EVL4986A-1KWBL

EVL4986A-1KWBL Data brief 1 kW bridgeless CCM-PFC pre-regulator based on L4986A Features • • • • • • • • • Input mains range: 90 to 265 Vac - frequency 45 to 65 Hz Output voltage / load: 400 V / 2.5 A Efficiency: – above 98% at 230 Vac (full load) – above 95.5% at 115 Vac (full load) – above 94% between 10% and 100% of full load No load mains consumption: below 250 mW at 230 Vac Mains harmonics in compliance with EN61000-3-2 Class-A and JEITA-MITI, Class-A EMI in accordance with EN55022 Class-B Safety in accordance with EN62368 Dimensions 145 x 160 mm, height = 35 mm PCB: double sided, 70 µm, FR-4, mixed PTH/SMT Description The EVL4986A-1KWBL demonstration board is a bridgeless PFC pre-regulator, double boost topology, featuring 1 kW output power (400 Vdc) and wide input voltage range (90 Vac-265 Vac), based on the new L4986A peak current mode CCM power factor controller. Product status link EVL4986A-1KWBL Product label It is intended as a front-end converter up to 1 kW, able to be compliant with IEC61000-3-2 and JEITA-MITI. The demo is designed on the double boost (Barbi) topology using two branches, each consisting of a boost stage, managing half mains cycle. Each section operates at almost fixed frequency (65 kHz). Thanks to the bridgeless approach and the L4986A control IC, the board offers high efficiency and low input current THD across the entire input voltage range. This is achieved using a low complexity schematic and fewer components compared to similar bridgeless solutions. DB4680 - Rev 1 - March 2022 For further information contact your local STMicroelectronics sales office. www.st.com DB4680 - Rev 1 1 Schematic diagrams Figure 1. EVL4986A-1KWBL demo board schematic HS 1 HS 2 P 174 P 174 Z1 5x20 J3 MKDS 1,5/ 2-5,08 VOUT D6 a nd D7 with isola tion kit D10 FUSE HOLDER 20x5 R11 33R Q1 1M RL1 BC807 Q5 R14 33R 5 R12 DNM D9 DNM R7 0R0 1 2 Q2 R17 15R R15 DNM D8 DNM R8 0R0 R13 75k VGS 1 R16 75k R24 0R082 2W VCC12V D3 DNM R18 DNM GD EN1_U4 R46 0R0 1 3 4 P OS _LINE C17 100pF R64 VCC12V 1M R34 10M R45 10K R36 1R0 C20 560pF 0R082 2W D13 S 1M C38 DNM C31 2.2 uF EN2 P WM1 OUT1 GND VCC P WM2 OUT2 3 5 R32 680k R68 150K 1 2 3 4 C36 1nF R29 20k C35 D14 1nF 1N4148WS R33 20k D15 1N4148WS Out1 Vcc+ In1- Out2 In1+ In2- 7 C13 2.2 uF VGS 3 6 5 C14 10uF R74 0R0 Vcc- In2+ U2 LM293ADT VGS 1 P G_OUT P G_IN 7 6 R54 15k8 R49 DNM C28 1nF C25 2.2 uF C32 470pF R50 DNM R55 25k5 C27 DNM C26 220nF EN1_U4 2N7002 R72 C43 100pF R40 1R0 NEG_LINE R48 43k R60 0R0 DNM R75 0R0 VGS 2 R58 0R0 100K VCC12V 1 2 3 C22 100pF C40 1nF R38 10M R63 1M C18 560pF 4 EN1 GND VCC P WM2 OUT2 U3 P M8834 IN OUT 8 EN2_U3 7 VGS 2 C15 2.2 uF J5 1 2 J4 FAN-CONN._DNM FAN-S CREW-CONN. C33 47uF C39 47uF DNM C16 10uF Z_FAN FAN VCC12V 6 5 1 2 VGS 4 U6 L78L12ACZ D17 S TP S 1L40A VCC 15V GND 1 2 3 4 IN D16 BAT48J FILM C29 100uF R56 VCC OUT GND C30 22uF 1R0 MOLEX_4P _2,54 J2 GD R42 0R0 Schematic diagrams page 2/7 EVL4986A-1KWBL C19 DNM EN2 P WM1 OUT1 VFAN U5 LF120ABDT C34 220nF R41 10K 7 R66 150K FB CS R62 0R0 8 COMP Q9 6 5 9 NC GND VHV 10 R47 47R VCS Q8 2N7002 C42 100pF C23 100nF 8 GD HV 8 Q6 2N7002 R67 2 4 3K3 10M GD R57 100k EN2_U3 U1 L4986A VCC Q7 2N7002 R35 R37 3K3 C24 100uF P G_OUT R70 470K R69 10M C41 1nF EN1 R53 2M2 1 R71 470K R28 680k R52 2M2 VGS 4 U4 P M8834 2 C21 DNM R31 680k R22 75k R10 0R0 VCC 1R0 R27 680k R21 DNM D5 DNM R19 75k R9 0R0 R51 2M2 Q4 S TFW69N65M5 G D12 S 1M R65 R73 100K R44 R30 680k C9 1000pF S P S T-NA 0R082 2W R26 680k C8 220uF VGS 2 R23 P HAS E R20 15R VGS 3 D1 S TP S 1L40A NEUTRAL Q3 G 8 C12 470nF GND R4 3K3 D7 S TFW69N65M5 G S R3 P G_OUT C11 1000pF S TP S C12065 D S TFW69N65M5 G R6 1K0 C10 220uF S 0R0 S TFW69N65M5 D 0R0 D2 GF1M D VHV C4 10uF R25 2 3 L4 270uH S D4 GF1M R61 C37 470nF S 3M NEUTRAL R2 1M S TP S C12065 D11 4 5 10 RV1 VAR 275Va c R5 0R0 D6 2 3 C7 2.2uF-X2 D C3 2n2-Y1 1R VFAN C6 2.2uF-X2 2.2uF-X2 2 RT1 4 1 C5 2 90-265Vac C2 2n2-Y1 R1 1M VOUT GND 1 2 S 3M L3 270uH 4 5 10 S C1 2.2uF-X2 DNM P HAS E L2 7448041502 2x2mH 3 1 2 3 4 L1 7448041502 2x2mH 1 PH EARTH N F1 FUS E 15A 3 J1 MKDS 3/ 3-5,08 EVL4986A-1KWBL Measurements 2 Measurements 2.1 Efficiency The following figure shows the overall efficiency of the EVL4986A-1KWBL demo board (load between 10% and 100%), measured at the nominal mains voltages (115 Vac and 230 Vac), after a warm-up time of about 1h. Figure 2. EVL4986A-1KWBL efficiency Efficiency [%] 99.00% 97.00% 95.00% 93.00% 91.00% 89.00% 115Vin 230Vin 87.00% 85.00% 100 200 300 400 500 600 700 800 900 1,000 Pout [w] DB4680 - Rev 1 page 3/7 EVL4986A-1KWBL THD and PF 2.2 THD and PF The total harmonic distortion (THD) and the power factor (PF) have been measured against the mains voltage, from full load 100% to 10%. The results are summarized in the following figures. Note that THD is always below 10%. Figure 3. EVL4986A-1KWBL THD THD [%] 20.00% 18.00% 115Vin 16.00% 230Vin 14.00% 12.00% 10.00% 8.00% 6.00% 4.00% 2.00% 0.00% 100 200 300 400 500 600 700 800 900 1,000 Pout [W] Figure 4. EVL4986A-1KWBL PF PF[%] 1 0.95 0.9 0.85 115Vin 0.8 230Vin 0.75 0.7 0.65 0.6 0.55 0.5 100 200 300 400 500 600 700 800 900 1,000 Pout [W] DB4680 - Rev 1 page 4/7 EVL4986A-1KWBL Revision history Table 1. Document revision history DB4680 - Rev 1 Date Version 07-Mar-2022 1 Changes Initial release. page 5/7 EVL4986A-1KWBL Contents Contents 1 Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 2.1 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.2 THD and PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 DB4680 - Rev 1 page 6/7 EVL4986A-1KWBL IMPORTANT NOTICE – READ CAREFULLY STMicroelectronics NV and its subsidiaries (“ST”) reserve the right to make changes, corrections, enhancements, modifications, and improvements to ST products and/or to this document at any time without notice. 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Information in this document supersedes and replaces information previously supplied in any prior versions of this document. © 2022 STMicroelectronics – All rights reserved DB4680 - Rev 1 page 7/7