Application Note 1830 Author: Alan Yu ISL6730AEVAL1Z and ISL6730CEVAL1Z: Boost CCM PFC for 90W Universal Input Adaptors Introduction Design Specifications This application note describes the design and implementation of a 390V, 90W, Continuous Conduction Mode (CCM) Boost PFC converter using the ISL6730A, ISL6730C. The converter exhibits high power factor, Low THD and high conversion efficiency. The ISL6730A, ISL6730C are voltage mode power factor correction (PFC) controllers designed to drive cost-effective converters to meet input line harmonic regulations. The IC can be ISL6730A (Fixed Skip threshold) or ISL6730C (non-Skip). A detailed design procedure can be found in the datasheet (FN8258). • Input Voltage, VIN: 85V - 265VAC Application • Output Voltage, VO: 390VDC • Output Current, IO: 0.23A (90W) • Switching Frequency: 124kHz • Efficiency: Full Load, 94.5% @ 115VAC ; 96% @ 230V • PF: Full Load, 0.999 @ 115VAC ; 0.997 @ 230VAC • THD: Full Load, 2% @ 115VAC , 5% @ 230VAC • Board Dimension: 155mm×80mm×38mm3(L×W×H) 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. Figure 3 on page 2 shows the test setup. VI + VLINE VOUT VCC ISEN GATE ICOMP GND ISL6730 VIN FB COMP BO VREG FIGURE 1. SIMPLIFIED SCHEMATIC April 5, 2013 AN1830.0 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 1830 FIGURE 2. TOP VIEW OF THE EVALUATION BOARD POWER ANALYZER AC SOURCE L ISL6730xEVAL1Z IIN TP9 A IO P2 P1 V + + UUT VLINE LOAD P4 P3 N TP10 - V VO - - P7 P6 + 12V FIGURE 3. TEST SETUP 100 100 95 95 90 90 85 EFFICIENCY (%) EFFICIENCY (%) Performance Curves and Typical Waveforms ISL6730A, SKIP 80 ISL6730C 75 80 75 70 70 65 65 60 0 20 40 60 LOAD (W) 80 FIGURE 4. LOW LINE EFFICIENCY vs LOAD 2 100 ISL6730A SKIP ISL6730C 85 60 0 20 40 60 LOAD (W) 80 100 FIGURE 5. HIGH LINE EFFICIENCY vs LOAD AN1830.0 April 5, 2013 Application Note 1830 Performance Curves and Typical Waveforms 1.000 (Continued) 20 85VAC 0.995 18 115VAC 16 0.990 264VAC THD (%) 230VAC 264VAC 14 PF 0.985 0.980 12 230VAC 10 8 6 0.975 115VAC 4 0.970 2 0.965 0 10 20 30 40 50 60 70 80 90 100 0 85VAC 0 10 20 POUT (W) 30 40 50 60 70 80 90 100 POUT (W) FIGURE 6. POWER FACTOR vs LINE VOLTAGE FIGURE 7. THD vs LINE VOLTAGE 120 100 ILINE 80 MEASUREMENT VLINE EN61000-3-2 CLASS D 60 40 CH2: LINE CURRENT CH4: LINE VOLTAGE 20 0 1 3 FIGURE 8. WAVEFORMS OF LINE CURRENT AND VOLTAGE (115V/96W) 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 FIGURE 9. HARMONIC CURRENTS (115V/96W) 120 VLINE 100 ILINE 80 60 MEASUREMENT EN61000-3-2 CLASS D 40 CH2: LINE CURRENT CH4: LINE VOLTAGE 20 0 1 3 FIGURE 10. WAVEFORMS OF LINE CURRENT AND VOLTAGE (230V/96W) 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/96W) AN1830.0 April 5, 2013 Application Note 1830 Performance Curves and Typical Waveforms (Continued) CH4: VDS CH2: IL CH3: VGS FIGURE 12. SWITCHING WAVEFORMS 4 AN1830.0 April 5, 2013 Schematic F1 3.15A 1 2 C1 56u 450V D6 C6 470p R4 51K 0.22 R5 C8 C26 DNP DNP 3.3M R6 R9 2.1k DNP C11 R8 4.3M 470p C10 6.8n R11 4.3M 3 TP6 ISEN ICOMP I* gm DNP P8 DNP R20 10k 2 R21 25k DNP 1 C17 1n DNP GND 1 CEQ OTP Gen PWM BO 2N7002 Q2 DNP DNP P9 AN1830.0 April 5, 2013 FIGURE 13. SCHEMATIC OF EVALUATION BOARD gm COMP ISL6730 TP4 TP2 VIN COMP R18 68K C15 C14 470n C18 100n 2.2u P6 TP7 GND GATE R10 FB SKIP 5 VCC VCC GATE 10 3.3M 2.5V 3 220p U1 C SKIP OPL + - C13 VCC UVLO LOGIC 4 VIN TP3 1u VREF Lin.Reg. VCC Vin*C I*= 4*BO*BO VIN R13 64.9K C24 47n 2 ISENI MIRROR 2:1 TP5 GND C9 R14 5.36k ICOMP C12 DNP DZ1 3.3V 220n D8 S1M P3 TP10 S3KB-TP S3KB-TP D7 S1M 3 D5 390V 2 R2 2.2 R3 2M 6 4 C4 DNP C3 330n AC2 PE IPP60R600C6 Q1 1 7 TP1 C16 1n R17 1.5k R19 40K FB P7 Application Note 1830 P5 TP9 P2 7.5mH L3 C5 470p DC+ C3D04060E 9 P4 VOUT 1 D2 L2 2.2m 8 100n C2 1 5 UNIVERSAL INPUT 85~265Vac 3 R1 2M 3 2 P1 L1 0u D4 D3 AC1 2 S3KB-TP D1 S3KB-TP S3KB-TP Application Note 1830 TABLE 1. BILL OF MATERIALS QTY REFERENCE DESIGNATOR 1 C1 CAP; TH 56u 450V; 20%; ELECT, Aluminum Nichion UPTW6560MHD 1 C2 CAP; TH; Radial 100n X2; 20%; EMI, X2-class EPCOS B32922C3104M 1 C3 CAP; TH; Radial 330n 450V; 10%; Metallized Polyester Panasonic-ECG Film ECQ-E2W474KH 2 C5, C6 CAP; TH; Radial 470p Y1; 10%; EMI, Y1-class Murata DE1B3KX471KA5B 1 C8 CAP; SM; 0603 220n 25V; 20%; X7R TDK TYPE/PACKAGE VALUE VOL/TOL/MAT MANUFACTURER MFR. PART # 1 C9 Cap; SM; 0603 1u 50V; 20%; X7R TDK 1 C10 CAP; SM; 0603 6.8n 25V; 10%; X7R TDK 1 C11 CAP; SM; 0603 470p 25V; 10%; X7R TDK 1 C13 CAP; SM; 0603 220p 16V; 5%; NPO TDK 1 C14 CAP; SM; 0603 470n 16V; 10%; X7R TDK 1 C15 CAP; SM; 0603 100n 50V; 10%; X7R TDK 1 C16 CAP; SM; 0603 1n 50V; 10%; X7R TDK 1 C18 CAP; SM; 0603 2.2u 16V; 10%; X7R TDK 1 C24 CAP; SM; 0603 47n 25V; 10%; X7R TDK 1 DZ1 Zener; SM; SOD323 3.3V 5%; Zener NXP 5 D1, D3, D4, D5, D6 Diode; SM; SMB S3KB-TP 800V; 3A; Standard Recovery Micro Commercial Co S3KB-TP 1 D2 Diode; SM; DPAK C3D04060E 600V; 3A; SiC Schottky Cree C3D04060E 2 D7, D8 Diode; SM; SMA S1M 1kV; 1A; Standard Recovery Diodes Inc S1M-13-F 1 F1 Fuse; TH; TE5 3.15A 250V; Littelfuse 39213150000 1 L1 Ind; TH 0u bar wire 1 L2 Ind; TH 2.2m Inductor CoilCraft CT8494-AL Txfmr; TH 7.5mH Common Chock CoilCraft CMT1-7.5-2 TP; TH - - KEYSTONE 1514-2 1 L3 6 P1, P2, P3, P4, P6, P7 BZX384-B3V3 1 Q1 MOSFET; TH; TO-220F IPP60R600C6 600V; ; N-Chan Infineon IPP60R600C6 2 R1, R3 Res; SM; 1206 2M Panasonic-ECG ERJ-8GEYJ205 1 R2 Res; SM; 0603 2.2 1%; Thick Film Yageo 1 R4 Res; SM; 0603 51K 1%; Thick Film Yageo 5%; Thick Film 1 R5 Res; TH; Axial 0.22 1W; 1%; Wire Wounded Yageo KNP100JR-73-0R33 2 R6, R10 Res; SM; 1206 3.3M 1%; Thick Film Yageo RC1206FR-073M3L 2 R8, R11 Res; SM; 1206 4.3M 1%; Thick Film Yageo RC1206FR-074M3L 1 R9 Res; SM; 0603 2.1k 1%; Thick Film Yageo 1 R13 Res; SM; 0603 64.9K 1%; Thick Film Yageo 1 R14 Res; SM; 0603 5.36k 1%; Thick Film Yageo 1 R17 Res; SM; 0603 1.5k 1%; Thick Film Yageo 1 R18 Res; SM; 0603 68K 1%; Thick Film Yageo R19 Res; SM; 0603 1 9 TP1, TP2, TP3, TP4, TP5, Pole; TH TP6, TP7, TP9, TP10 SM; MSOP10 40K 1%; Thick Film Yageo - - KEYSTONE 5007 ISL6730 - Intersil ISL6730AFUZ or ISL6730CFUZ 1 U1 0 C4, C12, C16 DNP 0 R20, R21, P5, P8, P9, C17, Q2 DNP 0 C19~23, D9~13, Q3, R22~25, TP8, TP11 DNP 6 AN1830.0 April 5, 2013 Application Note 1830 PCB Layout FIGURE 14. TOP LAYER FIGURE 15. BOTTOM LAYER 7 AN1830.0 April 5, 2013 Application Note 1830 Assembly Drawing ISL6730AEVAL1Z GND VCC P7 P6 FIGURE 16. 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 8 AN1830.0 April 5, 2013