Application Note 1726 ISL78220EVAL1Z: 6-Phase Interleaved Synchronous Boost Converter ISL78220EVAL1Z Evaluation Board The ISL78220EVAL1Z evaluation board features the ISL78220 6-phase interleaved boost controller and six ISL6609A MOSFET drivers. The ISL78220 and ISL6609A are configured as a 6-phase synchronous boost converter for 6-11V input into 12V output at 30A. The interleaved timing reduces input and output ripple current, thereby reducing the required number of input and output capacitors. Recommended Equipment • 0V to 20V main power supply with at least 70A source current capability • 12V electronic load capable of sinking up to 30A • Digital Multimeters (DMMs) • 100MHz Quad-Trace Oscilloscope Quick Test Guide The ISL78220 enhances light load efficiency by dropping phases with decreasing load, by emulating a diode while stopping reverse current in the synchronous output switch, and by skipping switch pulses at very light loads. The ISL6609A facilitates diode emulation by translating the midrange of the tri-level PWM out from the ISL78220 to turn both output switches off. 1. Set main power supply to 6V, turn off, and connect to VIN and GND terminals on board. For a 4-phase interleaved boost controller, please see the ISL78225. 5. Adjust the main power supply in the range of 6V to 11V as desired. What’s Inside 6. Adjust the electronic load in the range of 0A to 30A as desired. The evaluation board kit contains the following materials: • The ISL78220EVAL1Z • The ISL78220 Datasheet FN7688 • The ISL6609A Datasheet FN9221 2. Set electronic load for 1A, turn off, and connect to VOUT and GND terminals on board. 3. Turn on the main power supply. 4. Turn on the electronic load. 7. Turn off the main power supply. 8. Turn off the electronic load. The default is phase dropping mode. For continuous switching mode, move shunt from JP14 to JP16 while the main power is turned off. • This Evaluation Board Kit document (AN1726) February 9, 2012 AN1726.0 1 CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures. Copyright Intersil Americas Inc. 2012. All Rights Reserved. 1-888-INTERSIL or 1-888-468-3774 | 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 1726 . DC SUPPLY VIN = 6V TO 11V ELECTRONIC LOAD FIGURE 1. ISL78220EVAL1Z CONNECTIONS 2 AN1726.0 February 9, 2012 Application Note 1726 Typical Performance Curves 0.98 0.99 WITH PHASE DROPPING 0.97 0.98 0.96 0.96 EFFICIENCY EFFICIENCY 0.95 0.94 0.93 0.92 0.91 0.94 0.93 0.91 6V INPUT, 12V OUTPUT SYNCHRONOUS BOOST 0.89 11V INPUT, 12V OUTPUT SYNCHRONOUS BOOST 0.90 0.89 0.88 0 5 10 15 20 OUTPUT CURRENT (A) 25 0 30 FIGURE 2. 6V INPUT EFFICIENCY vs OUTPUT CURRENT vs PHASE DROPPING MODE 12.5 12.5 12.4 12.4 12.3 12.3 12.2 12.1 12.0 11.9 11.8 5 10 15 20 OUTPUT CURRENT (A) 25 30 FIGURE 3. 11V INPUT EFFICIENCY vs OUTPUT CURRENT vs PHASE DROPPING MODE OUTPUT VOLTAGE (V) OUTPUT VOLTAGE (V) WITHOUT PHASE DROPPING 0.95 0.92 0.90 12.2 12.1 12.0 11.9 11.8 11.7 11.7 11.6 11.5 WITH PHASE DROPPING 0.97 WITHOUT PHASE DROPPING 11.6 6V INPUT 30A OUTPUT 11.5 0 5 10 15 20 OUTPUT CURRENT (A) 25 6 30 7 8 9 INPUT VOLTAGE (V) 10 11 FIGURE 5. OUTPUT VOLTAGE vs INPUT VOLTAGE FIGURE 4. OUTPUT VOLTAGE vs OUTPUT CURRENT 5V PHASE 1 100mV 50mV VOUT (AC-COUPLED) VOUT (AC-COUPLED) 6V INPUT, 30A OUTPUT 1µs/DIV FIGURE 6. FULL LOAD OUTPUT RIPPLE 3 6V INPUT, 0 TO 30A TO 0 STEP LOAD 2ms/DIV FIGURE 7. FULL STEP LOAD TRANSIENT AN1726.0 February 9, 2012 Schematics VCC5 TP12 TP10 JP16 10K R29 10K MODE C109 PGOOD EN DMAX VOUT_OV VOUT_SEN VIN_OV VIN_SEN IOUT MODE GND VCC IN 1UF IN IN VIN ISEN6P ISEN6N ISEN4P ISEN4N ISEN2P ISEN2N ISEN5P ISEN5N ISEN3P ISEN3N 33 32 31 30 29 28 27 26 25 24 23 IN IN IN IN IN IN IN IN IN DRIVE_EN TP27 JP23 IN R1 0 OUT JP20 JP15 DRAWN BY: VCC5 IN E DNP TP30 TP31 R103 RELEASED BY: TP29 E AN1726.0 February 9, 2012 INSTALL SHUNTS JP13,JP14 & JP26 FIGURE 8. ISL78220EVAL1Z SCHEMATIC PAGE 1 UPDATED BY: ISEN6P ISEN6N ISEN4P ISEN4N ISEN2P ISEN2N ISEN5P ISEN5N ISEN3P ISEN3N ISEN1P ISEN1N DRIVE_EN OUT JP22 JP21 JP13 JP24 TP28 VIN1 E 1UF C10 OUT TP6 VCC JP25 JP19 JP26 R102 10K CLK_OUT E IN EP CLK_OUT JP14 VCC5 R15 IN 1UF VCC VCC IN TP4 DNP VCC PWM_INV E SYNC E DNP U7 R18 6800PF 6.81K J7 R19 IN 45 1000PF E TP25 44 43 42 41 40 39 38 37 36 35 34 C106 FS SS COMP FB ISL78220 VREF2 GND SLOPE PLL_COMP SYNC CLK_OUT PWM_TRI DNP R25 OPEN R16 C15 SS 1 2 3 4 5 6 7 8 9 10 11 82.5K J8 VIN1 TP2 0.022UF 47.5K 0.1UF C110 OPEN C13 R14 PWM1 PWM3 PWM5 PWM2 PWM4 PWM6 DRIVE_EN NC ISEN1N ISEN1P DNP OPEN R24 R23 C34 2K R22 DNP 10K C35 R21 JP9 E E 158K 270PF C14 OUT C16 200K R12 C104 IOUT PWM6 OUT PWM4 OUT PWM2 OUT PWM5 OUT PWM3 OUT PWM1 TIM KLEMANN Application Note 1726 FB TP5 TP3 TP7 E R28 E COMP E IN VIN_VO TP9 2N7002 VOUT1 C36 0.01UF 12 13 14 15 16 17 18 19 20 21 22 4 Q1 PGOOD R27 TP8 R30 2 8.06K EN 10K 4.99K 4 TP11 R20 IN VOUT_OV JP17 E VIN1 IN R26 10K R89 1 VOUT_SENSE VIN_SENSE IN JP18 3.32K R88 3 RED R87 LED2 SSL_LXA3025IGC 3.32K IN GRN VCC Schematics (Continued) R34 3.01K R79 0 PWM EN 7 VCC 6 4 GND LGATE 5 ISL6609AIBZ E 4 470UF DNP C56 C55 10UF 1UF C39 C38 3 V12P10 DNP Q6 RJK0332DPB E 1 2 3 DNP OPEN 0 D1 E R36 PHASE 1 TO NEXT SHEET 5 VOUT 5 0 3 E RJK0328DPB 2 R33 BOOT R32 R104 UGATE 2 TP13 PHASE 8 1 2 3 1 2.2 DNP ISEN1N PWM1 U1 1 R37 IN R105 4.7 C19 DNP 0.22UF C37 470PF R35 1UF 249 R91 249 R31 C18 Q3 4 IN VCC5 IN DRIVE_EN E VOUT OUT R46 PWM2 OUT OUT ISEN2N TP15 R107 0 UGATE PHASE 8 2 BOOT EN 7 3 PWM VCC 6 4 GND LGATE 5 ISL6609AIBZ E PHASE 2 FIGURE 9. ISL78220EVAL1Z SCHEMATIC PAGE 2 IN VCC5 IN DRIVE_EN 470UF DNP C62 C61 E E 2.2 10UF C45 1UF RJK0332DPB R38 E DNP Q8 4 C44 DNP E 3 V12P10 1 2 3 U2 D2 0 1 OPEN DNP 4.7 VOUT 5 2 R40 470PF 0.22UF RJK0328DPB 5 DNP R41 R42 R39 C20 C21 R45 249 249 TP16 IN ISEN2P PHASE2 C22 2.2UH 1 2 3 1 TO NEXT SHEET Q9 4 0 0.005 0 R106 L2 R92 R93 750 R2 10UF C42 R44 E 1UF C43 DNP C59 C60 220UF E 1UF 1UF OUT PHASE1 TP14 C17 ISEN1P 13K VIN C107 2.2UH 0 Application Note 1726 LAYOUT C107 AS CLOSE TO PIN 38 OF U1 0.005 OUT VIN1 OUT L1 OUT R82 OUT VIN_SENSE R3 R43 5 0 R90 750 10UF 1UF E R84 E C41 C40 C57 DNP C58 J2 220UF C94 DNP C93 DNP GND DNP C92 J1 C46 VIN AN1726.0 February 9, 2012 Schematics (Continued) 2 BOOT EN 7 3 PWM VCC 6 4 GND LGATE 5 TP17 PHASE ISL6609AIBZ E OPEN 470UF DNP C66 C65 10UF 1UF E E R47 PHASE 3 C50 DNP RJK0332DPB 1 2 3 E 8 3 V12P10 Q12 4 C49 DNP 0 R53 D3 0 UGATE 5 R49 U3 1 1 2.2 DNP 0 4.7 5 IN VCC5 IN DRIVE_EN VOUT IN FROM PREVIOUS SHEET E ISEN4N PWM4 IN TP19 R110 0 BOOT 3 4 7 PWM VCC 6 GND LGATE 5 DNP 5 Q16 4 RJK0332DPB 1 2 3 E E R55 2.2 E FIGURE 10. ISL78220EVAL1Z SCHEMATIC PAGE 3 IN VCC5 IN DRIVE_EN DNP 470UF V12P10 C70 C69 10UF C71 3 1UF D4 C54 DNP OPEN R61 8 EN ISL6609AIBZ E PHASE 4 PHASE 5 0 UGATE 2 E RJK0328DPB 2 R57 1 U4 1 2 3 1 DNP DNP 4.7 R56 470PF 0.22UF C128 R58 R59 1UF C26 C27 Q17 4 0 TP20 249 249 PHASE4 R111 2.2UH 0 C72 0.005 R96 L4 750 R5 10UF R60 C75 R97 OUT OUT ISEN4P E 1UF C76 DNP C73 C74 220UF R62 VOUT OUT TO NEXT SHEET Application Note 1726 TO NEXT SHEET ISEN3N ISEN3P OUT PWM3 R109 0.22UF R48 DNP R51 RJK0328DPB 1 2 3 2 C25 470PF C24 Q13 4 1UF R50 OUT FROM PREVIOUS SHEET VIN R108 249 C23 OUT IN PHASE3 TP18 IN VIN 0 C51 2.2UH R94 R4 R52 0.005 750 6 E R95 249 10UF 1UF C47 C48 DNP C63 220UF C64 R54 L3 AN1726.0 February 9, 2012 Schematics (Continued) ** LAYOUT C108 AS CLOSE TO PIN 40 OF U1 GND LGATE 5 TP21 ISL6609AIBZ E IN 2.2 FROM PREVIOUS SHEET E TP23 R115 0 PWM 4 GND 7 6 LGATE 5 DNP RJK0332DPB 1 2 3 E E VCC5 IN R71 2.2 IN DRIVE_EN E FIGURE 11. ISL78220EVAL1Z SCHEMATIC PAGE 4 470UF C87 DNP C86 10UF C89 1UF 3 V12P10 Q24 4 C88 DNP E D6 2 OPEN R77 C90 0 R114 EN VCC ISL6609AIBZ E PHASE 6 8 5 0 BOOT PHASE Q25 RJK0328DPB 5 R73 2 3 4.7 1 2 3 1 DNP IN UGATE U6 R72 OUT OUT ISEN6N PWM6 1 R75 4 1UF 0.22UF DNP 750 R76 C33 R74 470PF ISEN6P TP24 249 C32 E PHASE6 15K 3.01K R86 GND 0 C91 2.2UH R100 0.005 249 R7 10UF C79 1UF C80 C77 DNP C78 220UF L6 J4 E R78 R101 1UF C108 IN DRIVE_EN J3 VOUT VOUT Application Note 1726 PHASE 5 R85 470UF DNP C82 E IN R63 OUT TO NEXT SHEET C81 10UF 1UF C84 DNP OPEN 0 C83 1 2 3 VCC5 1UF VCC 4 VOUT_SENSE VOUT E 1UF PWM 6 VOUT1 OUT C102 3 E E 1UF EN 7 RJK0332DPB ** 0 8 DNP Q20 4 C100 BOOT PHASE 3 V12P10 1UF 0 2 2 OUT 0 C99 R113 U5 UGATE D5 5 R65 1 R69 R112 4.7 R80 C98 ISEN5N VIN 0.22UF Q21 RJK0328DPB 5 1 2 3 1 DNP IN PWM5 R67 C31 DNP C30 R64 470PF ISEN5P FROM PREVIOUS SHEET 249 R66 OUT IN TP22 C29 OUT VIN PHASE5 4 1UF 2.2UH R98 0.005 0 C85 R68 R6 L5 750 7 E R99 249 10UF 1UF C52 C53 C67 DNP C68 220UF R70 AN1726.0 February 9, 2012 Application Note 1726 TABLE 1. BILL OF MATERIALS ITEM QTY PART REFERENCE VALUE DESCRIPTION PART # MANUFACTURER 1 24 C10, C37, C38, C40, C43, C44, C46, C48, C49, C51, C53, C54, C72, C76, C80, C83, C85, C88, C91,C98C100, C102, C109 1µF CAP Ceramic X7R, 50V, 0805 GRM21BR71H105KA12L Murata 2 1 C13 0.022µF CAP Ceramic X7R, 50V, 0603 Generic 3 1 C14 0.1µF CAP Ceramic X7R, 25V, 0603 Generic 4 1 C15 6800pF CAP Ceramic X7R, 50V, 0603 Generic 5 1 C16 4.7µF CAP Ceramic X7R, 16V, 0805 6 4 C17, C20, C23, C26 470pF CAP Ceramic X7R, 50V, 0603 Generic 7 4 C18, C21, C24, C27 0.22µF CAP Ceramic X7R, 50V, 0603 Generic 8 1 C36 0.01µF CAP Ceramic X7R, 16V, 0603 Generic 9 12 C39, C41, C42, C45, C47, C50, C52, C71, C75 ,C79, C84, C89 10µF CAP Ceramic X7R, 50V, 2220 C5750X7R1H106K TDK 10 6 C56, C62, C66, C70, C82, C87 470µF Polymer CAP SEPC Series 16SEPC470M Sanyo 11 6 C58, C60, C64, C68, C74, C78 220µF Alum. Elec. CAP KY Series EKY350ELL221MJC5S United Chemi-con 12 1 C104 270pF CAP Ceramic X7R, 50V, 0603 Generic 13 1 C106 1000pF CAP Ceramic X7R, 50V, 0603 Generic 14 2 C107, C108 1µF CAP Ceramic X7R, 16V, 0603 C1608X7R1C105K TDK 15 4 J1-J4 Wire Connector Lug KPA8CTP Burndy 16 2 J7, J8 50Ω PCB MOUNT RECEPTACLE 31-5329-52RFX Amphenol 17 15 JP9, JP13-JP26 Two Pin 0.1" Jumper 18 4 L1-L4 19 1 20 2.2µH GRM21BR71C475KA73L Murata Generic LOW PROFILE HIGH CURRENT INDUCTOR (RoHS COMPLIANT) IHLP-6767GZ-ER-2R2-M-01 Vishay LED2 3x2.5mm Surface Mount RED/GREEN LED SSL-LXA3025IGC Lumex 1 Q1 N-Channel 60V 115ma MOSFET 2N7002L On Semi 21 6 Q3, Q9, Q13, Q17, Q21, Q25 N-Channel 30V 60A Power MOSFET RJK0328DPB Renesas 22 6 Q6, Q8, Q12, Q16, Q20, Q24 N-Channel 30V 35A Power MOSFET RJK0332DPB Renesas 23 27 R1, R33, R34, R40, R46, R49, R54, R57, R62, R65, R70, R73, R78, R80, R84, R104-R115 0Ω Resistor, 1% 0603 Generic 24 12 R2-R7, R91, R92, R94 ,R96, R98, R100 249Ω Resistor, 1% 0603 Generic 25 1 R12 158kΩ Resistor, 1% 0603 Generic 26 1 R14 47.5kΩ Resistor, 1% 0603 Generic 8 AN1726.0 February 9, 2012 Application Note 1726 TABLE 1. BILL OF MATERIALS (Continued) ITEM QTY PART REFERENCE VALUE DESCRIPTION 27 6 R15, R20, R21, R27, R29, R89 10kΩ Resistor, 1% 0603 Generic 28 1 R16 82.5kΩ Resistor, 1% 0603 Generic 29 1 R18 6.81kΩ Resistor, 1% 0603 Generic 30 1 R22 2kΩ Resistor, 1% 0603 Generic 31 1 R28 200kΩ Resistor, 1% 0603 Generic 32 1 R30 4.99kΩ Resistor, 1% 0603 Generic 33 6 R35, R42, R51, R59, R67, R75 4.7Ω Resistor, 5% 0603 Generic 34 6 R36, R38, R47, R55, R63, R71 2.2Ω Resistor, 5% 0603 Generic 35 6 R43, R44, R52, R60, R68, R76 750Ω Resistor, 1% 0603 Generic 36 2 R79, R86 3.01kΩ Resistor, 1% 0603 Generic 37 1 R82 13.0kΩ Resistor, 1% 0603 Generic 38 1 R85 15.0kΩ Resistor, 1% 0603 Generic 39 2 R87, R88 3.32kΩ Resistor, 1% 0603 Generic 40 6 R90, R93, R95, R97, R99, R101 0.005Ω SURFACE MOUNT POWER METAL STRIP RESISTOR, 1% WSH28185LOOOFE Vishay 41 29 TP2-TP25, TP27-TP31 Miniature White Test Point .100 Pad .040 Thole 5002 Keystone 42 6 U1-U6 Synchronous Rectified MOSFET Driver ISL6609AIBZ Intersil 43 1 U7 SIX-PHASE BOOST PWM CONTROLLER (Pb-FREE) ISL78220ANEZ Intersil 9 PART # MANUFACTURER AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout FIGURE 12. ASSEMBLY TOP 10 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 13. SILK SCREEN TOP 11 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 14. TOP LAYER COMPONENT SIDE 12 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 15. LAYER 2 13 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 16. LAYER 3 14 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 17. LAYER 4 15 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 18. LAYER 5 16 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 19. BOTTOM LAYER SOLDER SIDE 17 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 20. SILK SCREEN BOTTOM 18 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 21. SILK SCREEN BOTTOM (MIRRORED) 19 AN1726.0 February 9, 2012 Application Note 1726 ISL78220EVAL1Z Board Layout (Continued) FIGURE 22. ASSEMBLY BOTTOM 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 20 AN1726.0 February 9, 2012