EVL4984-350W

EVL4984-350W 350 W CCM PFC pre-regulator demonstration board based on the L4984D Data brief Description The EVL4984-350W demonstration board, based on the new L4984D continuous conduction mode PFC controller, implements a 350 W wide-range input PFC pre-conditioner. It is suitable for all SMPS from 150 W to several kWs, and is compliant with IEC61000-3-2 and JEITA-MITI standards. Features • Line voltage range: 90 to 265 Vac • Minimum line frequency (fL): 47 Hz • Regulated output voltage: 400 V • Rated output power: 350 W • Maximum 2 fL output voltage ripple: 12.5 V (peak-to-peak) • Hold-up time: 20 ms (VDROP after hold-up time: 300 V) • Switching frequency: 70 kHz • Minimum efficiency: 94% (at Vin = 90 Vac, Pout = 350 W) • PCB: single-side, 70 um, CEM-1, 112 x 114 mm May 2013 DocID023720 Rev 2 For further information contact your local STMicroelectronics sales office. 1/10 www.st.com 10 General information and electrical schematics 1 EVL4984-350W General information and electrical schematics The main purpose of a PFC pre-conditioner is to correct input current distortion in order to decrease the harmonic contents below the limits of the relevant regulations. Therefore, this demonstration board has been tested in accordance with the European standard EN610003-2 Class-D and Japanese standard JEITA-MITI Class-D at full load and at both the nominal input voltage mains. The power stage of the PFC is a traditional boost PFC converter, connected to the output of the rectifier bridge D2. It is made up of the boost inductor L3, the power switch consisting of the parallel of MOSFETs Q1 and Q2, diode D3, and the output capacitors C3 and C4. The 300 V varistor RV1, connected between the line and neutral, protects the circuit against high input voltage transients, while the F1 fuse disconnects the mains in case of shortcircuit. To meet EMC standards, the board is equipped with an input EMI filter, cutting the switching noise coming from the boost stage. In particular, L2 filters common mode emissions while L1, C1, and C2 reduce differential mode emissions. The L4984D must be supplied by an external power supply, connected between pin #1 (VCC) and pin #2 (GND) of J3. The capacitor C14, connected to the TIMER (#7) pin, determines the switching frequency. The resistor divider R12, R16, R22 and R24 provides the information regarding the instantaneous mains voltage to the L4984D multiplier (MULT, #3), which is used to modulate the peak current of the boost and the TOFF duration, and is fed to the VFF block. The resistors R6, R8, R13 with R17 and R18 are dedicated to sensing the output voltage and feeding, to the inverting input of the error amplifier (INV, #1), the feedback information necessary to keep the output voltage regulated. Between the INV (#1) and COMP (#2) pins, components C8, R21 and C11 form the error amplifier compensation network to maintain the required loop stability. The inductor peak current is sensed by resistors R27, R30, and R31 placed in series with the MOSFET source and the derived signal is fed into the current sense pin (CS, #4) of the L4984D via the filter by R29 and C13. C15 and R28, connected to the VFF pin (#5), complete an internal peak-holding circuit providing information on the RMS mains voltage, deriving a DC voltage equal to the peak of the MULT (#3) voltage, which is fed to the multiplier to compensate the control loop gain dependence on the mains voltage. The brownout function is also implemented by this pin. A voltage below 0.8 V on the VFF pin (#5) shuts down (no latch) the IC and brings its consumption to a considerably lower level. The L4984D starts as the voltage at the pin rises above 0.88 V. The divider R5, R10, R14 and R23 provides the information regarding the output voltage level to the L4984D PFC_OK pin (#7), to implement the so-called dynamic OVP protection, preventing the output voltage from excessive values during the load transients due to the slow response caused by the intrinsic narrow bandwidth of PFC systems. If the voltage on the PFC_OK pin (#7) exceeds 2.5 V, the L4984D stops switching, and restarts as the voltage on the pin falls below 2.4 V. The open loop protection (also called feedback failure protection) is realized by monitoring the PFC_OK (#7) and INV (#1) pins. If the voltage on the PFC_OK pin (#7) exceeds 2.5 V, and at the same time the voltage on the INV pin (#1) falls below 1.66 V, a feedback failure is assumed and the device is latched off. Normal operation can be resumed only by cycling 2/10 DocID023720 Rev 2 EVL4984-350W General information and electrical schematics Vcc (#10), bringing its value lower than the VCCrestart (6 V, typ), before moving up to the turn-on threshold VCCon (12 V, typ). Additionally, a remote on/off control input is present. If the voltage on the PFC_OK pin (#7) is tied below the PFC_OK disable threshold (VPFC_OK_D, 0.23 V typ.), the L4984D is shut down and the operation is restarted when the voltage on the PFC_OK pin (#7) increases above the PFC_OK enable threshold (VPFC_OK_E, 0.27 V typ.). L4984D operation can also be disabled or enabled to properly manage light load or failure by the D2D via the PFC_OK pin (#7), using pin #3 of J3 (ON/OFF). DocID023720 Rev 2 3/10 2 1 R14 3M3 R22 4M7 C12 2N2 R10 3M3 R16 3M9 R23 56K R5 3M3 C13 330pF C8 68N F1 FUSE T6.3A R12 3M9 R24 100K 90-264Vac J1 RV1 300Vac C15 1uF C11 680N R21 100K VFF CS MULT U1 L4984D COMP INV R17 56K JPX2 R4 750K C5 470N-X2 R28 1M0 5 4 3 2 1 R13 2M2 R8 2M2 R6 2M2 R3 750K R1 750K PFC-OK TIMER GND GD 6 7 8 9 10 C16 2N2 1 4 VCC R18 160K 3 C6 1uF-X2 2 3 L2 3mH - 7A 2 JPX3 C9 470N C14 680pF PCB REV. 1 Z1 4 C10 100uF-35V HS1 HEAT-SINK _ ~ 1 3/7 C1 220nF-520V R29 1K0 C2 1uF-520V D7 LL4148 D6 LL4148 R33 100R R32 10R JPX4 R26 3R9 R25 6R8 R20 3R9 R19 6R8 11 9 L3 700uH 5 2 R27 0R33 GND ON/OFF 3 VCC 2 1 R31 0R33 1 C17 470nF-520V J3 22-27-2031 R30 0R33 1 Q2 STF21N65M5 JPX5 L4 2743005112 D3 STTH8S06FP 2 L1 70uH - 7A C4 100uF - 450V HS2 HEAT-SINK Q1 STF21N65M5 C3 100uF - 450V R2 NTC 1R0-S237 2 D2 D15XB60H ~ DocID023720 Rev 2 3 + 4/10 3 D1 1N5406 JPX1 1 2 3 4 5 J2 +400Vdc +400Vdc NC RTN RTN +400Vout General information and electrical schematics EVL4984-350W Figure 1. EVL4984-350W CCM PFC demonstration board electrical schematic AM13391v1 EVL4984-350W Test results and significant waveforms 2 Test results and significant waveforms 2.1 Harmonic content measurement As shown in the illustrations that follow, the circuit can reduce the harmonics well below the limits of the previously-mentioned standards, from full load down to light load. An output power of 70 W was chosen because it is near the lowest power limit at which the harmonics must be limited according to these standards. Figure 2. EVL4984-350W: compliance with EN61000-3-2 standard at full load Vin = 230 Vac - 50 Hz Pout = 350 W THD = 16.7 %, PF = 0.976 AM13392v1 Figure 4. EVL4984-350W: compliance with EN61000-3-2 standard at 70 W load Vin = 230 Vac - 50 Hz Pout = 70 W THD = 17.5 %, PF = 0.814 AM13394v1 Figure 3. EVL4984-350W: compliance with JEITA-MITI standard at full load Vin = 100 Vac - 50 Hz Pout = 350 W THD = 4.13 %, PF = 0.999 AM13393v1 Figure 5. EVL4984-350W: compliance with JEITA-MITI standard at 70 W load Vin = 100 Vac - 50 Hz Pout = 70 W THD = 9.9 %, PF = 0.989 DocID023720 Rev 2 AM13395v1 5/10 Bill of material 3 EVL4984-350W Bill of material Table 1. EVL4984-350W CCM PFC demonstration board bill of material Part type/ Case style/ part value package C1 220 nF-520 V 7.5X26.5 mm 520 V-FLM CAP - B32673T5224 EPCOS C2 1 uF-520 V 10.5X26.5 mm 520 V-FLM CAP - B32673Z5105 EPCOS C3 100 uF-450 V Dia. 18X40 mm 450 V - aluminum ELCAP-KXG series-105 °C NipponChemicon C4 100 uF-450 V Dia. 18X40 mm 450 V - aluminum ELCAP-KXG series-105 °C NipponChemicon C5 470N-X2 10.5X26.5 mm X2-FLM CAP - B32923A3474M EPCOS C6 1 uF-X2 11X26.5 mm X2-FLM CAP - B32923C3105 EPCOS C8 68N 0805 100 V CERCAP - general purpose - X7R - 10% AVX C9 470N 1206 100 V CERCAP - general purpose - X7R - 10% KEMET C10 100 uF-35 V Dia. 8X11 mm 50 V - aluminum ELCAP-YXF series - 105 °C Rubycon C11 680N 0805 25 V CERCAP - general purpose - X7R - 10% KEMET C12 10N 0805 50 V CERCAP - general purpose - X7R - 10% KEMET C13 330 pF 0805 50 V CERCAP - general purpose - COG - 5% EPCOS C14 680 pF 0805 50 V CERCAP - general purpose - COG - 5% EPCOS C15 1 uF 1206 50 V CERCAP - general purpose - X7R - 10% TDK C16 2N2 0805 50 V CERCAP - general purpose - X7R - 10% KEMET C17 470 nF-520 V 7X26.5 mm 520 V - FLM CAP - B32673Z5474K*** EPCOS D1 1N5406 DO-201 Rectifier - general purpose Vishay D2 D15XB60H DWG SIngle-phase bridge rectifier Shindengen D3 STTH8S06FP TO-220 Ultrafast high voltage rectifier ST D6 LL4148 Mini-melf High speed signal diode Vishay D7 LL4148 Mini-melf High speed signal diode Vishay F1 FUSE T6.3A 4x8.5 mm pitch 5.08 Sub-miniature fuse 392/TE5 - time delay 6.3 A mm Littelfuse HS1 Heatsink DWG Heatsink for D2 Meccal HS2 Heatsink DWG Heatsink for Q1, Q2 & D3 Meccal J1 09-65-2038 DWG KK PCB Conn. - straight - pitch 3.96 mm - 3 pins (centrally removed) Molex J2 10-16-1051 DWG KK PCB Conn. - straight - pitch 5.08 mm - 5 pins (centrally removed) Molex J3 22-27-2031 DWG KK PCB Conn. - straight, pitch 2.54 mm - 3 pins Molex JPX1 Shorted WIRE Wire jumper Des. 6/10 Description DocID023720 Rev 2 Supplier - EVL4984-350W Bill of material Table 1. EVL4984-350W CCM PFC demonstration board bill of material (continued) Part type/ Case style/ part value package JPX2 Shorted WIRE Wire jumper - JPX3 Shorted WIRE Wire jumper - JPX4 Shorted WIRE Wire jumper - JPX5 Shorted WIRE Wire jumper - L1 70 uH - 7 A DWG DM inductor - 1119.0013 Magnetica L2 3 mH - 7 A DWG EMI filter - 1606.0007 Magnetica L3 700 uH DWG PFC inductor - 2097.0002 Magnetica L4 2743005112 DWG Ferrite bead dia. 3.5x6 mm vertical Q1 STF21N65M5 TO-220FP N-channel power MOSFET ST Q2 STF21N65M5 TO-220FP N-channel power MOSFETpower MOSFET ST R1 750 K 1206 Des. R2 Description SMD standard film res. - 1/4 W - 5% - 250 ppm/°C NTC 1R0-S237 Dia. 15x7 p. 7.5 mm NTC resistor P/N B57237S0109M000 Supplier Fair-Rite Vishay EPCOS R3 750 K 1206 SMD standard film res. - 1/4 W - 5% - 250 ppm/°C Vishay R4 750 K 1206 SMD standard film res. - 1/4 W - 5% - 250 ppm/°C Vishay R5 3M3 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R6 2M2 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R8 2M2 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R10 3M3 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R12 1M0 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R13 2M2 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R14 3M3 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R16 1M0 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R17 56 K 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R18 160 K 1206 SMD standard film res. - 1/4W - 1% - 100 ppm/°C Vishay R19 6R8 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R20 3R9 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R21 100 K 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R22 1M0 1206 SMD standard film res. - 1/4 W - 1% - 100 ppm/°C Vishay R23 56 K 0805 SMD standard film res. - 1/8 W - 1% - 100 ppm/°C Vishay R24 24 K 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R25 6R8 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R26 3R9 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R27 0R33 PTH RSMF1TB - metal film res. - 1 W - 2% - 250 ppm/°C DocID023720 Rev 2 Akaneohm 7/10 Bill of material EVL4984-350W Table 1. EVL4984-350W CCM PFC demonstration board bill of material (continued) Part type/ Case style/ part value package R28 1M0 R29 Des. Description Supplier 0805 SMD standard film res. - 1/8 W - 1% - 100 ppm/°C Vishay 1 K0 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R30 0R33 PTH RSMF1TB - metal film res. - 1 W - 2% - 250 ppm/°C Akaneohm R31 0R33 PTH RSMF1TB - metal film res. - 1 W - 2% - 250 ppm/°C Akaneohm R32 10R 0805 SMD standard film res. - 1/8 W - 5% - 250 ppm/°C Vishay R33 100R 1206 SMD standard film res. - 1/4 W - 5% - 250 ppm/°C Vishay RV1 300 Vac U1 L4984D Z1 PCB REV. 1 8/10 Dia. 15x5 p. 7.5 mm 300 V metal oxide varistor - B72214S0301K101 SSOP10 CCM PFC controller DocID023720 Rev 2 EPCOS ST EVL4984-350W 4 Revision history Revision history Table 2. Document revision history Date Revision Changes 09-Oct-2012 1 Initial release. 31-May-2013 2 Updated title in cover page. Minor text changes. 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