Author: Alan Yu ISL6730AEVAL1Z and ISL6730CEVAL1Z: Boost CCM PFC for 90W Universal Input Adaptors Introduction 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). Application 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. Design Specifications Input Voltage, V IN : 85V - 265V AC Output Voltage, V O : 390V DC Output Current, I O : 0.23A (90W) Switching Frequency: 124kHz Efficiency: Full Load, 94.5% @ 115V AC ; 96% @ 230V PF: Full Load, 0.999 @ 115V AC ; 0.997 @ 230V AC THD: Full Load, 2% @ 115V AC, 5% @ 230V AC Board Dimension: 155mm 80mm 38mm 3 (L W H) Figure 3 on page 2 shows the test setup. V LINE V I + V OUT ISEN ICOMP VIN ISL6730 GATE GND FB COMP BO VREG FIGURE 1. SIMPLIFIED SCHEMATIC 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.
FIGURE 2. TOP VIEW OF THE EVALUATION BOARD AC SOURCE L POWER ANALYZER A I IN ISL6730xEVAL1Z TP9 + IO P1 P2 + N V V LINE P4 UUT P3 - LOAD V V O TP10 - P6 + - P7 12V FIGURE 3. TEST SETUP Performance Curves and Typical Waveforms 100 100 95 95 EFFICIENCY (%) 90 85 80 75 ISL6730A, SKIP ISL6730C EFFICIENCY (%) 90 85 80 75 ISL6730C ISL6730A SKIP 70 70 65 65 60 0 20 40 60 80 100 LOAD (W) FIGURE 4. LOW LINE EFFICIENCY vs LOAD 60 0 20 40 60 80 100 LOAD (W) FIGURE 5. HIGH LINE EFFICIENCY vs LOAD 2 AN1830.0
Performance Curves and Typical Waveforms (Continued) 1.000 20 0.995 85V AC 115V AC 18 16 264V AC PF 0.990 0.985 0.980 230V AC 264V AC THD (%) 14 12 10 8 230V AC 0.975 0.970 0.965 0 10 20 30 40 50 60 70 80 90 100 P OUT (W) FIGURE 6. POWER FACTOR vs LINE VOLTAGE 6 4 115V AC 2 85V AC 0 0 10 20 30 40 50 60 70 80 90 100 P OUT (W) FIGURE 7. THD vs LINE VOLTAGE 120 I LINE V LINE 100 80 60 MEASUREMENT EN61000-3-2 CLASS D 40 CH2: LINE CURRENT CH4: LINE VOLTAGE FIGURE 8. WAVEFORMS OF LINE CURRENT AND VOLTAGE (115V/96W) 20 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/96W) 120 V LINE 100 I LINE 80 60 40 MEASUREMENT EN61000-3-2 CLASS D CH2: LINE CURRENT CH4: LINE VOLTAGE FIGURE 10. WAVEFORMS OF LINE CURRENT AND VOLTAGE (230V/96W) 20 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/96W) 3 AN1830.0
Performance Curves and Typical Waveforms (Continued) CH2: I L CH4: V DS CH3: V GS FIGURE 12. SWITCHING WAVEFORMS 4 AN1830.0
Schematic 5 AN1830.0 P1 AC1 F1 3.15A UNIVERSAL INPUT 85~265Vac P4 P5 AC2 PE 100n C2 1 2 4 3 C5 470p 7.5mH L3 R1 2M R3 2M C6 470p D7 S1M C12 D3 D5 D8 S1M R8 4.3M D4 D6 R11 4.3M VIN TP3 R13 64.9K C3 330n R9 2.1k ISEN TP5 C13 220p P8 P9 L1 0u R20 10k C11 470p ICOMP TP6 R21 25k 1 C4 C17 1n 0.22 R5 R14 5.36k 3 2 8 L2 2.2m 5 2N7002 Q2 FIGURE 13. SCHEMATIC OF EVALUATION BOARD VIN C14 470n D1 C9 1u C8 220n 9 R18 68K C18 2.2u 6 IPP60R600C6 Q1 1 R2 2.2 C15 100n DZ1 3.3V TP2 COMP R4 51K 3 2 C24 47n C10 U1 6.8n VREF Lin.Reg. GATE 10 3 ICOMP UVLO LOGIC I MIRROR CEQ OTP GND 1 2 ISEN 2:1 Gen I* PWM I*= Vin*C 4*BO*BO gm 4 2.5V VIN C SKIP OPL FB 7 + gm - SKIP BO COMP ISL6730 TP4 2 3 1 D2 C3D04060E TP7 GATE 3.3M R6 C16 1n R10 3.3M R17 1.5k R19 40K DC+ FB TP1 1 2 C1 56u 450V C26 GND VOUT TP9 P2 390V P3 TP10 GND P6 P7 Application Note 1830
TABLE 1. BILL OF MATERIALS QTY REFERENCE DESIGNATOR TYPE/PACKAGE VALUE VOL/TOL/MAT MANUFACTURER MFR. PART # 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 ECQ-E2W474KH Film 2 C5, C6 CAP; TH; Radial 470p Y1; 10%; EMI, Y1-class Murata DE1B3KX471KA5B 1 C8 CAP; SM; 0603 220n 25V; 20%; X7R TDK 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 BZX384-B3V3 5 D1, D3, D4, D5, D6 Diode; SM; SMB 800V; 3A; Standard Recovery Micro Commercial Co 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 1 L3 Txfmr; TH 7.5mH Common Chock CoilCraft CMT1-7.5-2 6 P1, P2, P3, P4, P6, P7 TP; TH - - KEYSTONE 1514-2 1 Q1 MOSFET; TH; TO-220F IPP60R600C6 600V; ; N-Chan Infineon IPP60R600C6 2 R1, R3 Res; SM; 1206 2M 5%; Thick Film 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 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 1 R19 Res; SM; 0603 40K 1%; Thick Film Yageo 9 TP1, TP2, TP3, TP4, TP5, Pole; TH - - KEYSTONE 5007 TP6, TP7, TP9, TP10 1 U1 SM; MSOP10 ISL6730 - Intersil ISL6730AFUZ or ISL6730CFUZ 0 C4, C12, C16 0 R20, R21, P5, P8, P9, C17, Q2 0 C19~23, D9~13, Q3, R22~25, TP8, TP11 6 AN1830.0
PCB Layout FIGURE 14. TOP LAYER FIGURE 15. BOTTOM LAYER 7 AN1830.0
Assembly Drawing ISL6730AEVAL1Z GND 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