IntersilA Power Management CompanyInnovative PFC Control Solutions

Staff Applications Engineer

October 24, 2014Power Technology Innovation Application ForumShenzhen, China

Alan Yu

• Intersil Overview

• Intersil’s Innovative Power Factor Correction (PFC) Controllers

• Advantages of PFC Control Solutions

• Intersil Support, Design Tools and Evaluation Boards

Agenda

2

Intersil’s Core Capabilities and Technologies

Intelligent Power

Management

Multi-phase

Modulation

Radiation

Hardened & High

Reliability

Process and

Packaging

Precision

Analog

High Performance AnalogLight and motion sensingLaser driversVideo

Power ConversionVcore power management

Buck Boost/RegulationDigital Power

Best-in Class Rad HardIn-house ELDRS radiation

testing facilityMIL-PRF-38535 compliant

and 100% burned in

Innovative ProcessProprietary process technologyMulti-source, high reliability

3

Four Product Groups Addressing Key Markets

Wired/Wireless InfrastructureServers and Storage

Industrial

Industrial & Infrastructure

SecurityMotion and Light Sensing

Specialty Analog

Specialty Products

Automotive RadHard Aerospace

High Precision Analog

Precision Products

Computing PCConsumer HandheldConsumer Display

Mobile Power

4

PFC Controller Family: ISL6730A/B/C/D & ISL6731A/B • Patented Negative

Capacitance Technology- Better THD performance- Better PF performance- Smaller EMI filter components - Support high freq operation

• Switching Freq Jittering - 75%-100% by VIN pin voltage- Better conduction EMI Performance

• Intelligent Burst mode

- User adjustable pulse skipping level

PN Fosc Skip Mode Package StatusISL6730A 124kHz Yes-Fixed MSOP-10 ReleasedISL6730B 62kHz Yes-Fixed MSOP-10 ReleasedISL6730C 124kHz No MSOP-10 ReleasedISL6730D 62kHz No MSOP-10 ReleasedISL6731A 124kHz Yes-Programmable SOIC-14 ReleasedISL6731B 62kHz Yes-Programmable SOIC-14 Released

• Flexible packaging- 62K & 124K FSW option- 10 pin MSOP or 14 pin SOIC package

• Robust Design - CCM mode operation

• Extensive Protection- Input rail brownout protection- Adjustable OVP

• Better control over board response

- Dual protection from over current

• Cycle by Cycle Current Limit

• Input power limit

5

Key Feature #1: Negative Capacitance Provides Low THD, High PF and Smaller Size Solution

Over load and line conditions:

Small phase shift High PF Low THD

Intersil’s PFC Controller Performance Outperforms the Digital

Controlled PFC

Without Requiring a MCU/DSP (and Firmware)

Superior Performance! and Low Cost!

Preferred application choice with very tight THD/PF spec

Time

18ms 20ms 22ms 24ms 26ms1 -I(V2) 2 V(VLINE,D6:2)

-1.0A

0A

1.0A1

-400V

0V

400V2

>>

Time

18ms 20ms 22ms 24ms 26ms1 -I(V2) 2 V(VLINE,D6:2)

-1.0A

0A

1.0A1

>>-400V

0V

400V2

VIN

Iin

PH Shift6

Negative Capacitance Enables Smaller Size (Cont’d)• Allows Smaller X-Cap size while meeting or improving THD/PF

performance

• Allows shift of EMI filter after bridge rectifier

Eliminating the need for safety-grade parts

Reducing EMI filter cost and size

• Reduced system cost & size while meeting or improving THD

and PF performance

EMI Filter Moves After RectifierSTANDARD EMI Filter

C1 +C2+C3 = 1.04uF

C1 +C2+C3 - CEQ = 1.41uF - 1.09uF= 0.32uF Conventional Control

Negative Cap Control

7

PFC

Problem with a Conventional PFC Solution

PFC EVAL BOARD: P = 300W,ONE CYCLE CONTROL

EMIC1, C2 Noise SuppressionL3, Differential Noise SuppressionL2, Common Mode Noise Suppression

L1

HEATSINK

L3

L2Im

Re

iC

ia

iin

va

q

Input voltage and current phasor diagram.

+va

ic1 iaic2

ic3

ic= ic1 + ic2 + ic3

iin

C1,2,3 prefer bigger size.

But limited by power factor requirement.

L3 is sized to meet the differential mode noise

attenuation.8

Bulky EMI Filter

Intersil Solution: Create an Equivalent Negative Capacitor to Cancel Effect of the Input Capacitors

C I N

eqR

iinC E 2X2

C E 1X2

L 1C H O K E

13

25

L 2

L 3

iC ia

ip

C I N

eqC

icn

+

va

Im

Re

iC

iava

iinqicn

ipip = ia + icn

CONVENTIONAL CURRENT CONTROL

Time

18ms 20ms 22ms 24ms 26ms1 -I(V2) 2 V(VLINE,D6:2)

-1.0A

0A

1.0A1

-400V

0V

400V2

>>

VLINE

IL + ICIN

Time

18ms 20ms 22ms 24ms 26ms1 -I(V2) 2 V(VLINE,D6:2)

-1.0A

0A

1.0A1

>>-400V

0V

400V2

Current Control with CEQ

VLINE

IL + ICIN

iin = ip + ic

9

FB

COMP

GATE

Vref

VIN

ISEN

GND

BO

ICOMP

Q 1 C OUT

VOUTL

R CS

C F1VLINE C F3

EMI CHOKE

RFB2

L m

CBO

D

COMPB

D F1D F2

V I

Gmv

C F2

RSEN

RIN2

RIN1

RFB1

SKIP

20uA

SKIP CLAMP

COMP-1V

RSKIP

Key Feature #2: ISL6731A/B’s Auto Skipping Provides High Efficiency @ Light Load

Programmable Skip Threshold (ISL6731A/B)

0.0 20.0 40.0 60.0 80.0 100.060.0065.0070.0075.0080.0085.0090.0095.00

100.00Efficiency vs Load

Skip Disabled Skip Enabled

LOAD (%)EFFIC

IEN

CY (

%)

10

FB

COMP

GATECONTROL

LOGIC

Vref

GND

Q 1 C OUT

VOUTL

R CS

C F1VLINE C F3

EMI CHOKE

RFB2

L m

D

D F1

V I

Gmv

C F2

RFB1

OVP

Vro2

Vro1

ROV2

ROV1

Key Feature #3: Dedicate OVP Pin Provides Flexible, High Reliability Required for Industrial Applications

Dedicate OVP pin

(ISL6731A/B)

11

FB

COMP

GATE

VCC

CONTROLLOGIC

Vref

VIN

ISEN

OSCILLATOR

PWM COMP

GND

OTP

VCC

BO

IFB

R IS

ICOMP

IREF

CEQ GEN

CURRENTMIRROR

OVER POWER LIMIT

SOFT-STARTENABLE

SKIP

20uA

SKIP CLAMP

SKIP

2: 1

Q 1 C OUT

VOUTL

COMP-1V

R CS

C F1VLINE C F3

EMI CHOKE

UVLO

RFB2

L m

CBO

D

I CS

COMPB

D F1D F2

CREG

LINEAR REGULATOR

VREG

V I

Gmi

Gmv

C F2

RSEN

RIN2

RIN1 RFB1

ICS > 0.5*|IOC |

Vcs=0.5*Ris*Isen

VIN*COMPB4*BO2

OVP

Vro2

Only for ISL6731

Vro1

ROV2

ROV1

Key Feature #4: Frequency Modulation Provides Low EMI

75

80

85

90

95

100

105Fosc vs Vin

VIN (V)Fsw

NO

RM

ALIZ

ED

(%

)

Frequency Modulation: reduces EMI filter size

12

FB

COMP

Vref

C OUT

VOUT

RFB2

D

Gmv

RFB1IFB

Key Feature #5: Open Loop Protection Increases Reliability

When the FB pin is below 10%, the device is put into shutdown mode. There is an internal pull-down current source for open loop protection to avoid run-away.

13

ISL673x: True Competitive Board Evaluation @ 300W

0.0 25.0 50.0 75.0 100.00

5

10

15

20

25

30

35

40

Ideg vs. Load 230Vac_UCC28019230Vac_ISL6730D230Vac_NCP1653A230Vac_ICE2PCS02

Load (%)

Deg

Intersil stands outIntersil & Competition tested under same circuit/condition

0.0 20.0 40.0 60.0 80.0 100.00.00

5.00

10.00

15.00

20.00 THD vs. Load230Vac_UCC28019230Vac_ISL6730D230Vac_NCP1653A230Vac_ICE2PCS02

Load (%)

TH

D (

%)

0.0 25.0 50.0 75.0 100.00.700000000000001

0.800000000000001

0.900000000000001

1 PF vs. Load

230Vac_UCC28019230Vac_ISL6730D230Vac_NCP1653A230Vac_ICE2PCS02

Load (%)

PF

14

Comp. A

Comp. BComp. C

Comp. A

Comp. BComp. CComp.

A

Comp. BComp. C

ISL673x : Industry’s Best Performance @ 750W

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.088.0

90.0

92.0

94.0

96.0

98.0Efficiency vs. Load

230Vac-A 230Vac-B

115Vac-A 115Vac-B

Load (%)

Eff

(%

)

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.00.850000000000011

0.900000000000011

0.950000000000011

PF vs. Load

115Vac-A 115Vac-B

230Vac-A 230Vac-B

Spec

Load (%)

PF

0 10 20 30 40 50 60 70 80 90 1000

2

4

6

8

10

12

14 THD vs. Load

Spec 115/230V 115Vac-B

115Vac-A

Load (%)

TH

D (

%)

0 10 20 30 40 50 60 70 80 90 1000

1

2

3

4

5

6

7

8

9

10 THD vs. Load

Spec 115/230V Spec 230V

230Vac-B 230Vac-A

Load (%)

TH

D (

%)

15

Major Customer Spec

Intersil PFC (AC/DC) + ZVS (DC/DC) at 750W

DC/DC ISL6754 AFB

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.00.850000000000001

0.900000000000001

0.950000000000001

1PF vs. Load

115Vac-B

230Vac-B

Spec

Load (%)

PF

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.00.00

4.00

8.00

12.00

16.00

20.00

24.00

28.00 THD vs. Load

115Vac-B

230Vac-B

Load (%)

TH

D (

%)

AC/DC ISL6731 PFC

16

Major Customer Spec

Specs: • VIN=90V -

265VAC 

• VO=390VDC

• 124×80×37 mm3

300W 64kHz ISL6730BEVAL1Z ISL6730DEVAL1Z

85W ISL6730AEVAL1Z ISL6730CEVAL1Z

Specs:• VIN=85V - 265VAC

• VO=390VDC

•Fosc=124kHz• 124x80x38 mm3

ISL6730BISL6730D

ISL6730AISL6730C

14

11

12

13

8

10

9

1

4

3

2

7

5

6

300W ISL6731AEVAL1Z (124kHz) ISL6731BEVAL1Z (64kHz)

ISL6731AISL6731B

Specs:• VIN=90V - 265VAC

• VO=390VDC

• 121x96x38 mm3

750W ISL6731AEVAL2Z (124kHz) ISL6731BEVAL2Z (64kHz)

17

Intersil Provides Full Evaluation Board Support

• Best-in-Class PFC Controllers Outperform Digital Control

• Easy-to-Use PFC Solution with No Software Programming Required

• Highly Integrated with Full Feature-Set Provides a Low Cost Solution to Challenging Power System Designs

• Excellent Engineering Support with Design Tools and Evaluation Boards

Intersil Delivers Innovative PFC Control Solutions

18

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