Application Note 1876 Author: Alan Yu ISL6730BEVAL1Z and ISL6730DEVAL1Z: Boost CCM PFC for 300W Universal Input Adaptors Introduction Design Specifications This application note describes the design and implementation of a 390V, 300W, Continuous Conduction Mode (CCM) Boost PFC converter using the ISL6730B, ISL6730D. The converter exhibits high power factor, Low THD and high conversion efficiency. The ISL6730B, ISL6730D are voltage mode power factor correction (PFC) controllers designed to drive cost-effective converters to meet input line harmonic regulations. The IC can be ISL6730B (Fixed Skip threshold) or ISL6730D (non-Skip). A detailed design procedure can be found in the datasheet (FN8258). • Input Voltage, VIN: 85V - 265VAC • Output Voltage, VO: 390VDC • Output Current, IO: 0.77A (300W) • Switching Frequency: 64kHz • Efficiency: Full Load, 96% @ 115VAC ; 98% @ 230V • PF: Full Load, 0.999 @ 115VAC ;0.996 @ 230VAC • THD: Full Load, 2% @ 115VAC , 2.5% @ 230VAC • Board Dimension: 124×92×43 mm3(L×W×H) Application Figure 3 on page 2 shows the test setup. The pre-regulator for AC/DC adaptors, such as Desktop/laptop Computer adaptors, or ATX power supply for the servers of networks or date centers, brick converters for telecom, flat-panel TVs, etc. VI + VLINE VOUT VCC ISEN GATE ICOMP GND ISL6730 VIN FB COMP BO VREG FIGURE 1. SIMPLIFIED SCHEMATIC July 29, 2013 AN1876.0 1 CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures. 1-888-INTERSIL or 1-888-468-3774 | Copyright Intersil Americas LLC 2013. All Rights Reserved Intersil (and design) is a trademark owned by Intersil Corporation or one of its subsidiaries. All other trademarks mentioned are the property of their respective owners. Application Note 1876 FIGURE 2. TOP VIEW OF THE EVALUATION BOARD POWER ANALYZER AC SOURCE L ISL6730 EVB IIN A TP9 + P2 + Io P1 V V LINE UUT P4 P3 - TP10 - N V Load V o - P7 P6 + 12V FIGURE 3. TEST SETUP Performance Curves and Typical Waveforms 264VAC-B 98 98 EFFICIENCY (%) EFFICIENCY (%) 264VAC-D 230VAC-B 96 230VAC-D ISL6730C 94 85VAC-B ISL6730A, SKIP 92 90 88 0 100 94 115VAC-D 92 115VAC-B 90 85VAC-D 50 96 150 200 250 LOAD (W) FIGURE 4. EFFICIENCY vs LOAD (85V, 230V) 2 300 88 0 50 100 150 200 250 300 LOAD (W) FIGURE 5. EFFICIENCY vs LOAD (115V, 264V) AN1876.0 July 29, 2013 Application Note 1876 Performance Curves and Typical Waveforms 1.0 30 85VAC-D 0.9 85VAC-D 25 264VAC-D 115VAC-D 0.8 20 THD (%) POWER FACTOR (Continued) 0.7 264VAC-D 0.6 115VAC-D 10 0.5 230VAC-D 0.4 0.3 0 230VAC-D 15 50 100 5 150 200 LOAD (W) 250 0 0 300 FIGURE 6. POWER FACTOR vs LOAD 50 100 150 200 LOAD (W) 250 300 FIGURE 7. THD vs LOAD VLINE ILINE CH2: LINE CURRENT CH4: LINE VOLTAGE HARMONIC CURRENT (mA) 50 45 Measurement EN61000-3-2 A14 class D 40 35 30 25 20 15 10 5 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 FIGURE 9. HARMONIC CURRENTS (115V/300W) FIGURE 8. WAVEFORMS OF LINE CURRENT AND VOLTAGE (115V/300W) 50 HARMONIC CURRENT (mA) VLINE ILINE CH2: LINE CURRENT CH4: LINE VOLTAGE FIGURE 10. WAVEFORMS OF LINE CURRENT AND VOLTAGE (230V/300W) 3 45 40 Measurement EN61000-3-2 A14 class D 35 30 25 20 15 10 5 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 FIGURE 11. HARMONIC CURRENT OF LINE CURRENTS (230V/300W) AN1876.0 July 29, 2013 Schematic D1 IN5406 L1 0u 1n DNP R11 470k VIN TP3 C12 DNP R13 5.76k C7 1u R9 3k DNP R20 10k 1 2 3.3M VREG TP8 1u C17 1n DNP TP4 2N7002 Q2 DNP DNP P9 FIGURE 12. SCHEMATIC OF EVALUATION BOARD 2 GND C26 2.2n R6 VCC R10 6.8n R21 25k DNP 1 DNP P8 P3 DZ1 3.3V U1 VREG Lin.Reg. VCC C10 GATE 10 UVLO LOGIC 3 ICOMP TP6 GND 1 ICOMP CEQ OTP 2 ISEN I MIRROR 2:1 Gen TP5 ISEN PWM Vin*C I*= 4*BO*BO I* gm 2.5V 4 VIN C SKIP OPL FB 7 gm + SKIP C13 COMP BO VCC ISL6730B/D 47p C11 0.1 C9 5 R8 470k 47n C20 R14 51k 390V TP10 C8 220n D8 D7 S1M S1M 0.1 3 - DNP DNP C5 C6 6 4 1 R4 51k R28 0.22 R27 0.22 R5 0.22 8 2.2n C35 R3 2M C21 C19 R2 2.2 3 PE 2.2n C36 L3 2.2m DB1 BU2508 C1 270u 450V TP2 BO C14 470n COMP R18 62k C15 C18 150n 1u VCC 3.3M P6 TP7 GND GATE DNP R26 49.9 TP1 C16 100n FB R17 0 R19 42.2k P7 Application Note 1876 P5 L4 2.2m P2 1 C3 680n 2 UNIVERSAL INPUT 85~265Vac 1 AC2 4 4 P4 Q1 TP12 GATE1 470n 470n TP9 SPP20N60C3 C22 C2 DC+ C3D04060 + R1 2M 1 9 3 2 F2 8A 3 AC1 2 P1 L2 1.5m VOUT D2 2 AN1876.0 July 29, 2013 Application Note 1876 TABLE 1. BILL OF MATERIALS QTY REFERENCE DESIGNATOR 1 C1 2 1 5 2 TYPE/PACKAGE VALUE VOL/TOL/MAT MANUFACTURER MANUFACTURER PART # Cap, TH 270µ 450V, 20%, ELECT, Aluminum Panasonic EETUQ2W271DA C2, C22 Cap, TH, Radial 470n X2, 20%, EMI, X2-class EPCOS B32922C3474M C3 Cap, TH, Radial 680n 450V, 20%, Metallized Polyester Film EPCOS B32672P4684K C5, C6, C35, C36, C26 Cap, TH, Radial 2.2n Y1, 20%, EMI, Y1-class TDK CS11-E2GA222MYNS C7,C9 Cap, SM, 0603 1µ 50V, 20%, X7R TDK 1 C8 Cap, SM, 0603 220n 25V, 20%, X7R TDK 1 C10 Cap, SM, 0603 6.8n 25V, 10%, X7R TDK 1 C11 Cap, SM, 0603 1n 25V, 10%, X7R TDK 1 C13 Cap, SM, 0603 47p 16V, 5%, NPO TDK 1 C14 Cap, SM, 0603 470n 16V, 10%, X7R TDK 1 C15 Cap, SM, 0603 150n 50V, 10%, X7R TDK 1 C16 Cap, SM, 0603 100n 50V, 10%, X7R TDK 1 C18 Cap, SM, 0603 1µ 16V, 10%, X7R TDK 2 C19, C21 Cap, SM, SM1812 0.1 630V, 10% Murata 1 C20 Cap, SM, 0603 47n 25V, 10%; X7R TDK 1 DB1 Diode, SM BU2508 GRM43DR72J104KW01L Diodes Inc 1 DZ1 Zener, SM, SOD323 3.3V 5%, Zener NXP 1 D1 Diode, SM, DO-201AD IN5406 800V, 3A, Standard Recovery Micro Commercial Co IN5406-TP 1 D2 Diode, SM, DPAK C3D04060 600V, 3A, SiC Schottky Cree 2 D7, D8 Diode, SM, SMA S1M 1kV, 1A, Standard Recovery Diodes Inc S1M-13-F 1 F2 Fuse, TH, 5x20mm 8A 250V, fast acting, ceramic Bel Fuse 5HF8-R 1 L1 Bare Wire 1 L2 Ind, TH 1.5m Core: Magmetics 0077071-A7 HT22, Wire: AWG20(or 0.8mm) 110T 2 L3, L4 CMC, TH 2.2m Common Mode Choke 7 P1, P2, P3, P4, P5, P6, P7 TP, TH 1 Q1 MOSFET, TH, to220_std 2 R1, R3 Res, SM, 1206 2M 5%, Thick Film Panasonic-ECG 1 R2 Res, SM, 0603 2.2 1%, Thick Film Yageo 2 R4, R14 Res, SM, 0603 51k 1%, Thick Film Yageo 3 R5, R27, R28 Res, TH, Axial 0.22 1W, 5%, metal oxide Yageo KNP100JR-73-0R22 2 R6, R10 Res, SM, 1206 3.3M 1%, Thick Film Yageo RC1206FR-073M3L 2 R8, R11 Res, SM, 1206 470k 1%, Thick Film Yageo 1 R9 Res, SM, 0603 3k 1%, Thick Film Yageo 1 R13 Res, SM, 0603 5.76k 1%, Thick Film Yageo 1 R17 Res, SM, 0603 0 1%, Thick Film Yageo 1 R18 Res, SM, 0603 62k 1%, Thick Film Yageo 1 R19 Res, SM, 0603 42.2k 1%, Thick Film Yageo 1 R26 Res, SM, 0603 49.9 1%, Thick Film Yageo 10 TP1~6, TP8~10, TP12 Pole, TH 1 U1 IC, SM, MSOP10 0 C12, TP7; C17, R20, R21, P8, P9, Q2 SPP20N60C3 600V, N-Chan ISL6730B/D CCM PFC Controller BZX384-B3V3 Customized Wurth 744824622 KEYSTONE 1514-2 Infineon ERJ-8GEYJ205 KEYSTONE 5007 Intersil ISL6730BFUZ or ISL6730DFUZ DNP 5 AN1876.0 July 29, 2013 Application Note 1876 PCB Layout FIGURE 13. TOP LAYER FIGURE 14. BOTTOM LAYER 6 AN1876.0 July 29, 2013 Application Note 1876 Assembly Drawing FIGURE 15. ASSEMBLY ON TOP Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is cautioned to verify that the Application Note or Technical Brief is current before proceeding. For information regarding Intersil Corporation and its products, see www.intersil.com 7 AN1876.0 July 29, 2013