STEVAL-ILL022V1 solar-LED streetlight controller with 25
Contents
1. WEVWIVWS 022 1 5 1 5 ee Ort meri dicor 6018 X a 82 T d 4 eed vin ls S8919NAL DNA Doc ID 14469 Rev 2 12 18 UM0512 Schematic and bill of materials Table 8 BOM Reference Value generic part number Package class B1 One way 6x6 mm SMD 4 3 mm H tactile switch C1 C6 1 pF 1210 100 V ceramic capacitor C2 C3 C12 C14 C24 C36 C39 C41 C42 C43 C46 C48 C49 C50 C51 C52 C56 C57 C58 100 nF 0603 50 V ceramic capacitor C60 C62 C65 C66 C67 C68 C77 C79 C4 C5 C13 470 63 V Al cap electrolytic capacitor CT cs GSS pe p Can Cra 1 pF 0805 25 V ceramic capacitor C9 C22 C34 C44 C75 C76 C80 22 uF 50 V Al cap electrolytic capacitor C10 C11 C25 C26 220 pF 0805 50 V ceramic capacitor C15 C20 1 pF 1206 50 V ceramic capacitor C17 560 pF 0603 50 V ceramic capacitor C18 C19 C30 C33 220 uF 50 V Al cap electrolytic capacitor C23 C59 C pes C69 C70 330 nF 0805 50 V ceramic capacitor C27 C29 C32 C64 C83 100 pF 0603 50 V ceramic capacitor C28 220 pF 0603 250 V ceramic capacitor C47 10 pF 8528 21 16 V tantalum C54 C55 20 pF 0603 50 V ceramic capacitor CN1 20 way Box header Right angle mounting JTAG connector D1 D11 D13 D17 D18 D19 D20 D21 D22. Y IN LED streetlight Solar panel 6 5 p AC line in Mains enable AM03451v1 Each block s function is described below e sunlight delivers pockets of photons solar energy to the solar panel also called photovoltaic or PV module The photons energy are absorbed by the PV module and electrons are released e Theelectrons flow along the metal contact of the PV module and create electricity The battery charger then converts the electrical energy and charges the battery e The battery stores the electricity supplied by the battery charger The controller monitors the status of the battery e The LED lamp LED streetlight is activated by the LED driver The LED light controller monitors the system and controls the light on and light off in daytime and nighttime e When the battery goes low the controller sends an enable signal to the mains switch and the AC offline power supply is enabled The AC offline power supply not covered in this document acts as a backup source to power the LED streetlight The solar LED streetlight controller plays the key role in the system for electricity solar energy storage control and LED lamp light on off control Doc ID 14469 Rev 2 5 18 Hardware description UM0512 3 Hardware description 3 1 Board description Table 1 describes the various functions
3. UM0512 User manual STEVAL ILLO22V 1 solar LED streetlight controller with 25 W LED lamp driver and 80 W battery charger based on the STM32F101Rx Introduction The solar LED streetlight controller consists of one 80 W battery charger and one 25 W LED driver During the daytime when there is sufficient sunlight the charger converts the electricity from the solar panel and charges the battery At nighttime the battery powers on the LED lamp as streetlight If it is rainy or cloudy for several continuous days the battery will gradually run out of power The controller then resorts to the AC mains supply to power on the LED until the battery has had time to fully charge again Main features of the solar LED streetlight controller m Maximization of electricity conversion efficiency from solar panel by way of maximum power point tracker MPPT Automatic day night weather detection Automatic battery mains switch over Constant current control for LED lamp Battery charge control Optional LED lighting duration mode Easy system monitoring via debug LED indicators Full protection function for OTP OCP and UVP Figure 1 Snapshot of the solar LED streetlight controller AM03446v1 September 2010 Doc ID 14469 Rev 2 1 18 www st com Contents UM0512 Contents 1 Safety instructions i nn mn DR CR d ow Dae o i c i 4 1 1 Intended use 4 1 2 Installation ii
4. Hong Kong India Israel Italy Japan Malaysia Malta Morocco Philippines Singapore Spain Sweden Switzerland United Kingdom United States of America www st com 18 18 Doc ID 14469 Rev 2 ki
5. Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Description of functions 0 0 0 hh 6 Recommended electrical parameters for solar 8 Recommended electrical parameters for battery 8 Recommended electrical parameters for LED 8 Symptoms and corrective 9 DIP switch for LED lamp light on time 10 LED indicator and error 10 T IM 13 5 seca e eed e ux aaa Rd Gee s 16 Document revision history 17 Doc ID 14469 Rev 2 3 18 Safety instructions UM0512 1 1 1 2 1 3 1 4 4 18 Safety instructions Warning The demonstration board must be used in a suitable laboratory by qualified personnel only familiar with the installation use and maintenance of electrical systems Intended use The demonstration board is a component designed for demonstration purposes only and shall not be used for domestic or industrial installations The technical data and information concerning the power supply and working conditions must be taken from the documentation provided with the delivery and must be strictly observed Installation
6. The installation instructions of the demonstration board must be taken from the present document and strictly observed The components must be protected against excessive strain In particular no components are to be bent or isolating distances altered during the transportation handling or use The demonstration board contains electro statically sensitive components that are prone to damage through improper use Electrical components must not be mechanically damaged or destroyed to avoid potential risks and health injury Electrical connection Applicable national accident prevention rules must be followed when working on the mains power supply The electrical installation must be completed in accordance with the appropriate requirements e g cross sectional areas of conductors fusing and PE connections Board operation A system architecture that supplies power to the demonstration board must be equipped with additional control and protective devices in accordance with the applicable safety requirements e g compliance with technical equipment and accident prevention rules Doc ID 14469 Rev 2 UM0512 General description 2 General description The solar LED streetlight controller is the key element of the system also comprising the solar panel battery and LED streetlight lamp Figure 2 shows the structure of the system Figure 2 System block diagram Ny 2 3 4 Ps E33
7. LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION OR INFRINGEMENT OF ANY PATENT COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED ST REPRESENTATIVE ST PRODUCTS ARE NOT RECOMMENDED AUTHORIZED OR WARRANTED FOR USE IN MILITARY AIR CRAFT SPACE LIFE SAVING OR LIFE SUSTAINING APPLICATIONS NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR MALFUNCTION MAY RESULT IN PERSONAL INJURY DEATH OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE ST PRODUCTS WHICH ARE NOT SPECIFIED AS AUTOMOTIVE GRADE MAY ONLY BE USED IN AUTOMOTIVE APPLICATIONS AT USER S OWN RISK Resale of ST products with provisions different from the statements and or technical features set forth in this document shall immediately void any warranty granted by ST for the ST product or service described herein and shall not create or extend in any manner whatsoever any liability of ST ST and the ST logo are trademarks or registered trademarks of ST in various countries Information in this document supersedes and replaces all information previously supplied The ST logo is a registered trademark of STMicroelectronics All other names are the property of their respective owners 2010 STMicroelectronics All rights reserved STMicroelectronics group of companies Australia Belgium Brazil Canada China Czech Republic Finland France Germany
8. in Table 1 Figure 4 the schematic is updated Table 8 the BOM is updated Doc ID 14469 Rev 2 17 18 UM0512 Please Read Carefully Information in this document is provided solely in connection with ST products STMicroelectronics NV and its subsidiaries ST reserve the right to make changes corrections modifications or improvements to this document and the products and services described herein at any time without notice All ST products are sold pursuant to ST s terms and conditions of sale Purchasers are solely responsible for the choice selection and use of the ST products and services described herein and ST assumes no liability whatsoever relating to the choice selection or use of the ST products and services described herein No license express or implied by estoppel or otherwise to any intellectual property rights is granted under this document If any part of this document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products or services or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein UNLESS OTHERWISE SET FORTH IN ST S TERMS AND CONDITIONS OF SALE ST DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO THE USE AND OR SALE OF ST PRODUCTS INCLUDING WITHOUT
9. 14 BC807 SOT 23 PNP bipolar transistor Q10 TYN616RG TO 220AB Triac is ee 0 10 1206 196 resistor R5 R7 R10 R12 R15 R16 R22 R23 R24 R26 R28 R31 R40 100 0805 196 resistor R53 R101 R6 R13 R29 10 kQ 0805 596 resistor R8 0 20 Axial lead cement 2W resistor R11 R45 R48 R49 R59 R60 R61 R62 R63 R64 R65 R67 CL 0609 ress R118 R119 R120 R121 R122 R123 R124 R125 R14 R27 R50 1 2 0805 596 resistor Ec R73 R74 330 Q 0603 596 resistor R106 R25 1 8 ko 0603 596 resistor R30 R33 R54 33 mO 1210 1 resistor R32 R88 NTC 10 kQ 0805 NTC resistor R34 R107 R108 R116 1 kO 0603 1 resistor R35 240 1206 5 resistor R36 R41 10 kQ 0603 1 resistor R37 12 0603 196 resistor R38 R39 4 7 KQ 0603 5 resistor R102 560 Q 1206 5 resistor 14 18 Doc ID 14469 Rev 2 UMO0512 Schematic and bill of materials Table 8 BOM continued Reference Value generic part number Package class R43 9 1 KQ 0603 196 resistor R44 R89 R91 R93 3 3 KQ 0603 196 resistor R51 330 0603 596 resistor R52 120 Q 0603 596 resistor R56 R58 R96 47 0603 596 resistor R57 3 3 KQ 0603 596 resistor R66 1MO 0603 196 resistor R68 1 8 KQ 0603 196 resistor R75 150 0805 196 resistor R76 R78 R81 R84 10 0805 196 resist
10. 2 D23 D24 D25 D26 D27 028 D29 D30 D31 D32 BAT46JFILM SOD323 small signal Schottky diode D33 D34 D35 D36 D37 D2 D3 D12 15V SOD 80C Zener diode D4 D10 STPS20H100CFP TO 220FPAB power Schottky rectifier SMA or DO 214AC 24 V 400 W D5 D9 SMAJ24A TR Transil TVS D7 3 9 V SOD 80C Zener diode D8 STPS1H100A SMA or DO 214AC power Schottky rectifier D14 STPS2045CFP TO 220FPAB power Schottky rectifier D16 STPS1L60A SMA or DO 214AC power Schottky rectifier F1 10A 2 54 x 7 2 mm axial lead 251 series fuse JP1 see Table 9 0 64x0 64 mm 2 way 2 54 mm pitch pin strip header ky Doc ID 14469 Rev 2 13 18 Schematic and bill of materials UM0512 Table 8 BOM continued Reference L2 see Table 9 Value generic part number 39 uH Package class Inductor L5 L6 600 100 MHz 0603 Chip ferrite bead 25 200mA max LD1 LD2 LD3 LD4 80 mcd yellow 0603 LED LD5 45 mcd red 3 0 diffused radio lead LED LD6 10 mcd green 3 0 undiffused radio lead LED P1 P2 P3 Terminal block 2 Terminal pitch 7 5mm P4 P5 P6 Header 2 pin HDR1x2 pitch 2 54mm Q1 STP40NF10 TO 220 N channel MOSFET Q2 Q4 STP75NF75FP TO 220FP N channel MOSFET Q3 Q5 Q6 Q7 Q11 Q12 MMBTA42 SOT 23 NPN bipolar transistor Q8 Q9 Q13 Q
11. ED 1 LED 2 LED 3 LED 4 Error message Q Battery over voltage or under voltage Battery overcurrent O LED over voltage Q o o Abnormal LED driving current Q Q Short circuit LED driver Doc ID 14469 Rev 2 11 18 UM0512 Schematic and bill of materials Board schematic Schematic and bill of materials Figure 4 6 gt e wo gt Jewayy sa61ey gt s 3001 ETI soo oj s 4 WOLD 699 J Fa Dye tad q Tala d 668 yaan eni palc ms 69 23999 F i GND T EE 65d k 15 EWN Bug 1 aran 5A L YG3pnsia EQ31 5ngiq zan ngad 103190830 91 179 Tins iva Suew n 90 Ln 9 9 91 4 tea L Gan s laf Aee 8 NOD an9 OLRULOLAZEWLS viii ELY 4doot wee HO VOOLHISdis 2e p W w jm NL 815 5 sa T 1 1 dis 25 E s aaa m MI VVZIVWS z
12. Winding 2 pin 2 to pin 4 18 turns CCW 4 Wire gage AWG31 20 5 Core EER28 Z PC40 6 Bobbin BEER28 1110CPFR T1 1 33 pH 4 W1 W3 at 50 kHz 1 Vrms 2 Leakage 0 1 uH W2 short circuit 2 Winding 1 pin 1 to pin 5 b turns CCW 3 Winding 2 pin 8 to pin 10 10 turns CCW 4 Winding 3 pin 5 to pin 3 5 turns CCW 4 Wire gage AWG31 20 5 Core EER28 Z PC40 6 Bobbin BEER28 1110CPFR 6500 46 507 10 40 10 20 Remarks Marking shows pin 1 1 mH W1 W3 at 50 kHz 1 Vrms 2 Leakage lt 10 uH W2 short circuit 3 air gap is required 2 Winding 1 pin 1 to pin 2 17 turns CCW 3 Winding 2 pin 8 to pin 6 34 turns CCW 4 Winding 3 pin 2 to pin 17 turns CCW 4 Wire gage AWG31 5 Core 10 11 2 40 6 Bobbin BE10 118CPSFR 16 18 Doc ID 14469 Rev 2 UM0512 Revision history 7 Revision history Table 10 Document revision history Date 08 Jan 2010 Revision 1 Changes Initial release 28 Sep 2010 Changed connectors 1 P1 solar panel connector 2 P2 battery connector 3 P3 LED lamp connector 4 SW1 SWA mode selection DIP switch Battery use only 12VDC type Figure 1 changed due to the connectors outline changed Re new the connectors location in Figure 3 which is based on the description
13. are to install the hardware Connect an NTC resistor battery temperature sensor to P4 refer to Section 3 1 Connect an NTC resistor LED lamp temperature sensor to P5 refer to Section 3 1 Connect the mains switch controller enable input to P6 refer to Section 3 1 Set SW1 SW4 according to DIP selection mapping table Table 6 Connect P3 refer to Section 3 1 to LED lamp Connect P2 refer to Section 3 1 to battery Connect P1 refer to Section 3 1 to solar panel N 4 2 Recommended peripheral parameters 4 2 1 Solar panel Table 2 Recommended electrical parameters for solar panel Parameters Symbol Typ Unit Condition Maximum power voltage Vom 17 8 V Maximum power current lom 4 52 A Irradiance 1000 W m Open circuit voltage Voc 21 82 V Module temperature 25 Short circuit current lac 5 01 A Module efficiency Nm 13 42 4 2 2 Battery Table 3 Recommended electrical parameters for battery Parameters Typ Unit Nominal capacity 50 Ah Nominal voltage 12 V 4 2 3 LED Table 4 Recommended electrical parameters for LED Parameters Typ Unit Nominal power 25 W Nominal current 2 45 A 8 18 Doc ID 14469 Rev 2 ki UM0512 Operating instructions 4 2 4 Mains switch When the battery is low a high logic level output is generated by the MCU which then enables the mains power 4 3 Troubleshooting Table 5 Symptom
14. from the MCU Table 6 describes the jumper positions of each switch The positions L and H are shown in Table f Table 6 DIP switch for LED lamp light on time selection Status DIP 1 DIP 2 DIP 3 DIP 4 Mode description E I L L L Switch on LED for 5 minutes then turn off Switch on LED for 2 hours during nighttime Switch on LED for 4 hours during nighttime Switch on LED for 6 hours during nighttime Switch on LED for 8 hours during nighttime Switch on LED for 10 hours during nighttime Switch on LED for 12 hours during nighttime Ir r r r r r zcrm lrT Ir r r mr irj r lT IrI criimj ri rir Always switch on LED o o xo occ BR jN r ri rir riririr Always switch on LED at nighttime LED indicator The demonstration board has four LED indicators LED1 LED2 LED3 and LED4 which are used to indicate any error messages during operation Table 7 describes each type of error message The messages are there to assist technicians in their troubleshooting and maintenance tasks Table 7 LED indicator and error message LED 1 LED 2 LED 3 LED 4 Error message o No error Battery charger overheat Battery overheat LED driver overheat LED overheat Incorrect solar panel polarity Doc ID 14469 Rev 2 UMO0512 DIP selection and LED indicator Table 7 LED indicator and error message continued L
15. of the controller s demonstration board Figure 3 provides the top view of the board Table 1 Description of functions Category Index Designator Description 1 P1 Solar panel connector 2 P4 Battery temperature sensor connector connected to NTC 3 P5 LED lamp temperature sensor connector connected to NTC System 7 P6 Mains enable output j connectors 10 LED lamp connector 0 11 P2 Battery connector itch 1 i s 4 SW1 SWA DIP switch mode selection 1234 5 LED1 LED4 Debug indicators HMI 6 LED 5 red ON battery charged OFF battery not charged LED5 LED6 LED 6 white ON battery full OFF battery not full 9 PB1 Reset ICP interface 8 CN1 JTAG 1 Refer to Table 6 for dip selection mapping 2 Refer to Table 7 for debug message mapping 6 18 Doc ID 14469 Rev 2 UMO0512 Hardware description 3 2 Figure 3 view of demonstration board Controller characteristics The controller has the following characteristics e Battery operation voltage 13 8 V 11 V min for 12 V system e Charger input voltage range x 50 VDC Output power x 80 W e LED lamp driver output current 2 45 A output power x 25 W e Dimensions 118 mm x 98 mm x 50 mm Doc ID 14469 Rev 2 AM03452v1 7 18 Operating instructions UM0512 4 Operating instructions 4 1 Hardware installation The following steps
16. or R77 R80 82 0805 196 resistor BUS POS B bs R87 R90 100 0603 5 resistor R83 39 kQ 0805 196 resistor R98 R99 R100 R103 1kQ 0603 5 resistor R109 R115 20 kQ 0603 1 resistor 51 DIP switch 4 Position DIP Switch T1 see Table 9 33 uH EER25 5 transformer T2 see Table 9 1 mH Driver transformer U1 U5 LM258D SO8 me ue U2 U4 U8 TS391ILT SO single voltage comparator U3 09 TSC101 AILT SO current sense IC U6 L78L12ABD TR SO8 narrow positive voltage regulator U7 LM193D SO8 dual voltage comparator U10 STM32F101RXT6 LQFP64 32 bit microprocessor U11 L4931ABD33 TR SO8 narrow linear regulator x1 8 MHz 3 x 8 crystal oscillator Reference Value generic part number Package class Note STM32F101R4 STM32F101R6 STM32F101R8 STMS2F101RB STM32F101RC STM32F101RD and STM32F101RE are all equivalent for the purpose Doc ID 14469 Rev 2 15 18 Schematic and bill of materials UM0512 Table 9 Pin strip header Accessory for JP1 Figure Description M20 series jumper socket op oe ive A q 66062609 T lt 20 0 29 0 23 0 Remarks Marking shows no pin 1 0475 M 3 iA 2 e 5 6 4 1 Oz ie g e 29 0 oct 23 0 Remarks Marking shows no pin L2 1 39 pH 4 W1 W2 and twisted 2 Winding 1 pin 1 to pin 5 18 turns CCW 3
17. s usss e Sua au A E Ra ee a ees 4 1 3 Electrical connection errada maau sna eee eens 4 1 4 B ard he thet nee ee Sen ee kas wakay kusasqa 4 2 General description 5 3 Hardware description 6 3 1 Board description 6 3 2 Controller characteristics 7 4 Operating instructions leere 8 4 1 Hardware installation 8 4 2 Recommended peripheral parameters 8 4 2 1 Solar panel ER x d usd uum 8 4 2 2 Batley sioe nt pee weed dete 8 OO poeta 8 4 2 4 Mains switch a 9 4 3 Troubleshooting i voe e EPOR ER ERR ERG ERR Rok 9 5 DIP selection and LED indicator 10 5 1 DIP selection switch 10 5 2 LED indicator rh 10 6 Schematic and bill of materials 12 7 Revision history 17 2 18 Doc ID 14469 Rev 2 UM0512 List of tables List of tables Table 1 Table 2 Table 3 Table 4
18. s and corrective action Symptom None of the LED s is powered on The LED s include LED lamp debug LED and battery status LED Battery status LED fails to light during daytime Corrective action Set up the system as per the hardware installation procedure described in Section 4 1 Check the mains enable signal on P6 A high logic level indicates that the battery voltage is too low to power the LED light This status will persist until the battery is fully charged Reset the system by pressing the reset button PB1 Check the battery type and polarity Only 12 V battery can be applied to this system If the battery has previously been connected reversely replace the fuse F1 with a new one Check that the LED lamp is available Set up the system as per the hardware installation procedure described in Section 4 1 Reset the system by pressing the reset button PB1 Check that it is not too dark to enable the solar panel s output Check that the solar panel is available Dim LED lamp Try to cool down the LED lamp Check that the LED lamp s lifecycle is still valid Doc ID 14469 Rev 2 9 18 DIP selection and LED indicator UM0512 5 5 1 5 2 10 18 DIP selection and LED indicator DIP selection switch The DIP switches DIP1 DIP2 DIP3 and DIP4 are used to define the LED lamp s on time after the switch on signal has been received
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