Application Note 1884 ISL6731AEVAL1Z and ISL6731BEVAL1Z: 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 ISL6731A, ISL6731B. The converter exhibits high power factor, Low THD and high conversion efficiency. The ISL6731A, ISL6731B are voltage mode power factor correction (PFC) controllers designed to drive cost-effective converters to meet input line harmonic regulations. The IC can be ISL6731A (124kHz) or ISL6731B (64kHz). • Input Voltage, VIN: 85V - 265VAC Application • THD: Full Load, 2% @ 115VAC , 3% @ 230VAC 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. Test Setup • Output Voltage, VO: 390VDC • Output Current, IO: 0.77A (300W) • Switching Frequency: ISL6731A (124kHz) or ISL6731B (64kHz) • Efficiency: Full Load, 95% @ 115VAC ; 97% @ 230V • PF: Full Load, 0.999 @ 115VAC ; 0.996 @ 230VAC • Board Dimension: 124×80×38 mm3(L×W×H) • See the test set-up in Figure 3, on page 2 Ordering Information References • “ISL6731A, ISL6731B” datasheet PART NUMBER DESCRIPTION ISL6731AEVAL1Z 300W Boost CCM PFC, 124kHz ISL6731BEVAL1Z 300W Boost CCM PFC, 64kHz VI + V L IN E VOUT VCC G A TE IS E N GND V IN OVP IS L 6731 IC O M P FB COMP BO S K IP VREG FIGURE 1. SIMPLIFIED SCHEMATIC March 20, 2014 AN1884.0 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 2014. 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 1884 FIGURE 2. PHOTO OF THE EVALUATION BOARD POWER ANALYZER AC SOURCE ISL6731 EVB Iin L TP9 + A Io P2 P1 V VLINE + UUT Load P4 P3 N TP10 P6 - + - V Vo - P7 12V FIGURE 3. TEST SETUP Submit Document Feedback 2 AN1884.0 March 20, 2014 D1 IN5406 + 470n 2 R28 0.22 R27 0.22 R5 0.22 2.2n 2.2n C5 C6 C21 0.1 2 R2 2.2 C19 C1 0.1 270u 450V 390V 3 DB1 GBU806 RV1 MOV /DNP - 4 R3 2M C3 680n R4 51k P3 GND C8 220n D8 D7 S1M S1M 47n C20 TP10 R23 3.3M C9 TP7 DNP 1u DNP VCC VREG GATE C11 TP8 R8 R24 1n C7 470k U1 3.3M 6.8n 1u VREG Lin.Reg. VCC C10 GATE 14 UVLO LOGIC 4 ICOMP R9 R11 TP6 3k GND 2 ICOMP CEQ OTP 470k 3 ISEN I MIRROR 2:1 Gen TP5 ISEN OVP 7 PWM Vin*C I*= 4*BO*BO I* gm VIN C23 2.5V 5 VIN 1n C SKIP OPL TP3 FB 9 gm + SKIP COMP BO R13 C13 VCC ISL6731A/B 5.76k 47p R21 69.8K TP4 TP2 25k R22 DNP 2N7002 BO COMP Q2 1 DNP DNP P8 C15 R18 150n C14 62k DNP C17 470n R20 1n 10k DNP C18 1u DNP P9 R14 30k 6 3 2 AN1884.0 March 20, 2014 FIGURE 4. SCHEMATIC OF EVALUATION BOARD 10 11 C12 DNP DZ1 3.3V 1 13 PE P5 2.2n C36 L3 2.2m Q1 3.3M R6 C26 2.2n R10 3.3M DNP TP11 VCC OVP 42.2k R25 R26 49.9 TP1 GND FB R17 0 C16 100n R19 42.2k P6 P7 Application Note 1884 2.2n C35 1 4 AC2 L4 2.2m P2 1 12 P4 1 470n TP9 SPP20N60C3 TP12 GATE1 C22 C2 DC+ C3D04060A 3 UNIVERSAL INPUT 90~265Vac 1 1 R1 2M L2 1.5m L1 0u VOUT D2 2 8 3 F1 8A 2 AC1 3 P1 2 Submit Document Feedback Schematic Application Note 1884 TABLE 1. BILL OF MATERIALS QTY REF DES 2 C2, C22 1 C18 5 DESCRIPTION CAP-EMI, RADIAL, 18x9, 0.47µF, 630V, 20%, 15mmLS C3 2 C11, C23 MFR. PART # B32922C3474M TDK CS11-E2GA222MYNS PANASONIC ECW-F2W684JA CAP, SMD, 0603, 1.0µF, 16V, 10%, X7R C5, C6, C26, C35, CAP, RADIAL DISK, 10.5x14.5mm, 2200pF, 250V, 20%, X1Y2 C36 1 MANUFACTURER EPCOS, INC CAP-FILM, RADIAL, 18.1x7.5, 0.68µF, 450V, 5% CAP, SMD, 0603, 1000pF, 25V, 10%, X7R 1 C16 2 C7, C9 CAP, SMD, 0603, 0.1µF, 50V, 10%, X7R 1 C15 CAP, SMD, 0603, 0.15µF, 50V, 10%, X7R 1 C8 CAP, SMD, 0603, 0.22µF, 25V, 10%, X7R 1 C13 CAP, SMD, 0603, 47pF, 25V, 5%, NP0 1 C20 CAP, SMD, 0603, .047µF, 25V, 10%, X7R 1 C14 CAP, SMD, 0603, 0.47µF, 16V, 10%, X7R 1 C10 CAP, SMD, 0603, 6800pF, 25V, 5%, C0G 2 C19, C21 CAP, SMD, 1812, 0.1µF, 630V, 10%, X7R MURATA GRM43DR72J104KW01L 1 L2 COIL-TOROID INDUCTOR, TH, 1.5mH, 3.9A, 20AWG, 110T INTERSIL ENGINEERING 77552-A7-HT22-300W 1 C1 CAP, ALUM.ELEC, TH, 30x30mm, 270µF, 450V, 20%, 1.78A PANASONIC EET-UQ2W271DA 1 D1 DIODE, RECTIFIER, AXIAL, DO-201AD, 3A, 600V DIODES, INC. 1N5406 1 DZ1 DIODE-ZENER, SMD, SOD-323, 3.3V, 300mW NXP SEMICONDUCTOR BZX384-B3V3,115 1 D2 DIODE-RECTIFIER, SCHOTTKY, TH, TO-220-2, 600V, 4A CREE, INC C3D04060A 1 DB1 DIODE-BRIDGE RECTIFIER, TH, 4P, 600V, 8A DIODES, INC. GBU806 2 D7, D8 DIODE-RECTIFIER, SMD, 2P, SMA, 1000V, 1A, 1.4W FAIRCHILD S1M 2 L3, L4 COIL-FILTER CHOKE, TOROID, TH, 27.5x18.5, 2.2mH, 30%, 6A, 250V Wurth Electronics 744824622 1 F1 FUSE-FAST ACTING, CARTRIDGE, 5x20mm, 8A, 250V BEL FUSE INC. 5HF8-R 1 Q1 MOS, N-CHANNEL, TH, TO-220-3, 650V, 20.7A INFINEON TECHNOLOGY SPP20N60C3 1 R2 RES, SMD, 0603, 2.2Ω, 1/10W, 1%, TF 1 R17 RES, SMD, 0603, 0Ω, 1/10W, TF 1 R9 RES, SMD, 0603, 3k, 1/10W, 1%, TF 1 R14 RES, SMD, 0603, 30k, 1/10W, 1%, TF 2 R19, R25 RES, SMD, 0603, 42.2k, 1/10W, 1%, TF RES, TH, AXIAL, 0.22Ω, 1W, 5%, WW, 300ppm YAGEO KNP100JR-73-0R22 IC-PFC CONTROLLER, 14P, SOIC INTERSIL ISL6731AFBZ or ISL6731BFBZ CAP, SMD, 0603, 1µF, 50V, 10%, X5R 1 R26 RES, SMD, 0603, 49.9Ω, 1/10W, 1%, TF 1 R4 RES, SMD, 0603, 51k, 1/10W, 1%, TF 1 R13 RES, SMD, 0603, 5.76k, 1/10W, 1%, TF 1 R18 RES, SMD, 0603, 62k, 1/10W, 1%, TF 1 R22 2 R1, R3 RES, SMD, 0603, 69.8k, 1/10W, 1%, TF 4 R6, R10, R23, R24 RES, SMD, 1206, 3.3M, 1/4W, 1%, TF 2 R8, R11 RES, SMD, 1206, 470k, 1/4W, 1%, TF 3 R5, R27, R28 1 U1 RES, SMD, 1206, 2M, 1/4W, 1%, TF Submit Document Feedback 4 AN1884.0 March 20, 2014 Application Note 1884 PCB Layout FIGURE 5. TOP LAYER FIGURE 6. BOTTOM LAYER Submit Document Feedback 5 AN1884.0 March 20, 2014 Application Note 1884 Assembly Drawing FIGURE 7. ASSEMBLY ON TOP Submit Document Feedback 6 AN1884.0 March 20, 2014 Application Note 1884 Performance Curves and Typical Waveforms 230VAC-A-skip 99 230VAC-A 97 85VAC-A 95 EFFICIENCY (%) EFFICIENCY (%) 97 264VAC-A 264VAC-A-skip 99 93 85VAC-A - skip 91 95 115VAC-A 91 89 89 87 87 85 0 50 100 150 200 250 85 300 115VAC-A-skip 93 0 50 100 150 LOAD (W) FIGURE 8. EFFICIENCY vs LOAD (85V, 230V), ISL6731AEVAL1Z 230VAC-B-skip 99 200 250 300 LOAD (W) FIGURE 9. EFFICIENCY vs LOAD (115V, 264V), ISL6731AEVAL1Z 230VAC-B 264VAC-B-skip 99 97 264VAC-B 97 95 EFFICIENCY (%) EFFICIENCY (%) 85VAC-B 85VAC-B- skip 93 91 95 115VAC-B-skip 91 89 89 87 87 85 0 50 100 150 200 250 85 300 115VAC-B 93 0 50 100 150 LOAD (W) 200 250 300 LOAD (W) FIGURE 10. EFFICIENCY vs LOAD (85V, 230V), ISL6731BEVAL1Z FIGURE 11. EFFICIENCY vs LOAD (115V, 264V), ISL6731BEVAL1Z 1.0 35 115VAC-A 0.9 30 85VAC-A 0.8 264VAC-A 25 THD (%) PF 0.7 264VAC-A 0.6 230VAC-A 230VAC-A 20 15 115VAC-A 0.5 85VAC-A 10 0.4 5 0.3 0.2 0 50 100 150 200 250 LOAD (W) FIGURE 12. POWER FACTOR vs LOAD, ISL6731AEVAL1Z Submit Document Feedback 7 300 0 0 50 100 150 200 250 300 LOAD (W) FIGURE 13. THD vs LOAD, ISL6731AEVAL1Z AN1884.0 March 20, 2014 Application Note 1884 Performance Curves and Typical Waveforms 1.0 35 0.9 30 115VAC-B 0.8 85VAC-B 0.7 264VAC-B 25 THD (%) PF (Continued) 230VAC-B 0.6 264VAC-B 20 230VAC-B 15 0.5 115VAC-B 0.4 5 0.3 0.2 85VAC-B 10 0 50 100 150 200 250 0 300 0 50 100 LOAD (W) 150 200 250 300 LOAD (W) FIGURE 14. POWER FACTOR vs LOAD, ISL6731BEVAL1Z FIGURE 15. THD vs LOAD, ISL6731BEVAL1Z 1000 100V/DIV HARMONIC CURRENT (mA) 900 2.0A/DIV 800 700 600 500 400 300 MEASUREMENT 200 EN61000-3-2 A14 Class D 100 0 5.0ms/DIV FIGURE 16. WAVEFORMS OF LINE CURRENT AND VOLTAGE (115V/300W) 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 FIGURE 17. HARMONIC CURRENTS (115V/300W) 1000 1.0A/DIV 5.0ms/DIV FIGURE 18. WAVEFORMS OF LINE CURRENT AND VOLTAGE (230V/300W) Submit Document Feedback 8 HARMONIC CURRENT (mA) 100V/DIV 800 600 400 MEASUREMENT EN61000-3-2 A14 Class D 200 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 FIGURE 19. HARMONIC CURRENT OF LINE CURRENTS (230V/300W) AN1884.0 March 20, 2014 Application Note 1884 Performance Curves and Typical Waveforms (Continued) CH4: VDS CH2: IL CH3: VGS 5.0µs/DIV FIGURE 20. SWITCHING WAVEFORMS 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 Submit Document Feedback 9 AN1884.0 March 20, 2014