_P
MC1_IDC_P MC1_FO
40.2R MC1_FAULT
DGND PGND (0805 ) MC1_FO

FIGURE 6 : INVERTER MODULE POWER STAGE SCHEMATIC (SHEET 3 OF 10)

DGND
R343
D CI N D
CIN
10K
(0805 ) Title
It rip_peak = Vcin/Rshunt = 0.48/0.01 = 48A C315 Airco nditioner - 1.8KW
100pF
tdelay >> 4.7k x 470pF = 2.2uS 25V Size: Numb er: Revision:
(0805 )
B RSI-B-0039 REV 1.0
DGND
Date: 1/29/201 9 Tim e: 10:32:57 AM Sheet3 of To talpage s
File:
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USER MANUAL
 1 2 3 4 5 6

MC2_ Gate Dri ver VDC MC 2_ P ower S tage

+15V D400
A K
+ C400 C402 2 2 2
A C401 US1M Q400 Q403 Q404 A
10uF R401 R402 R403
50V
0.1uF 1000 V M C2_G ATEU H 1 RGT8BM65DTL M C2_G ATEV H 1 RGT8BM65DTL M C2_G ATEWH 1 RGT8BM65DTL
25V SM A 2.2uF MC2_GATEUH 650V MC2_GATEVH 650V MC2_GATEWH 650V
(0805 )
U400 10R 10R 10R
1A 50V DP AK DP AK DP AK
(1206 ) (0805 ) R406 (0805 ) R407 (0805 ) R408
3 8 47K 3 47K 3 47K 3
VCC VB
DGND (0805 ) (0805 ) (0805 )
R400 2 7
M C2_PWM UH M C2_G ATEU H M C2_U M C2_V M C2_W
MC2_PWM UH HIN HO MC2_GATEUH C413 MC2_U MC2_V MC2_W
100R
(0805 ) 1 5 M C2_G ATEU L
100nF
LIN LO MC2_GATEUL 630VD C
R404 TH - 13x6x12_10P
M C2_PWM UL R409 R405 4 6 M C2_U
MC2_PWM UL COM VS MC2_U
100R 10K 10K 2 2 2
(0805 ) (0805 ) (0805 ) Q401 Q402 Q405
BS211 4F R410 1 RGT8BM65DTL R411 1 RGT8BM65DTL R412 1 RGT8BM65DTL
M C2_G ATEU L M C2_G ATEV L M C2_G ATEWL
MC2_GATEUL 650V MC2_GATEVL 650V MC2_GATEWL 650V
600V 10R 10R 10R
DP AK DP AK DP AK
(0805 ) R413 (0805 ) R414 (0805 ) R415
47K 3 47K 3 47K 3
DGND
(0805 ) (0805 ) (0805 )
R416 R417
M C2_I U_P M C2_I V_P
D401 MC2_IU_P MC2_IV_P
+15V 40.2R 40.2R
A K R418 (0805 ) R419 (0805 )
+ C404 C406 100mR 100mR
C405 US1M (2512 ) (2512 )
10uF R420 R421
50V 0.1uF 1000 V M C2_I U_N M C2_I V_N
B 25V SM A 2.2uF MC2_IU_N MC2_IV_N B
(0805 )
U401 40.2R 40.2R
1A 50V
(1206 ) (0805 ) (0805 )
3 8 R422
VCC VB
DGND 100mR MC2_U
R425 2 7 R423
M C2_PWM VH M C2_G ATEV H (2512 ) M C2_I DC_P M C2_U
MC2_PWM VH HIN HO MC2_GATEVH MC2_IDC_P MC2_U
100R PGND 40.2R MC2_V
(0805 ) 1 5 M C2_G ATEV L (0805 ) M C2_V
LIN LO MC2_GATEVL MC2_V
R426 R424 MC2_W
M C2_PWM VL R431 R427 4 6 M C2_V M C2_I DC_N M C2_W
MC2_PWM VL COM VS MC2_V MC2_IDC_N MC2_W
100R 10K 10K 40.2R
(0805 ) (0805 ) (0805 ) (0805 )
BS211 4F
600V

DGND MC2_BEMF Clamp AVDD

D403 M C2_U M C2_V M C2_W
MC2_U MC2_V MC2_W
2
+15V D402 M C2_VU 3 R428 R429 R430
MC2_VU
A K 1 100K 100K 100K
+ C410 C412 (1206 ) (1206 ) (1206 )
C411 US1M DAN217UM
10uF SO T-323FL
50V
0.1uF 1000 V
25V SM A
R432 R433 R434
(0805 ) U402 2.2uF D404 100K 100K 100K
1A 50V 2
C (1206 ) (1206 ) (1206 ) C
(1206 )
3 8 M C2_VV 3
VCC VB MC2_VV
DGND 1 R435 R436 R437
R444 2 7
M C2_PWM WH M C2_G ATEWH 100K 100K 100K
MC2_PWM WH HIN HO MC2_GATEWH DAN217UM
100R (1206 ) (1206 ) (1206 )
SO T-323FL R438 R439 R440
(0805 ) 1 5 M C2_G ATEWL D405 M C2_VU M C2_VV M C2_VW
LIN LO MC2_GATEWL MC2_VU MC2_VV MC2_VW
2 300 R 300 R 300 R
R445 4 6 3
M C2_PWM WL R448 R447 M C2_W M C2_VW (0805 ) (0805 ) (0805 )
MC2_PWM WL COM VS MC2_W MC2_VW
100R 10K 10K 1 R441 R442 R443
(0805 ) (0805 ) (0805 ) 2.2K C407 2.2K C408 2.2K C409
BS211 4F DAN217UM (0805 ) 4.7nF (0805 ) 4.7nF (0805 ) 4.7nF
SO T-323FL 25V 25V 25V
600V (0805 ) (0805 ) (0805 )

DGND
AGND PGND PGND PGND

Test Points
TP400 TP401 TP402 TP403 TP404

FIGURE 7 ODU INVERTER POWER STAGE SCHEMATIC (SHEET 4 OF 10)

MC2_PWM UH MC2_PWM UL MC2_GATEUH MC2_GATEUL MC2_VU
MC2_PWM UH MC2_PWM UL MC2_GATEUH MC2_GATEUL MC2_VU

D D
TP405 TP406 TP407 TP408 TP409
MC2_PWM VH MC2_PWM VL MC2_GATEVH MC2_GATEVL MC2_VV
MC2_PWM VH MC2_PWM VL MC2_GATEVH MC2_GATEVL MC2_VV Title
Airco nditioner - 1.8KW
TP410 TP411 TP412 TP413 TP414 Size: Numb er: Revision:
MC2_PWM WH MC2_PWM WL MC2_GATEWH MC2_GATEWL MC2_VW
MC2_PWM WH MC2_PWM WL MC2_GATEWH MC2_GATEWL MC2_VW B RSI-B-0039 REV 1.0
Date: 1/29/201 9 Tim e: 10:32:58 AM Sheet4 of To talpage s
File:
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 1 2 3 4 5 6

MC1 Voltage Reference MC2 Voltage Reference Test Points

R500 R501
AVDD AVDD AVDD AVDD TP500
1K 1K MC1_VREF
(0805 ) C500 (0805 ) C501 MC1_VREF
R502 R503
10K C502 10K C503
AVDD 100 0pF 0.1uF AVDD 100 0pF 0.1uF TP501
(0805 ) (0805 )
25V 25V 25V 25V MC1_IBUS

8
8
(0805 ) (0805 ) (0805 ) (0805 ) MC1_IBUS
A A
R504 6 AGND R505 2 AGND

2
2
2.49K - R506 2.49K - R507 TP502
7 M C1_VR EF 1 M C2_VR EF
(0805 ) A MC1_VREF (0805 ) A MC2_VREF MC1_IU
U502 1 5 20R 1 3 20R MC1_IU
+ +
DNP U500A (0805 ) U503 (0805 )
C504 DNP U501A C505

3
3
R508 R509

4
4
C506 C507 0.1uF C508 C509 0.1uF TP503
7.5K 7.5K MC1_IV
100pF 0.1uF 25V 100pF 0.1uF 25V
(0805 ) (0805 ) MC1_IV
25V 25V (0805 ) 25V 25V (0805 )
AGND
(0805 ) (0805 ) (0805 ) (0805 )

AGND AGND AGND TP504

MC2_VREF
MC2_VREF
AGND AGND Vref = 1.65V AGND AGND Vref = 1.65V
TP505
MC2_IBUS
MC1 Current Sense MC2 Current Sense C511 MC2_IBUS
R510 DNP C510
R511 TP506
C514 6.04K C515 DNP MC2_IU
AGND DNP (0805 ) AGND DNP MC2_IU
2.7K
(0805 )
R512 R513
M C1_I DC_N M C2_I DC_N TP507
MC1_IDC_N MC1_BUS_GAIN = 6004/600.2 = 10 MC2_IDC_N MC2_BUS_GAIN = 2700/600.2 = 4.49
560R 560R MC2_IV
B (0805 ) 2 (0805 ) 6 MC2_IV B
- R514 - R515
C516 1 M C1_I BUS
C517 7 M C2_I BUS
DNP B MC1_IBUS 1nF B MC2_IBUS
3 0R 5 0R
+ +
(0805 ) (0805 )
R516 C518 R517 C519
M C1_I DC_P U500B M C2_I DC_P U501B
MC1_IDC_P 1nF MC2_IDC_P 1nF
560R 560R R519
C520 (0805 ) R518 C521 (0805 ) 2.7K
DNP 6.04K DNP (0805 )
(0805 ) AGND AGND
M C1_VR EF M C2_VR EF
MC1_VREF MC2_VREF
AGND AGND

C522 C523
AVDD AVDD
R520 DNP R521 DNP
C526 C524 C527 C525
6.04K 2.7K
AGND DNP (0805 )
0.1uF AGND DNP (0805 )
0.1uF
AVDD 25V AVDD 25V
R522 (0805 ) R523 (0805 )
M C1_I U_N M C2_I U_N

8
8
MC1_IU_N MC2_IU_N
560R AGND 560R AGND
(0805 ) 2 - (0805 ) 2 -
C528 1 R524 C529 1 R525
M C1_I U M C2_I U
1nF A MC1_IU 1nF A MC2_IU
C 3 0R 3 0R C
+ +
U504A (0805 ) (0805 )
R526 C530 R527 U505A C531
M C1_I U_P M C2_I U_P

4
MC1_IU_P MC2_IU_P 4
1nF 1nF
560R 560R
C532 (0805 ) R528 C533 (0805 ) R529
DNP 6.04K AGND DNP 2.7K AGND
(0805 ) AGND (0805 ) AGND
M C1_VR EF M C2_VR EF
MC1_VREF MC2_VREF
AGND AGND

C534 C535

R531 DNP R532 DNP

C538 C539
6.04K 2.7K
AGND DNP (0805 ) AGND DNP (0805 )

R533 R534
M C1_I V_N M C2_I V_N
MC1_IV_N MC2_IV_N
560R 560R
(0805 ) 6 - (0805 ) 6 -
C540 7 R535 C541 7 R536
M C1_I V M C2_I V
1nF B MC1_IV 1nF B MC2_IV
5 0R 5 0R
+ +
D (0805 ) (0805 ) D
R537 R538

FIGURE 8 COMPRESSOR & ODU FEEDBACK STAGE SCHEMATIC (SHEET 5 OF 10)

M C1_I V_P U504B C542 M C2_I V_P U505B C543
MC1_IV_P 1nF MC2_IV_P 1nF
560R 560R Title
C544 (0805 ) R539 C545 (0805 ) R540
Airco nditioner - 1.8KW
DNP 6.04K DNP 2.7K
(0805 ) AGND (0805 ) AGND Size: Numb er: Revision:
M C1_VR EF M C2_VR EF
MC1_VREF MC2_VREF B RSI-B-0039 REV 1.0
AGND AGND
Date: 1/29/201 9 Tim e: 10:33:00 AM Sheet5 of To talpage s
File:
1 2 3 4 5 6
USER MANUAL
 1 2 3 4 5 6

GPIO1
dsPIC33CH128MP508 PIN 25 G PIO _1
GPIO_1
AVDD
U600 DVDD
GPIO2
G PIO _2
M CLR 9 GPIO_2
MCLR MCLR
12 + C601
VDD C600 C602 R600 GPIO3
G PIO _3
71 16 PF C_I A
4.7uF 4.7K GPIO_3
DVDD VDD RA0 PFC_IA 0.01uF 25V
0.1uF
31 18 PF C_I B 25V 25V (0805 )
A VDD RA1 PFC_IB CASEA(120 6) GPIO4 A
51 20 VA C_SE NSE (0805 ) (0805 ) G PIO _4
VDD RA2 VAC_SENSE GPIO_4
21 M C1_I U
RA3 MC1_IU R601
32 23 M C1_I V 1 SW600 4 M CLR
VSS RA4 MC1_IV MCLR GPIO5
11 100R G PIO _5
VSS GPIO_5
50 AGND 2 3 (0805 )
VSS
AVDD DGND 70
VSS PIN 12 PIN 31 4 Pin SPST-NO GPIO6
G PIO _6
C603 GPIO_6
25 DVDD DVDD 0.1uF
AVDD
26 25V
AVSS
(0805 )
BLD C_SP EED_FB 74 34 O SCI DE BUG _TX
BLDC_SPEED_FB RD0 RB0 OSCI DEBUG_TX 1
AGND BLD C_SP EED_RE F 73 35 O SCO DGND DGND DVDD DVDD
BLDC_SPEED_REF RD1 RB1 OSCO 2
M C2_PWM WL 72 41 dsPI C_PI N_41
MC2_PWM WL RD2 RB2 dsPIC_PIN_41 C604 C605 C606 C607 3
M C1_PWM WL 69 43 dsPI C_PI N_43
MC1_PWM WL RD3 RB3 dsPIC_PIN_43 0.01uF 0.1uF 0.01uF 0.1uF C617 4
M C1_PWM WH 68 45 dsPI C_PI N_45
MC1_PWM WH RD4 RB4 dsPIC_PIN_45 25V 25V 25V 25V 0.1uF 5
M C2_PWM UL 54 55 PG D DE BUG _RX
MC2_PWM UL RD5 RB5 PGD (0805 ) (0805 ) (0805 ) (0805 ) R602 25V DEBUG_RX 6
M C2_PWM UH 53 56 PG C dsPI C_PI N_41 PF C_I BUS
MC2_PWM UH RD6 RB6 PGC dsPIC_PIN_41 PFC_IBUS (0805 )
M C2_PWM WH 52 58 TE MP_SU CTI ON
0R J601
MC2_PWM WH RD7 RB7 TEMP_SUCT ION
M C1_FA ULT 49 60 TE MP_DI SC HAR GE (0805 ) DGND
MC1_FAULT RD8 RB8 TEMP_DISCHARGE DGND
M C2_FA ULT 48 61 TE MP_EX HAU ST DGND DGND
MC2_FAULT RD9 RB9 TEMP_EXHAUST
M C1_I BUS 38 75 PF C_PWM B
MC1_IBUS RD10 RB10 PFC_PWM B
M C2_VV 36 76 I DU_RX
MC2_VV RD11 RB11 IDU_RX Debug Interface
M C1_VU 27 78 EE V_AL
MC1_VU RD12 RB12 EEV_AL PIN 51 PIN 71
G PIO _6 14 80 EE V_AH DVDD
B GPIO_6 RD13 RB13 EEV_AH R605 R604 B
PF C_FA ULT_O V 13 1 EE V_BL DVDD DVDD dsPI C_PI N_43 M C1_I PM_TE MP
PFC_FAULT_OV RD14 RB14 EEV_BL dsPIC_PIN_43 MC1_IPM_TEMP
PF C_FA ULT_O C 10 3 EE V_BH
0R 4.7K
PFC_FAULT_OC RD15 RB15 EEV_BH
(0805 ) M CLR (0805 )
MCLR

RE LAY_4WAY 2 15 VD C_SE NSE

C608 C609 C610 C611 DVDD
REL AY_4WAY RE0 RC0 VDC_SENSE 0.01uF 0.1uF 0.01uF 0.1uF
RE LAY_I NRU SH 4 28 M C2_I V
REL AY_INRUSH RE1 RC1 MC2_IV 25V 25V 25V 25V
LED 1 17 29 M C2_I U
LED1 RE2 RC2 MC2_IU (0805 ) (0805 ) (0805 ) (0805 ) R607
LED 2 19 33 M C2_I BUS dsPI C_PI N_45 M C1_VV
C612
LED2 RE3 RC3 MC2_IBUS dsPIC_PIN_45 MC1_VV 0.1uF
LED 3 22 63 M C1_PWM VH
0R
LED3 RE4 RC4 MC1_PWM VH 25V 1
LED 4 24 65 M C1_PWM VL (0805 )
LED4 RE5 RC5 MC1_PWM VL DGND DGND (0805 ) 2
G PIO _5 37 30 M C2_VU
GPIO_5 RE6 RC6 MC2_VU 3
G PIO _4 39 40 TE MP_AM BI EN T
GPIO_4 RE7 RC7 TEMP_AMBIENT 4
G PIO _3 42 46 DE BUG _TX
GPIO_3 RE8 RC8 DEBUG_TX 5
G PIO _1 44 47 DE BUG _RX
GPIO_1 RE9 RC9 DEBUG_RX
PF C_EN ABLE A 57 66 M C1_PWM UH Level Shifter DGND J602
PFC_ENABLEA RE10 RC10 MC1_PWM UH +15V
PF C_EN ABLE B 59 67 M C1_PWM UL PG D
PFC_ENABLEB RE11 RC11 MC1_PWM UL PGD
EE PRO M_CL K 62 5 PF C_PWM A R619
EEPROM_CLK RE12 RC12 PFC_PWM A R617
EE PRO M_DA TA 64 6 I DU_TX PFC_PWM A PG C
EEPROM_DAT A RE13 RC13 IDU_TX 470R PGC

1
RE LAY_AC IM 77 7 M C2_PWM VH
0R
REL AY_ACI M RE14 RC14 MC2_PWM VH (0805 ) (0805 )
G PIO _2 79 8 M C2_PWM VL
GPIO_2 RE15 RC15 MC2_PWM VL
2 3 Main Program/Debug Interface
dsPIC33CH128MP508 PFC_PWM A_G
C C
Q601
RQ5E030AJ
DGND
+15V Test Points
R620
PFC_PWM B LED1
R618 LED1
0R 470R
(0805 )1
(0805 )
LED2
LED2

LE D1
LED2
LED3
LE D4
OSCI
OS CO
2 3
PFC_PWM B_G

Q602 LED3
RQ5E030AJ LED3

LED 1
LED 2
LED 3
LED 4
DVDD
DGND
XTAL600

O SCI
O SCO
R613 R614 R615 R616 LED4
U601 LED4

FIGURE 9 DIGITAL MCU STAGE SCHEMATIC (SHEET 6 OF 10)

1K 1K 1K 1K 8mHZ R611 R612
(0805 ) (0805 ) (0805 ) (0805 ) 10K 10K 8 1
SM D_HC 49/US VCC A0
(0805 ) (0805 ) 7 2
WP A1

A
A
A
A
EE PRO M_CL K 6 3
LD600 LD601 LD602 LD603 C613 C614 EEPROM_CLK SCL A2
EE PRO M_DA TA 5 4
Gre en Gre en RED RED 33pF 33pF EEPROM_DAT A SDA GND

K
K
K
K
(0805 ) (0805 ) (0805 ) (0805 ) 50V 50V AT24C512C
D (0805 ) (0805 )
D
C616
0.1uF Title
DGND DGND DGND DGND DGND DGND 25V Airco nditioner - 1.8KW
(0805 )

Size: Numb er: Revision:

B RSI-B-0039 REV 1.0
DGND DGND
Date: 1/29/201 9 Tim e: 10:33:01 AM Sheet6 of To talpage s
File:
1 2 3 4 5 6
USER MANUAL
 1 2 3 4 5 6

F700
AVDD U700
VDC
RE LAY_AC IM 1 16 RE LAY_AC IM _CT RL
REL AY_ACI M IN1 OUT1 REL AY_ACI M_CTRL
J700 500V 6A
MC2_BLDC TH - 5.8x22.5 RE LAY_I NRU SH 2 15 RE LAY_I NRU SH_CT RL
R700 1 REL AY_INRUSH IN2 OUT2 REL AY_INRUSH_CTRL
TE MP_AM BI EN T 1
TEMP_AMBIENT 2 VDC
0R R701 2 RE LAY_4WAY 3 14 RE LAY_4WAY_CT RL
A C701 NC REL AY_4WAY IN3 OUT3 REL AY_4WAY_CTRL A
(0805 ) 1K Air Te mper ature 3 +15V
0.1uF NC
(0805 ) 4 EE V_BH 4 13 R721 0R
(0805 ) GND EEV_BH IN4 OUT4 1
5 (0805 )
25V 15V
6 EE V_BL 5 12 R722 0R
VSP EEV_BL IN5 OUT5 2
7 PGND +15V R702 R703 (0805 )
FG
J702 2K 10K EE V_AH 6 11 R723 0R
EEV_AH IN6 OUT6 3
AGND J707 (0805 ) (0805 ) (0805 )
R704 1
TE MP_EX HAU ST EE V_AL 7 10 R724 0R
TEMP_EXHAUST 2 R705 EEV_AL IN7 OUT7 4
R706 VSP (0805 )
0R
C702 (0805 ) 1K Exhaust te mper atur e 8 9
1K GND COM 5
0.1uF (0805 ) BLD C_SP EED _FB (0805 )

3
(0805 ) BLDC_SPEED_FB Q700 BA120 03BF
25V R707 6
C703 2SST222 2A BLD C_SP EED_RE F 60V
10uF BLDC_SPEED_REF
1K DGND +12V J708
J703 (0805 ) Near U700 PIN5-6 of J708 +12V DGND
(0805 )

1
25V R708
AGND DNP +12V +12V
R709 1 E EV
TE MP_DI SC HAR GE (0805 )
TEMP_DISCHARGE 2
0R R710 +
C710
C704 (0805 ) 1K Discharg e Te mper ature C709
10uF
0.1uF (0805 ) DGND 0.1uF 50V
(0805 ) 25V
25V (0805 )
Optional : B LDC Condensor MC2
DGND DGND
B AGND J704 B

R711 1 Comm uni cation

TE MP_SU CTI ON
TEMP_SUCT ION 2
0R R712
C705 (0805 ) 1K Suction T empe ratur e
0.1uF (0805 ) ISO700 DVDD
(0805 )
N
25V N
DVDD
R713
I DU_RX
IDU_RX 1
R714 EL357N-G R716 DNP 2
AGND 680R C707 10K (0805 )
Tem perat ure sensors 80V 10uF IDU_RX 3
Ax ial R715 (0805 )
C706 25V IDU_TX 4
1 4.7k (0805 ) 5
(0805 ) 10uF
2 (0805 ) J701
3 ACV+ 25V
DGND
4
AC V+ ISO701 DGND DVDD
ACV+ 5
+12V
J709 C708 R717

1
4
RLY701 4.7nF D703

K
300VAC
10K
SJ-S-112DM-F K A (0805 )
10m m D ia EL357N-G
D700

3
US1M US1M 80V Q701
1000 V 1000 V 2SST222 2A R718
I DU_TX
C SM A SM A IDU_TX C
D702

3
R720

2
DNP DNP

A
RE LAY_4WAY_CT RL J705 I DU_CO M M K A R719 (0805 )

1
REL AY_4WAY_CTRL IDU_COMM 4.7k
2K (0805 )
1
AC V- US1M 2W
ACV- 2 IDU_COMM Ax ial
1000 V
DNP SM A DGND

Optional : 4 Way V al ve control

AC V+
Test Points
ACV+
+12V
TP700

1
4
TEMP_AMBIENT

FIGURE 10 APPLICATION STAGE SCHEMATIC (SHEET 7 OF 10)

RLY700

K
TEMP_AMBIENT
SJ-S-112DM-F
D701
US1M TP701
1000 V TEMP_EXHAUST
SM A TEMP_EXHAUST

2
DNP

A
D RE LAY_AC IM _CT RL J706 D
REL AY_ACI M_CTRL TP702
1 TEMP_DISCHARGE
AC V- TEMP_DISCHARGE Title
ACV- 2 Airco nditioner - 1.8KW
DNP
TP703 Size: Numb er: Revision:
TEMP_SUCT ION
TEMP_SUCT ION B RSI-B-0039 REV 1.0
Optional : A CIM CO NT RO L
Date: 1/29/201 9 Tim e: 10:33:02 AM Sheet7 of To talpage s
File:
1 2 3 4 5 6
USER MANUAL
 1 2 3 4 5 6

A A
DEBUG_TX_COMM 1
DVDD_C
5V_USB 2
3
4
5
5V_USB 5V_USB
J800 DEBUG_RX_COMM 6
C800
D800 J801
Isolated part - USB Powere d DGND_C
1 1 6 5V_USB DVDD_C
VBUS MCP220 0_USB_N 0.1uF
2 2 5 25V GND_USB
USB_N
D- R800 (0805 )

3 USB_P 3 4 4.7K U800 C802 C801

D+ MCP220 0_USB_P (0805 ) 0.1uF 0.1uF
1 20
X800 VDD VSS 25V 25V
4 USBLC6-2SC6 2 19
ID OSC1 D+ MCP220 0_USB_P (0805 ) (0805 )
SO T-23-6 C803 1 3 3 18
OSC2 D- MCP220 0_USB_N
5 4 17 GND_USB
GND MCP220 0_RST RST VUSB DGND_C
5 16 GND_USB
0.1uF GP7/TxL EDGP0 DVDD_C
6 15 DVDD_C

0
2
25V 12 M hz GP6/RxLEDGP1 C804
7 14 0.1uF
R801 (0805 ) GP5 GP2 DVDD_C
12 Mhz R802 R803 R804 8 13 25V
GP4 CTS 5V_USB
GND_USB 1K 1K DNP 9 12 (0805 )
330 R GP3 RX R805 R806
(0805 ) (0805 ) (0805 ) (0805 ) 10 11 GND_USB U801
TX RTS 3.3K 3.3K
1 8
B VDD1 VDD2 (0805 ) (0805 ) R807 B
C805 MCP220 0 2 7 DE BUG _TX_CO M M
GND_USB MCU_TX VOA VIA DEBUG_TX_COMM
3 6

K
K
MCU_RX VIB VOB 100R
LD800 LD801 4 5 (0805 )
0.1uF 5V_USB GND1GND2
GND_USB Gre en RED

A
A
25V (0805 ) (0805 ) ADUM120 1 R808
DE BUG _RX _CO M M
(0805 ) DEBUG_RX_COMM
GND_USB GND_USB 100R
DGND_C
(0805 )

Check feasilbility for placment on board

C C

FIGURE 11 COMMUNICATION STAGE SCHEMATIC (SHEET 8 OF 10)

D D

Title
Airco nditioner - 1.8KW
Size: Numb er: Revision:
B RSI-B-0039 REV 1.0
Date: 1/29/201 9 Tim e: 10:33:02 AM Sheet8 of To talpage s
USER MANUAL

File:
1 2 3 4 5 6
 1 2 3 4 5 6

P FC Over Vol tage P rotection MC1 Over Current Protection

AVDD C900 AVDD

R937
A 0.1uF A
4.7K
25V AGND
(0805 )
(0805 ) R939

5
MC1_IBUS CIN

3
VDC_SENSE 10K
4 U900 (0805 )
- R905 R938
6 1 2 Q900
- R906 A
7 3 SST222 2A
B PFC_FAULT_OV + 470R 470R
5 (0805 ) (0805 )

1
+ 1K R907
(0805 )
C902

2
R908 C903 MC1_OCP_REF 100 0pF
PFC_OVP_REF U901B 1K
56pF 25V
1K (0805 ) (0805 )
50V AGND
(0805 ) (0805 )
AGND AGND
AGND
AVDD R900
R901 MC1_OCP
1M
AVDD 1M (0805 )
(0805 ) R929
10K Itrip = 20A
R930 (0805 )
1K Vtrip = 410VDC Vref = MC1_BUS_GAIN X SHUNT X ITRIP = 2.8V
(0805 )
MC1_OCP_REF
Vref = VDC_GAIN X Vtrip = 0.0073 * 410 = 2.98V MC1_BUS_GAIN = 6.05 ( Refer Sheet 05)
B PFC_OVP_REF R931 B
VDC_GAIN = 0.0073 ( Refer Sheet 1) 47K C906
R932 (0805 ) 0.1uF
C907 25V
9.1K (0805 )
(0805 ) 0.1uF
25V
(0805 )
AGND

AGND

P FC Over Current Protection MC2 Over Current Prot ect ion Test Points
AVDD C901
AVDD C914 TP2 TP3
PFC_OVP_REF PFC_FAULT_OV
PFC_OVP_REF PFC_FAULT_OV
0.1uF
25V AGND 0.1uF
(0805 ) 25V AGND TP4 TP5

8
C PFC_IBUS (0805 ) PFC_OCP_REF PFC_FAULT_OC C
PFC_OCP_REF PFC_FAULT_OC

5
U901A MC2_IBUS
2 -
1 R919 4 U902
A PFC_FAULT_OC - R920 TP6 TP7
3 1K 1
+ A MC2_FAULT MC2_OCP_REF MC2_FAULT
(0805 ) 3 1K MC2_OCP_REF MC2_FAULT
R921 C908 +
(0805 )

4
PFC_OCP_REF 56pF R922 C909

2
1K 50V MC2_OCP_REF TP8 TP1
(0805 )
56pF
(0805 ) 1K 5 0V MC1_OCP_REF MC1_OCP
AGND (0805 ) MC1_OCP_REF MC1_OCP
(0805 )
AGND AGND
AVDD R915 AGND
1M AVDD R916
(0805 )
R933 1M
It rip = 19A (0805 )
10K R934
(0805 ) 10K
Vref = PFC_BUS_GAIN X SHUNT X ITRIP = 3.22V (0805 ) Itrip = 2.5A
PFC_OCP_REF
PFC_BUS_GAIN = 7.15 ( Refer Sheet 01) MC2_OCP_REF
Vref = MC2_BUS_GAIN X SHUNT X ITRIP = 1.765V
R935
470K C912 R936 MC2_BUS_GAIN = 4.55 ( Refer Sheet 05)
(0805 ) 0.1uF 10K C913
25V 0.1uF
(0805 )
(0805 ) 2 5V
D (0805 )
D

AGND Title
AGND Airco nditioner - 1.8KW
Size: Numb er: Revision:

FIGURE 12 COMPRESSOR & ODU- OCP & OVP STAGE SCHEMATIC (SHEET 9 OF 10)
B RSI-B-0039 REV 1.0
Date: 1/29/201 9 Tim e: 10:33:03 AM Sheet9 of To talpage s
File:
1 2 3 4 5 6
USER MANUAL
 1 2 3 4 5 6

PFC Voltage Reference PFC : Bus Current Sense C108

PFC :VDC Sense
VDC
R136 R126 DNP AVDD
AVDD 1K AVDD 14.3K R100
C112 R1
(0805 ) C122 (0805 ) 100K
A AGND DNP (1206 ) C113 A
R137 R128 1K
10K C123 PF C_I DC_N (0805 ) C1 0.1uF
PFC_IDC_N 25V
(0805 ) AVDD 100 0pF 0.1uF R103 (0805 )
25V 25V 2K
(0805 ) 6

8
(0805 ) (0805 ) - R130 100K
C116 7 PF C_I BUS (1206 ) AVDD 100 0pF AGND
R139 U103A DNP B PFC_IBUS 25V
2 AGND 5

2
8
- R141 R131 + 0R (0805 )
U104 2.49K 1 PF C_VR EF PF C_I DC_P (0805 ) R108
A PFC_VREF PFC_IDC_P C118 U101A
1DNP (0805 ) 3 20R 2K U103B 100K 2 -
+ C120 DNP R2
(0805 ) (0805 ) R134 (1206 ) 1 VD C_SE NSE
C125 DNP A VDC_SENSE
VD C_FD BK 3

3
R144 14.3K

4
+ 20R
7.5K C128 C129 0.1uF (0805 ) (0805 )
100pF 0.1uF 25V AGND C2
(0805 ) PF C_VR EF R113

4
25V (0805 ) PFC_VREF
25V AGND AGND 2.2K C105 0.1uF
(0805 ) (0805 ) 25V
(0805 ) 0.1uF
25V (0805 )
AGND
(0805 )

AGND AGND AGND PGND AGND AGND

Vref = 1.65V PFC_BUS_GAIN = 14.3/2 = 7.15 VDC_GAIN = 2.2/302.2 = 0.0073

PFC : Phase Current Sense VDC @ 280Vac >> 396Vdc Reference Generator for PFC
B B

K
K
R138
C109 D107 D108 100K
1N400 7 1N400 7 (1206 )
AVDD 1000 V 1000 V Vac_sense = Gain X Vac_Vol2 = 1.447V + 1.65V = 3.097V
R127 DNP 1A 1A
AC V+ R140
ACV+ DO -41 DO -41

A
A
11.5K 100K Gain = ( 40.2/40.2K)
C114 (0805 )
C115 (1206 )
AGND DNP AVDD 0.1uF Vac_vol2 = ( 396 * 1.1K) / ( 100K x3 + 1.1K) = 1.447V
R129 25V
PF C_I A_N (0805 ) R143

8
PFC_IA_N R145
AC V- 100K PF C_VR EF
2K ACV- PFC_VREF
(0805 ) 2 U102A AGND (1206 )
- R132 R146 R147 40.2K
C117 1 PF C_I A (0805 )
A PFC_IA

K
K
DNP 3
R133 + 0R 1K 39.2K
PF C_I A_P (0805 ) D109 D110 (0805 ) (0805 ) 5
PFC_IA_P + R149

K
C119 7 VA C_SE NSE

4
2K 1N400 7 1N400 7 R151 B VAC_SENSE
C121 (0805 ) R135 DNP 1000 V 1000 V 1.1K C131 C132 6
Z100 - 0R
DNP 11.5K 1A 1A (0805 ) DNP 3V 0.01uF (0805 )
AGND DO -41 DO -41 25V SO D-323F 25V C135

A
A
A
(0805 ) U101B
(0805 ) (0805 )
PF C_VR EF AGND 100 0pF
PFC_VREF R154 R156 25V
AGND
(0805 )
39.2K 40.2K DNP
(0805 ) (0805 ) Test Points
C AGND C
R153 AGND
TP900
Rshunt = 25mohm 1K PFC_VREF
R162 (0805 ) PFC_VREF
100K
PFC_Phase_GAIN = 11.5/2 = 5.75 (1206 )
TP901
PFC_IBUS
PFC_IBUS
R163
C124 100K TP902
(1206 )
PFC_IA
PFC_IA
R142 DNP R164
11.5K 100K TP903
C126 (0805 ) (1206 ) PFC_IB
AGND DNP PFC_IB
R148
PF C_I B_N
PFC_IB_N
K

2K TP904
(0805 ) 6 R165 VDC_SENSE
- R150 1.1K C140 Z101 VDC_SENSE
C130 7 PF C_I B 3V
B PFC_IB (0805 ) DNP
DNP 5 SO D-323F
A

+ 0R 25V
R152 (0805 )
PF C_I B_P (0805 ) TP905
PFC_IB_P C133
2K U102B VAC_SENSE
C134 (0805 ) DNP VAC_SENSE
R155
D DNP 11.5K D

FIGURE 13 VAC SENSE & VDC SENSE STAGE SCHEMATIC (SHEET 10 OF 10)
(0805 ) AGND
PF C_VR EF AGND Title
PFC_VREF Airco nditioner - 1.8KW
AGND

Size: Numb er: Revision:

B RSI-B-0039 REV 1.0
Date: 1/29/201 9 Tim e: 10:33:05 AM Sheet10 of To talpage s
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USER MANUAL
 USER MANUAL

5 Bill of Materials

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PART Description Value Designator Supplier Part Number Qty
no

Bridge SMD RED GBJ2508-F 800V - 4-

1 GBJ2508-F BR1 Diodes Inc GBJ2508-F 1
SIP, GBJ -
CMC TH 4.5mH 250VAC 36mm x 23
2 4.5mH L100 Wurth 7448051804 1
mm
C110, C400,
Capacitor Polarity SMD Electrolytic
3 10uF C404, C410, Wurth 865230643009 5
10uF 50V 20% D6.3_P5.4_H5.4
C710
Capacitor Polarity SMD Electrolytic C300, C302,
4 47uF Wurth 865090545008 3
47uF 35V 20% D6.6_P5.6 C304
Capacitor Polarity SMD Electrolytic
5 220uF C309, C312 Wurth 865060557008 2
220uF 35V 20% D10_P8.7
Capacitor Polarity SMD Tantalum
6 4.7uF C601 ROHM TCA1E475M8R 1
4.7uF 25V 20% CASEA(1206)
Capacitor Polarity SMD Tantalum
7 22uF C219 ROHM TCA1A226M8R 1
22uF 10V 20% CASEA(1206)
Capacitor Polarity TH Electrolytic
8 10uF C212 Wurth 860020772010 1
10uF 63V 20% 5x11 mm, P2mm
Capacitor Polarity TH Electrolytic
9 10uF C202 Wurth 860241478003 1
10uF 450V 20% 13x20mm, P5mm
Capacitor Polarity TH Electrolytic
10 100uF 25V 20% 5x11 mm,P2.5mm 100uF C206 Wurth 860080473006 1

Capacitor Polarity TH Electrolytic

11 330uF C210 Wurth 860080475013 1
330uF 25V 20% 5x11 mm, P2mm
Capacitor Polarity TH Electrolytic
12 330uF 35V 20% 8x20mm, 3.5mm 330uF C205 Wurth 860080574014 1

Capacitor Polarity TH Electrolytic

13 470uF C207 Wurth 860080475016 1
470uF 25V 20% 5x11 mm,P2.5mm
Capacitor Polarity TH Electrolytic
14 680uF 25V 20% 5x11 mm, P2mm 680uF C209 Wurth 860080475018 1

C132, C600,
Capacitor SMD Ceramic 0.01uF 25V
15 0.01uF C604, C606, Kemet C0805C103K3RACTU 6
10% (0805) X7R
C608, C610
Capacitor SMD Ceramic 0.1uF 25V C2, C105, C111,
10% (0805) X7R C113, C115,
C123, C125,
C129, C211,
C214, C220,
C301, C303,
C305, C310,
C313, C401,
C405, C411,
C502, C503,
C504, C505,
C507, C509,
C524, C525,
16 0.1uF C602, C603, Kemet C0805C104K3RACTU 54
C605, C607,
C609, C611,
C612, C616,
C617, C701,
C702, C704,
C705, C709,
C800, C801,
C802, C803,
C804, C805,
C900, C901,
C906, C907,
C912, C913,
C914
 USER MANUAL

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PART Description Value Designator Supplier Part Number Qty
no

C517, C518,
C519, C528,
Capacitor SMD Ceramic 1nF 25V C529, C530,
17 1nF Kemet C0805C102M3RACTU 11
10% (0805) X7R C531, C540,
C541, C542,
C543
Capacitor SMD Ceramic 2.2uF 25V
18 10% (0805) X7R 2.2uF C215 Murata GRM21BR71E225KE11L 1

Capacitor SMD Ceramic 2.2uF 50V C402, C406,

19 2.2uF Kemet C1206C225K5RACTU 3
10% (1206) X7R C412
Capacitor SMD Ceramic 4.7nF 25V C307, C311,
20 10% (0805) X7R 4.7nF C314, C407, Kemet C0805C472K3RACTU 6
C408, C409
Capacitor SMD Ceramic 10uF 25V C217, C703,
21 10uF Murata GRM21BC71E106KE11L 4
10% (0805) X7S C706, C707
Capacitor SMD Ceramic 33pF 50V
22 33pF C613, C614 Kemet C0805C330M5GACTU 2
20% (0805) COG
Capacitor SMD Ceramic 47uF 10V
23 47uF C218 Kemet C1206C476M8PACTU 1
20% 1206)
Capacitor SMD Ceramic 56pF 50V C903, C908,
24 56pF Kemet C0805C560K3RACTU 3
10% (0805) X7R C909
Capacitor SMD Ceramic 100pF 25V C128, C315,
25 100pF Kemet C0805C101K3RACTU 4
10% (0805) X7R C506, C508
Capacitor SMD Ceramic 1000pF C1, C122, C135,
25V 10% (0805) X7R C136, C137,
26 1000pF Kemet C0805C102K3RACTU 9
C213, C500,
C501, C902
C112, C114,
C116, C117,
C120, C121,
C126, C130,
C131, C134,
Capacitor SMD Ceramic DNP 25V C140, C514,
27 DNP 24
10% (0805) X7R C515, C516,
C520, C521,
C526, C527,
C532, C533,
C538, C539,
C544, C545
Capacitor SMD Ceramic DNP 50V C108, C109,
5% (0805) X7R C118, C119,
C124, C133,
28 DNP 12
C510, C511,
C522, C523,
C534, C535
Capacitor TH Ceramic 2.2nF_YCAP
29 2.2nF_YCAP C200 Murata DE2E3KY222MA3BU02F 1
300VAC ±20% 8mm Dia
Capacitor TH Ceramic 4.7nF
30 300VAC 20% 10mm Dia 4.7nF C708 Murata DE2E3KY472MA3BU02F 1

Capacitor TH Ceramic 47pF 1KV 5%

31 47pF C208 Murata RDE7U3A470J2K1H03B 1
5.5mm x 4mm
Capacitor TH Ceramic 100nF
32 100nF C413 Kemet R71PF3100AA30M 1
630VDC 10% TH - 13x6x12_10P
Capacitor TH Ceramic 220PF 100V
33 220PF C201, C204 Murata RDE5C2A221J0K1H03B 2
5% 4mm x 2.5mm COG
Capacitor TH Ceramic 4700pF CY100, CY101, C961U472MZWDBA731
34 440VAC 10% 13 mm Dia 4700pF Kemet 4
CY102, CY103 7
Capacitor TH Ceramic DNP 1KV 10%
35 DNP C203 1
TH_6x3.5 U2J
 USER MANUAL

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PART Description Value Designator Supplier Part Number Qty
no
Capacitor TH Electrolytic 680uF
36 680uF C103, C104 Capxcon UJ681M500Q600A 2
500V 40x60, 10mm
Capacitor TH Film 1uF 630VDC 10%
37 1uF C102, C308 Kemet R71PN4100AA30K 2
TH - 26.5x10x18.5_22.5P
Capacitor TH Film 1uF,X-Type
38 310VAC 10% 1uF,X-Type CX100, CX101 Kemet R463N4100CKN1M 2
TH_26.5x11x20mm_22.5P
39 Connector SMD USB CON USB-B CON USB-B J800 Hirose UX60-MB-5ST 1
Connector TH Berg CON_HDR_5
40 CON_HDR_5 J602, J701, J709 Wurth 61300511121 3
2.54mm Pitch 5 postions 1 row
Connector TH Berg CON_HDR_6
41 CON_HDR_6 J601, J801 Wurth 61300611121 2
2.54mm Pitch 6 postions 1 row
Connector TH Berg DNP 2.54mm
42 DNP J100 1
Pitch 5 postions 1 row
Connector TH Berg DNP 2.54mm
43 DNP J101 1
Pitch 6 postions 1 row
Connector TH Berg Right Angle
44 CON_HDR_5 2.54mm Pitch 5 pos- - J200 Wurth 61300511021 1
tions 1 row
Connector TH Berg Right Angle
45 CON_HDR_6 2.54mm Pitch 6 pos- - J201 Wurth 61300611021 1
tions 1 row
Connector TH Header Air Tempera-
46 ture 2.5mm pitch 2 postions 1 row - J700 JST B 2B-EH-A 1

Connector TH Header CON6

47 CON6 J708 JST B6B-EH-A 1
2.5mm pitch 6 postions 1 row
Connector TH Header DNP 5.08
48 DNP J705, J706 2
mm pitch 2 postions 1 row
Connector TH Header Discharge
49 Temperature 2.5mm pitch 2 pos- - J703 JST B 2B-EH-A 1
tions 1 row
Connector TH Header Exhaust tem-
50 perature 2.5mm pitch 2 postions 1 - J702 JST B 2B-EH-A 1
row
Connector TH Header MC2_BLDC
51 J707 JST B7B-EH-A 1
2.5mm pitch 7 postions 1 row
Connector TH Header Suction Tem-
52 perature 2.5mm pitch 2 postions 1 - J704 JST B 2B-EH-A 1
row
Crystal SMD Oscillator 8mHZ -
53 8mHZ XTAL600 ECS ECS-80-20-5PXDU-TR 1
±30ppm SMD_HC49/US
Crystal SMD Resonator 12 Mhz VOLT-
54 AGE ±0.08% CSTCE-G - 12 Mhz X800 Murata CSTCE12M0G15L99-R0 1

Diode SMD SCHOTTKY D200, D202,

55 MBRS2H100T3G ON Semi MBRS2H100T3G 4
MBRS2H100T3G 100V SMB 2A D204, D205
Diode SMD Switching 1SS355VM 90V
56 - SOD-323FL 100mA 4nS 1.2V - 1SS355VM D102, D103 ROHM 1SS355VMTE-17 2

Diode SMD Switching DAN217UM D303, D304,

57 80V - SOT-323FL 100mA 4 nS 1.2V DAN217UM D305, D403, ROHM DAN217UMTL 6
200mW D404, D405
Diode SMD Ultrfast DNP 1000V SMA
58 DNP D104, D105 2
1A
D106, D203,
Diode SMD Ultrfast US1M 1000V D400, D401,
59 US1M Diodes Inc US1M-13-F 9
SMA 1A D402, D700,
D701, D702, D703
Diode SMD ZENER 3.3V SOD-323F -
60 3.3V Z300 ROHM UDZVTE-173.3B 1
200mW
Diode SMD ZENER 3V SOD-323F -
61 3V Z100, Z101 ROHM UDZVTE-173.0B 2
200mW
Diode SMD ZENER 5.25V VOLTAGE -
62 USBLC6-2SC6 D800 ST USBLC6-2SC6 1
SOT-23-6 - - VF -
 USER MANUAL

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PART Description Value Designator Supplier Part Number Qty
no
Diode SMD ZENER 18V 18V SOD-
63 18V Z301, Z302 ROHM UDZVTE-1718B 2
323F - 200mW
Diode TH Fast Recovery RFUH30TS6S
64 RFUH30TS6S D100, D101 ROHM RFUH30TS6SGC11 2
600V TO247 30A
Diode TH Rectifier 1N4007 1000V D107, D108,
65 1N4007 Diodes Inc 1N4007-T 4
DO-41 1A 1V D109, D110
Diode TH TVS P6KE200A 190V 600W
66 P6KE200A D201 Little Fuse P6KE200A 1
DO-204AC 2.2A Peak - - -
FUSE Holder TH 500V 6A 500V TH -
67 500V 6A F700 schurter 0031.8201 1
5.8x22.5 -
FUSE TH 250VAC/ 25A 250VAC
68 250VAC/ 25A F101 Little Fuse 0325025.MXWP 1
6.99mm x 32.7mm -
FD1, FD2, FD3,
69 Fudicial VOLTAGE - NA NA 6
FD4, FD5, FD6
70 GDT TH GDT - 8 x15mm 250VAC GDT G100 Little Fuse GTCA28-601M-R05 1
IC SMD 7CH Trans Array BA12003BF
71 BA12003BF U700 ROHM BA12004BF-E2 1
60V SOP16
IC SMD Comparator MCP6541 1.6 V
72 ~ 5.5 V SOT-23-5 7mV @ 5.5V 70dB MCP6541 U900, U902 Microchip MCP6541T-I/OT 2

IC SMD Comparator MCP6542 1.6 V

73 MCP6542 U901 Microchip MCP6542-I/MS 1
~ 5.5 V 8-MSOP 7mV @ 5.5V 70dB
IC SMD Driver BS2114F 600V SOP8
74 BS2114F U400, U401, U402 ROHM BS2114F 3
500mA
75 IC SMD Driver MCP14E4 SOIC8 4A MCP14E4 U105 Microchip MCP14E4T-E/SN 1
76 IC SMD EEPROM AT24C512C SOIC8 AT24C512C U601 Microchip AT24C512C-SSHM-B 1
IC SMD Interface MCP2200 3 to 5.5V
77 MCP2200 U800 Microchip MCP2200-I/SS 1
SSOP-20
IC SMD Isolator ADUM1201 SOIC8 Analog
78 ADUM1201 U801 ADUM1201CRZ-RL7 1
Devices Inc
IC SMD MCU dsPIC33CH128MP508 dsPIC33CH128MP508-
79 dsPIC33CH128MP5 U600 Microchip 1
TQFP-80_12x12 I/PT
IC SMD Op AMP MCP6V92 8-MSOP U101, U102, U103,
80 9.5 V/µs 10MHz 9uV MCP6V92 U500, U501, U504, Microchip MCP6V92-E/MS 7
U505
IC SMD Optoisolator EL357N-G 80V ISO200, ISO700,
81 EL357N-G Everlight EL357N-G 3
4 SMD Gul wing ISO701
IC SMD Shunt regulator DNP - SOT-
82 DNP U104, U502, U503 3
23-3
IC SMD Shunt regulator TLV431A-D - ON Semi-
83 TLV431A-D U201 TLV431BSN1T1G 1
SOT-23-3 conductor
IC TH AC/DC BM2P014 650V DIP7
84 BM2P014 U200 ROHM BM2P014 1
65Khz
IGBT SMD N Ch COPACK 650V Q400, Q401,
85 DPAK 8A 2.1V 40nS 62W 13.5nS -- RGT8BM65DTL Q402, Q403, ROHM RGT8BM65DTL 6
40°C ~ 175°C (TJ) Q404, Q405
IGBT TH NCH RGTH80TS65 650V
86 TO247 70A 2.1V 234W 79nC --40°C RGTH80TS65 Q100, Q101 ROHM RGTH80TS65DGC11 2
~ 175°C (TJ)
IPM TH BM63967 600V HSDIP25 30A
87 2.1V @ 15V, 30A 59W -25°C ~ 125°C BM63967 U300 ROHM BM63967S-VA 1
(TJ)
Inductor TH 6.8uH - ±10% 7.8mm x
88 6.8uH L200, L201 Wurth 744779068 2
10 mm, P4mm 0.035Ω
Magnetic
89 Inductor TH 900uH 250VAC - - 900uH L101, L102 Custom 2
INC
LDO SMD LDO 3.3V SOT-223-3 MIC37100-3.3WS-CT-
90 MIC37100-3.3WS U202 Microchip 1
ND
LED SMD Green - (0805) 30mA LD600, LD601,
91 Green ROHM SML-M13MTT86 3
75mW LD800
LED SMD RED - (0805) 30mA 75mW LD200, LD602,
92 RED ROHM SML-M13VTT86 4
LD603, LD801
MOSFET SMD NCH 30V SOT-346T 3A
93 RQ5E030AJ Q601, Q602 ROHM RQ5E030AJ 2
1W --55°C ~ 150°C (TJ)
 USER MANUAL

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PART Description Value Designator Supplier Part Number Qty
no
Machine Screw M4 6.35mm length MH9, MH10,
VOLTAGE MH11, MH12,
94 Mounting Hole Keystone 7799-1 8
MH13, MH14,
MH15, MH16
MH1, MH2, MH3,
95 Mounting VOLTAGE Mounting Hole MH4, MH5, MH6, NA NA 8
MH7, MH8
PTC SMD ICL 22 Ohm 400 VDC ±25%
96 RT1 F100 TDK B59215J0130A020 1
- -
Relay TH SFK-112DMP-F 12V 10% -
97 SFK-112DMP-F RLY100 Sanyou SFK-112DMP-F 1
FORM A -40°C ~ 85°C
Relay TH SJ-S-112DM-F 12V 10% -
98 SJ-S-112DM-F RLY700, RLY701 Sanyou SJ-S-112DM-F 2
FORM A -40°C ~ 85°C
Resistor SMD 0R 1% (0805) 1/8 W R101, R102, R109,
±100ppm/°C R110, R114, R115,
R120, R121, R122,
R123, R130, R132,
R149, R150, R159,
R514, R515, R524,
99 0R ROHM MCR10EZPJ000 34
R525, R535, R536,
R602, R605, R607,
R619, R620, R700,
R704, R709, R711,
R721, R722, R723,
R724
Resistor SMD 0R 1% (1206) 1/4 W
100 0R R212 ROHM MCR18EZPJ000 1
±100ppm/°C
Resistor SMD 1.1K 0.1% (0805) 1/8 W
101 1.1K R151, R165 Yageo RT0805BRD071K1L 2
±100ppm/°C
Resistor SMD 1.2K 1% (0805) 1/8 W
102 1.2K R207 ROHM MCR10EZPF1201 1
±100ppm/°C
Resistor SMD 1K 1% (0805) 1/8 W R1, R136, R146,
±100ppm/°C R153, R500, R501,
R613, R614, R615,
R616, R701, R705,
104 1K R706, R707, R710, ROHM MCR10EZPF1001 26
R712, R802, R803,
R906, R907, R908,
R919, R920, R921,
R922, R930
Resistor SMD 1K 1% (1206) 1/4 W
105 1K R201 ROHM MCR18EZPF1001 1
±100ppm/°C
Resistor SMD 1M 1% (0805) 1/8 W R900, R901, R915,
106 1M ROHM MCR10EZPF1004 4
±100ppm/°C R916
R113, R304, R315,
Resistor SMD 2.2K 0.1% (0805) 1/8 W
107 2.2K R332, R441, R442, Yageo RT0805BRD072K2L 7
±100ppm/°C
R443
Resistor SMD 2.7K 1% (0805) 1/8 W R209, R511, R519,
108 ±100ppm/°C 2.7K R521, R529, R532, ROHM MCR10EZPF2701 7
R540
Resistor SMD 2.49K 1% (0805) 1/8 W
109 2.49K R139, R504, R505 ROHM MCR10EZPF2491 3
±100ppm/°C
Resistor SMD 2K 1% (0805) 1/8 W R128, R129, R131,
110 ±100ppm/°C 2K R133, R148, R152, ROHM MCR10EZPF2001 7
R702
Resistor SMD 3.3K 1% (0805) 1/8 W
111 3.3K R805, R806 ROHM MCR10EZPF3301 2
±100ppm/°C
Resistor SMD 3K 1% (1206) 1/4 W
112 3K R204 ROHM MCR18EZPF3002 1
±100ppm/°C
Resistor SMD 4.7K 1% (0805) 1/8 W R600, R604, R715,
113 4.7K ROHM MCR10EZPF4701 6
±100ppm/°C R720, R800, R937
Resistor SMD 5.6K 1% (0805) 1/8 W
114 5.6K R324 ROHM MCR10EZPF5601 1
±100ppm/°C
 USER MANUAL

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PART Description Value Designator Supplier Part Number Qty
no

Resistor SMD 6.04K 1% (0805) 1/8 W R510, R518, R520,

115 6.04K ROHM MCR10EZPF6041 6
±100ppm/°C R528, R531, R539
Resistor SMD 7.5K 1% (0805) 1/8 W
116 7.5K R144, R508, R509 ROHM MCR10EZPF7501 3
±100ppm/°C
Resistor SMD 9.1K 1% (0805) 1/8 W
117 9.1K R932 ROHM MCR10EZPF9101 1
±100ppm/°C
Resistor SMD 10K 1% (0805) 1/8 W R106, R107, R137,
±100ppm/°C R157, R158, R160,
R161, R210, R310,
R311, R312, R319,
R320, R321, R343,
118 10K R405, R409, R427, ROHM MCR10EZPF1002 33
R431, R447, R448,
R502, R503, R611,
R612, R703, R716,
R717, R929, R933,
R934, R936, R939
R104, R105, R401,
Resistor SMD 10R 1% (0805) 1/8 W
119 10R R402, R403, R410, ROHM MCR10EZPF10R0 8
±100ppm/°C
R411, R412
Resistor SMD 10mR 1% Strip 2W 40
120 10mR R118 TTE OARS1R010FLF 1
ppm/°C
Resistor SMD 10mR ±1% (2512) 3W
121 10mR R329, R330, R338 ROHM GMR100HTBFA10L0 3
±20ppm/°C
Resistor SMD 11.5K 1% (0805) 1/8 W R127, R135, R142,
122 11.5K ROHM MCR10EZPF1152 4
±100ppm/°C R155
Resistor SMD 14.3K 1% (0805) 1/8 W
123 14.3K R126, R134 ROHM MCR10EZPF1432 2
±100ppm/°C
Resistor SMD 15K 1% (0805) 1/8 W
124 15K R211 ROHM MCR10EZPF1502 1
±100ppm/°C
Resistor SMD 20R 1% (0805) 1/8 W R2, R141, R506,
125 20R ROHM MCR10EZPF20R0 4
±100ppm/°C R507
Resistor SMD 25mR 1% Strip 2W
126 25mR R111, R112 TTE OARS1R025FLF 2
±40ppm/°C
Resistor SMD 39.2K 1% (0805) 1/8 W
127 39.2K R147, R154 ROHM MCR10EZPF3922 2
±100ppm/°C
Resistor SMD 40.2K 1% (0805) 1/8 W
128 40.2K R145, R156 ROHM MCR10EZPF4022 2
±100ppm/°C
R325, R326, R333,
Resistor SMD 40.2R 1% (0805) 1/8 W R334, R336, R341,
129 40.2R ROHM MCR10EZPF40R2 12
±100ppm/°C R416, R417, R420,
R421, R423, R424
Resistor SMD 47K 1% (0805) 1/8 W R406, R407, R408,
130 ±100ppm/°C 47K R413, R414, R415, ROHM MCR10EZPF4702 7
R931
Resistor SMD 75K 1% (0805) 1/8 W
131 75K R208 ROHM MCR10EZPF7502 1
±100ppm/°C
Resistor SMD 100K 0.1% (1206) 1/4 R100, R103, R108,
W ±100ppm/°C R138, R140, R143,
R162, R163, R164,
R300, R301, R302,
132 100K R305, R308, R313, Yageo RT1206BRD07100KL 27
R322, R323, R327,
R428, R429, R430,
R432, R433, R434,
R435, R436, R437
R200, R203, R206,
R306, R307, R309,
Resistor SMD 100R 1% (0805) 1/8 W R316, R317, R318,
133 100R ROHM MCR10EZPF1000 18
±100ppm/°C R400, R404, R425,
R426, R444, R445,
R601, R807, R808
134 Resistor SMD 100mR 1% (2512) 1 W 100mR R418, R419, R422 ROHM MCR100JZHFLR100 3
Resistor SMD 300 R 1% (0805) 1/8 W R303, R314, R331,
135 300 R ROHM MCR10EZPF3000 6
±100ppm/°C R438, R439, R440
 USER MANUAL

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PART Description Value Designator Supplier Part Number Qty
no
Resistor SMD 330 R 1% (0805) 1/8 W
136 330 R R801 ROHM MCR10EZPF3300 1
±100ppm/°C
Resistor SMD 470K 1% (0805) 1/8 W
137 470K R935 ROHM MCR10EZPF4703 1
±100ppm/°C
Resistor SMD 470K 1% (2512) 1 W
138 470K R124, R125 Yageo AA2512FK-07470KL 2
±150ppm/°C
Resistor SMD 470R 1% (0805) 1/8 W R335, R339, R617,
139 470R ROHM MCR10EZPF4700 6
±100ppm/°C R618, R905, R938
Resistor SMD 560R 1% (0805) 1/8 W R512, R513, R516,
±100ppm/°C R517, R522, R523,
140 560R ROHM MCR10EZPF5600 12
R526, R527, R533,
R534, R537, R538
Resistor SMD 820mE 1% (2512) 1 W
141 820mR RS200 ROHM MCR100JZHFLR820 1
±100ppm/°C
Resistor TH 2K 500V ±5% Axial 2W
143 2K R719 Vishay PR02000202001JR500 1
±250ppm/°C
Resistor TH 680R 500V ±5% Axial 2W
144 ±250ppm/°C 680R R714 Vishay PR02000206800JA100 1

Switch SMD Tactile 12V 6.20mm x

146 4 Pin SPST-NO SW600 Wurth 430182043816 1
6.20mm -
Transformer TH EFD25, Horizontal
151 1.1mH TR1 Custom Custom 1
10 Pin
Transistor SMD NPN SST2222A 40V - Q700, Q701,
152 SST2222A ROHM SST2222AT116 3
SOT23 Q900
Varistor TH Disc 14mm 510V 14mm RV100, RV101,
153 14mm Little Fuse V14E320P 4
Dia RV102, RV103
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6 Transformer details
The transformer core selected is EFD25. Bobbin selected is EFD25 horizontal with 10 pins

The transformer winding table can be populated as below

Flyback Transformer
Core Type EFD 25 5 6

Bobbin 10 Pin Horizontal

Start Finish Turns Wire

VDC 15V
4
7

Primary1(1.2mH) 3 5 120 T 34 SWG

Secondary (15V/300mA) 6 7 4T 23 SWG 3 12V

8
Secondary
7 8 8T 23SWG 9

(12V/ 500mA) 2

Secondary
9 10 7T 23SWG
5V
Vbias
(5V/ 250mA) 1 10
TR 1
Primary 2 2 1 21T 34 SWG 1.2mH

TABLE 1 : TRANSFORMER WINDING DATA

Winding Sequence
Primary Winding. (34SWG)
Start on pin3 and wind 120 turns in 2 layers from left to right. At the end of 1st layer, continue to wind the next layer fro m right to left.
On the final layer, spread the winding evenly across entire bobbin. Finish this winding on pin 1.

Add 1 layer of tape, for insulation.

Bias winding. (34SWG)

Start on pin4 and wind 21 turns bifilar. Wind in same rotational direction as primary winding. Spread the winding evenly across entire
bobbin. Finish this winding on pin 5.

Add 1 layer of tape, for insulation.

Secondary Winding 1. (23SWG)
Start on pin 6 and wind 4 turns. Spread the winding evenly across entire bobbin. Wind in same rotational direction as primary
winding. Finish this winding on pin7.

Secondary Winding 2. (23SWG)

Start on pin 7 and wind 8 turns. Spread the winding evenly across entire bobbin. Wind in same rotational direction as primary
winding. Finish this winding on pin 8.

Secondary Winding 3. (23SWG)

Start on pin 9 and wind 7 turns. Spread the winding evenly across entire bobbin. Wind in same rotational direction as primar y
winding. Finish this winding on pin 10.
Add two layers of tape for insulation.
Primary Inductance at typical switching Frequency measured at Pin 3 to 1: 1.2mH + 5%

Start on pin 2 and wind 20 turns (1 X 2UEW 0.45) from left to right. At the end of 1st layer, continue to wind the next layer from right
to left. Spread the windings evenly across entire bobbin.
Finish the winding on pin 3.
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7 TEST and measurement data

PFC IGBT switching waveforms

The IGBT Collector-Emitter voltage and inductor current waveforms are captured to verify the designed parameters. The maxi-mum
Bus voltage is 380V at full load. The RMS inductor current is found to be 3.56A at full load.

CH1: Not Used, CH2: Inductor-A current, CH3: Inductor-B current, CH4: IGBT VCe

@220VAC, 2.5A load– Vds max =380 V @220VAC, 2.5A load– Vds max =380 V

@220VAC, 2.5A load– Vds max =380 V @220VAC,2.5A load– Vds max =380 V

PFC IGBT voltage vs shunt current switching waveforms

The IGBT Collector-Emitter voltage and inductor current waveforms are captured to verify the designed parameters. The maxi-mum
Bus voltage is 380V at full load. The power loss is captured at IGBT leg current of 2.56A RMS.

CH1: Shunt current, CH4: VCE-IGBT

@220VAC,2.5A load– Vds max =380 V

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8 Load Regulation curves

Output power Vs Efficiency and Bus voltage regulation.

PFC Efficiency
97 380
379.5
96 Efficiency
379
95 378.5
Voltage regulation
Efficiency

378
94
377.5
93 377
92 376.5
376
91 375.5
90 375
200 501 600 801 1000 1200
Load Power [W]

THD vs Power
1400
THD
1200 Iac
2
1000
THD %

800

600

400

200

0 0
200 501 Load
600 Power801
[W] 1000 1200
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9 PCB Layout
Top Layer
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Bottom layer