dm00130840

DN0028
Design note
STEVAL-ILL066V1
90Vac-305Vac input
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By Ambrogio D’Adda
Main components
STLUX385A
Digital controller for lighting and power supply applications
STEVAL-ILL066V1
(prev. STEVAL385LEDPSR)
100W LED street lighting demonstration board using
STLUX385A
Specification
The following Design Note specifies how to:

Increase the STEVAL-ILL066V1 input Vac voltage range to 90Vac - 305Vac

Reduce the THD below 20% when output power is between 50% and 100%
Circuit description
The STLUX385A based STEVAL-ILL066V1 demo board natively supports a 90 V to 265 V
AC input range. This Design Note describes in detail the hardware changes required to
modify the STEVAL-ILL066V1 demo board to increase the input ac voltage to 90Vac305Vac.
Support for the extended voltage range is provided by firmware release V3R29. The
firmware is structured to support any hardware configured Vac level. The user is required
to modify the software tables mapping the DALI and 0-10V interface to the output current.
This Design Note protects the user to misuse DALI and 0-10V by disabling the interfaces.
The following commands shall be entered via the serial line before implementing the
hardware modifications described in this Design Note:
1- “in 7 0”: disable the DEBUG mode.
2- “in 3 0”: disable DALI
3- “in 9 0”: disable the 0-10V interface
4- “in 27 251”: start the PFC when Vac >= 90V.
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The hardware modifications required are listed below.

Change the PFC output voltage: set R46, R52 and R55 so that the R46 + R52 +
R55 equals to 7420KΩ.

Decrease the THD current distortions: set R101 to 220Ω.

Set the PFC primary inductance T6 to be equal to 550uH (6A saturation)

the PFC MOSFET type Q12 must be STF18N60M2

Change the default C43 so that the minimum granted working Voltage of C43 is
600Vdc.

The HB MOSFET type Q10-Q11 must be STD13N60M2
Given the maximum input voltage of 305Vac, most of these hardware modifications are
required in order to support the increased PFC output voltage. In particular the new target
PFC output voltage is 462Vdc and the PFC OVP voltage is increased to 510Vdc. In order
to properly achieve this result, the R46, R52 and R55 resistors must be changed so that
R46+R52+R55 is increased from 6600KΩ to 7420KΩ.
Since STLUX385A monitors the voltage sensed at pin 38 (ADCIN[0]), the software PFC
loop compensation is automatically adapted to the new inductor-output voltage. The
reference to this pin, imposed internally, is:
(
)
(
)
Should a different PFC output voltage be required, the partition resistors can be modified to
a different value. Please note that the minimum input impedance of any ADC pin is more
the 10MΩ.
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The increased PFC voltage affects the association between the “ll” command parameters
and the real output current. When the hardware modifications are in place, the “ll” values
are mapped according to the Table 1. The user shall modify the software conversion tables
to enable the correct DALI and 0-10V conversion.
Table 1. "ll" value vs Iout
Target Iout
mA
10
100
200
300
400
500
600
700
800
900
1000
“ll”
Value
539
640
740
850
960
1070
1610
2075
2500
2900
3330
To reduce the THD current distortion, the value of R101 is modified. In this Design Note
R101 is set to 220Ω consequently resulting in a less than 20% THD current distortion for
output power ranging from 50% to 100%. The THD profile is reported in Figure 3.
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Measurement results
Figure 1 shows the demo board efficiency when input voltage varies from 90Vac to
305Vac. When output power ranges between 50% and 100%, the efficiency of the demo
board is more than 88%. The maximum efficiency, around 93%, is obtained with Iout of 1A
and high Vac input voltage. The x axis reports the output current.
Figure 1. Efficiency at various Vin
Efficiency
0.950
0.900
0.850
90Vac
125Vac
170Vac
220Vac
260Vac
305Vac
0
200
400
600
800
0.800
0.750
0.700
0.650
0.600
1000
Figure 2 shows the Power Factor (PF) for different output power and different input voltage.
Figure 2. Power Factor at various Vin
Power Factor
1.050
1.000
0.950
90Vac
125Vac
170Vac
220Vac
260Vac
305Vac
0
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200
400
600
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0.900
0.850
0.800
0.750
0.700
0.650
1000
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Figure 3 shows the THD distortion for different output power levels and different input
voltage.
Figure 3. THD distortion at various Vin
THD distortion
35.00
90Vac
125Vac
170Vac
220Vac
260Vac
305Vac
30.00
25.00
20.00
15.00
10.00
5.00
500
600
700
800
900
0.00
1000
Support material
Related design support material
STWS-PSRDEMO-V3R29: binary firmware for STEVAL-ILL066V1 or STEVAL385LEDPSR
Documentation
Datasheet: STLUX385A - Digital controller for lighting and power supply applications
Application note: AN4461 - 100 W LED street lighting application using STLUX385A
Revision history
Date
28-Aug-2014
August 2014
Version
1
Changes
Initial release
DN0028Rev 1
5/6
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