UPS25 Uninterruptible power supply and Ni-Mh/Ni-Cd charger unit User’s Manual BDM-610020008 Rev.
UPS25 Uninterruptible Power Supply User’s Manual RTD Embedded Technologies, INC. 103 Innovation Blvd. State College, PA 16803-0906 Phone: +1-814-234-8087 FAX: +1-814-234-5218 E-mail sales@rtd.com techsupport@rtd.com web site http://www.rtd.
Revision History 10/08/2000 10/07/2001 Rev A Rev B Rev C Rev D Rev E HW Release 1.0 Name of company corrected New manual naming convention Removed reference to EFAN; Included hot-swap warning Removed information about J12 Corrected backup power specifications. Included explanation of discharge circuit. Included explanation of J4 Published by: RTD Embedded Technologies, Inc. 103 Innovation Blvd. State College, PA 16803-0906 Copyright 1999, 2002, 2003, 2004, 2005 2012 by RTD Embedded Technologies, Inc.
Consortium. All other trademarks appearing in this document are the property of their respective owners.
TABLE OF CONTENTS CHAPTER 1 - INTRODUCTION ............................................................................... 8 Features ........................................................................................................................................................................ 8 Some of the key features of the UPS25 include: ................................................................................................... 8 Power supply unit ........................................
Using Interrupts in your Program ........................................................................................................................ 35 Writing an Interrupt Service Routine (ISR) ......................................................................................................... 36 The following C example shows what the shell of your ISR should be like: ....................................................... 37 Saving the Startup Interrupt Mask Register (IMR) and interrupt vector .
List of Illustrations and Tables .............................................................................................................................................................. Illustrations Fig. 2-1 UPS25 Board layout showing jumper locations Fig. 2-2 Base address jumpers illustrating address 300h Fig. 2-3 Interrupt jumpers from left to right: IRQ 2,5,7,10,11,12,15 Fig. 2-4 Charger control, solder blobs, located near the left side of the PC/104 bus connector Fig.
Chapter 1 - INTRODUCTION This user’s manual describes the operation of the UPS25 versatile uninterruptible power supply unit for automotive and industrial applications.
Power supply unit The UPS25 uninterruptible power supply unit is designed to provide a complete backup system for your embedded computer and its peripherals. Battery charging power is generated using a wide input voltage range (8 to 40V DC) step down converter with a maximum charging output power of 25W. Battery charging power is converted from this output using a second step-up DC/DC converter. This scheme will enable charging of the batteries at +12V, while operating at an input voltage of 10V.
What comes with your board Your UPS25 package contains the following items: • • UPS25 board with mating connectors for the supported power connections User's manual Note: Software and drivers can be downloaded from our website. If any item is missing or damaged, please send an EMAIL to RTD Embedded Systems, Inc. sales service department at .
Using this manual This manual is intended to help you install your new UPS25 module and get it working quickly, while also providing enough detail about the board and it's functions so that you can enjoy maximum use of it's features even in the most demanding applications. When you need help This manual and all the example programs will provide you with enough information to fully utilize all the features on this board.
Chapter 2 - BOARD SETTINGS The UPS25 board has jumper settings, which can be changed to suit your application and host computer configuration. The factory settings are listed and shown in the diagram at the beginning of this chapter. Make sure you completely study and understand this chapter before making changed to these settings.
Factory-Configured Jumper Settings Table 2-1 below illustrates the factory jumper setting for the UPS25. Figure 2-1 shows the board layout of the UPS25 and the locations of the jumpers. The following paragraphs explain how to change the factory jumper settings to suit your specific application.
Fig.
Base address jumper (Factory setting: 300h) The UPS25 is I/O mapped into the memory space of your host computer. The board occupies a consecutive memory window of 2 bytes starting from the base address. The most common cause of failure when you are first setting up your module is address contention. Some of your computers I/O space is already occupied by other devices and memory resident programs.
BASE ADDRESS JUMPER SETTINGS UPS25 Base address Hex Jumper settings A8 A7 A6 200 0 0 0 240 0 0 1 280 0 1 0 2C0 0 1 1 300 1 0 0 340 1 0 1 380 1 1 0 3C0 1 1 1 0 = JUMPER OFF 1 = JUMPER CLOSED Table 2-2 Base address jumper settings UPS25 Fig.
Host interrupt (Factory setting: Not Connected) The header connector, shown in Figure 2-3 below, lets you connect the onboard control logic interrupt outputs to one of the interrupt channels available on the host computer XT/AT bus. Fig. 2-3 Interrupt jumpers from left to right: IRQ 2,5,7,10,11,12,15 Note: The UPS25 hardware does not support interrupt sharing! This feature is sometimes regarded as a part of the PC/104 special features.
Chapter 3 - BOARD INSTALLATION The UPS25 uninterruptible power supply module is designed to directly mount on top or under your RTD PC/104 power supply unit. This chapter tells you step-bystep how to install your UPS25 into your system. Board installation Keep your board in its antistatic bag until you are ready to install it to your system! When removing it from the bag, hold the board at the edges and do not touch the components or connectors.
Fig. 3-1 UPS25 integrated in a RTD PC/104 cpuModule stack together with a HPWR104 power supply module Note: UPS25 For full output power performance, install your UPS25 toward the top of your PC/104 system, make sure adequate cooling is provided.
External power connections The illustration 3-2 below shows the input and output power connections of the UPS25 board. Fig.
Connector descriptions: • Note: The module input power may be 5 Amp peak, this will require a cable wire diameter of 1,5 sq. mm. Make sure this input wire is kept as short as possible to reduce voltage drops and interference. • • • • UPS25 VIN: Raw input power to the UPS25. Input voltage ranges 10-40V DC This input is fed to the power supply through the UPS25 in normal operation mode (no backup from the battery pack).
Chapter 4 - HARDWARE DESCRIPTION This chapter describes the major hardware building blocks of the UPS25, which are: • • • • • • • The main 25W +5V step-down converter Charger power converter Ni-MH/Ni-Cd battery charger Power switching circuitry Voltage monitors UPS control circuitry I/O interface connector Fig.
The main 25W +5V step-down converter The power supply circuitry is implemented with a switch-mode step down DC-DC converter. The peak charge output power of this unit is 25W. This output power is only available if adequate cooling is provided. The output current is internally limited against over current and short circuit faults. Connect a 10-40V DC source to the UPS25. A reverse voltage schottky diode will withstand reverse voltages up to 40V DC.
Ni-Mh/Ni-Cd battery charger Ni-Mh/Ni-CD Battery Pack and Thermistor Battery packs using Ni-Mh/Ni-CD technology are the only ones supported by the standard UPS25. RTD Embedded Systems, Inc. can deliver UPS25 units that support Ni-Cd technology. An UPS25 that is configured for Ni-MH batteries may not be used with Ni-Cd and vice-versa. For the UPS25 to operate correctly a total of 8 AA-cells must be used connected in series. This connection will give a nominal output voltage of 9,6V over the battery pack.
Ni-Mh\Ni-Cd battery charger To ensure long battery life and reliable charging a special battery charger circuitry is used based on the BQ2003 versatile battery charger chip. This chip is used in “gated charge mode” where the charger disconnects the supply from the battery based on the current state of the charging algorithm. State output of the charger chip can be monitored using LED labeled L3 or by interrogating the charger status register bit #2.
Discharging can also be initiated by setting the discharge bit #1 in the control register to a high, and bringing this bit to low again. Care must be taken not to overheat your system since the discharged battery power is converted to heat directly into the metal heat sink. Only discharge when the ambient temperature is low enough, or when adequate cooling is present. In any case Ni-MH batteries do not require as critically periodical discharging as Ni-Cd batteries do.
Fig. 4-3 Charger configuration, solder blobs B2 and B3 B3 controls the TM1 pin of the BQ2003 and B2 controls the TM2 pin. Below is shown a table that will illustrate the allowed modes of operation. The bold setup mode is the factory default.
If top off mode is enabled the charger will pulse charge for a period of 5 seconds and rest for 30 seconds. This mode will ensure that maximum charging capacity is reached. For long term maintaining of the charge of the backup battery a special trickle mode is supported by the UPS25. This state is entered after all other charge modes are complete.
Voltage monitors There are two independent voltage monitors on the UPS25. One continuously monitors for the presence/level of the main supply VIN. If the main supply drops under 10V the UPS25 stops charging and enters backup mode. In case the interrupt output of the control logic is enabled an IRQ is asserted to the host indicating low or failing power.
UPS control circuitry The UPS25 status can be monitored through the 4 bit Status register. A host interrupt can be asserted in the case that the main power VIN drops below the set trip-point, factory set to 10V. This interrupt can be disabled or enabled by the IRQ-enable bit (#0 of the control register). In case the interrupt is disabled you can monitor the status of the input power by polling the control register.
Chapter 5 - BOARD OPERATION AND PROGRAMMING This chapter shows you how to program and use your UPS25. It provides a complete detailed description of the I/O map and a detailed discussion of programming operations to aid you in programming. Defining the Memory Map The memory map of the UPS25 occupies two bytes of host PC I/O space. This window is freely selectable by the user as described in Chapter 2, Table 2-2.
BA+1 Status register (Read) The UPS25 status register gives you access to monitor the state of your board. This register is reset to all zeroes after power-up and reset of your CPU.
Clearing and setting bits in an I/O port When you clear or set bits in an I/O port you must be careful not to alter the status of other bits. You can preserve the status of all the bits you do not wish to change by proper use of the bitwise AND- and OR- operators. Using and /or operators, single or multiple bits can easily be set or cleared in a one-line operation. 1. To clear a single bit in a port, AND the current value of the port with the value "B", where B = 255-2(exp) bit. 2.
Your UPS25 can interrupt the main processor when the main power supply fails or falls below 10V if interrupts are enabled on the UPS25 board. By using interrupts you can write powerful code to interface to your UPS25. Interrupt request lines To allow different peripheral devices to generate interrupts on the same computer, the PC AT bus has interrupt request channels (IRQs). A rising edge transition on one of these lines will be latched into the interrupt controller.
What exactly happens when an interrupt occurs? Understanding the sequence of events when an interrupt is triggered is necessary to correctly write interrupt handlers. When an interrupt request line is driven high by a peripheral device (such as the UPS25), the interrupt controller checks to see if interrupts are enabled for that IRQ. It then checks to see if other interrupts are active or requested and determines which interrupt has priority. The interrupt controller then interrupts the processor.
Writing an Interrupt Service Routine (ISR) The first step in adding interrupts to your software is to write an interrupt service routine (ISR). This is the routine that will be executed automatically each time an interrupt request occurs for the specified IRQ. An ISR is different from other subroutines or procedures.
The second major concern when writing ISRs is to make them as short as possible in term of execution time. Spending long times in interrupt service routines may mean that other important interrupts are not serviced. Also, if you spend too long in your ISR, it may be called again before you have exited. This will lead to your computer hanging up and will require a reboot. Your ISR should have the following structure: • • • • Push any processor registers used in your ISR.
Before you install your ISR, temporarily mask out the IRQ you will be using. This prevents the IRQ from requesting an interrupt while you are installing and initializing your ISR. To mask the IRQ, read the current IMR at I/O port 21h, and set the bit that corresponds to the IRQ. The IMR is arranged so that bit 0 is for IRQ0 and bit 7 is for IRQ7. See the paragraph entitled Interrupt Mask Register (IMR) earlier in this discussion for help in determining your IRQs bit.
Example on Interrupt vector table setup in C-code: void far _interrupt new_IRQ1_handler(void ); /* ISR function prototype */ #define IRQ1_VECTOR 7 /* Name for selected IRQ*/ void (interrupt far *old_IRQ1_dispatcher) (es,ds,di,si,bp,sp,bx,dx,cx,ax,ip,cs,flags); /* Variable to store old IRQ_Vector */ void far _interrupt new_IRQ1_handler(void ); /*---------------------------------------------------------------------| Function: init_irq_handlers | Inputs: Nothing | Returns: Nothing | Purpose: Set the pointers
Chapter 6 - UPS25 SPECIFICATIONS Host interface 16-bit PC/104 bus Power supply specifications Input voltage range Output charge Power Efficiency Reverse voltage protection Over voltage clamp voltage 10-40V DC 25W continuous 75% aggregate efficiency -40V DC +39V DC Charger and batteries Battery technology Ni-MH part# UPS25-1 Ni-Cd part # UPS25-2 8 9.6V 1500mAh Ni-MH (24Watts for 30min.) 1000mAh Ni-Cd(24Watts for 30min.) 10.5 to 12.5V 1.
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Chapter 7 - RETURN POLICY AND WARRANTY Return Policy If you wish to return a product to the factory for service, please follow this procedure: Read the Limited Warranty to become familiar with our warranty policy. Contact the factory for a Return Merchandise Authorization (RMA) number.
UPS25 43 RTD Embedded Technologies, Inc
LIMITED WARRANTY RTD Embedded Technologies, Inc. warrants the hardware and software products it manufactures and produces to be free from defects in materials and workmanship for one year following the date of shipment from RTD Embedded Technologies, INC. This warranty is limited to the original purchaser of product and is not transferable.
RTD Embedded Technologies, Inc. 103 Innovation Blvd. State College PA 16803-0906 USA Our website: www.rtd.
