HESC-SER Manual - Diamond Systems Corporation
Contents
1. eMonitors up to 8 external temperatures using PC digital temperature sensors eRS232 serial port for setup monitoring and control eOptocoupled inputs for ignition and system shut down pushbutton cc se P ER c gt GER N q W t41 But aamu Thus 2825 HESC SER User Manual Rev A www diamondsystems com Page 5 gt iamonp SYSTEMS 1 3 SPECIFICATIONS Model L HEGER DO o heelen 3 55 W x 3 75 L x 0 6 Height Current rating includes current supplied to 12V 12V amp 5V regulators Measured on the 5V output LEDs disabled HESC SER User Manual Rev A www diamondsystems com Page 6 diamonp SYSTEMS CHAPTER 2 CONFIGURATION AND INSTALLATION 2 4 Introduction This chapter describes the configuration and installation of the HESC SER power supply In addition section 2 2 provides a formula to calculate the available 5VDC Figure 2 1 shows the HESC SER connectors jumpers and other options S JS3H Power Output Connectors CN 3 amp 4 Na s 5UDC output CN4 2 12V0C output CN4 1 12U0C output CN3 3 Common CN3 2 5UDC output CN3 1l IGN Igmition input CN2 2 SD PB Shut Down input CN2 27 BL Battery Low Output CN2 l PF Power Fail Output WOU Tay SANA 0495 3 a i T m q H EI 3 a Battery Connector CN LZ ebe SCL CNY 5 T2C Shfus SOA CH7 4 Battery Th CNF 3 d Battery common CNA 2 Battery input CH CN 2 Common CN 1 Main Power input 6 40U0C A2. DIAMOND SYSTEMS CORPORATION HESC SER Manual High Efficiency amp Smart Charging Vehicle Power Supply DC to DC Converter P N HESC SER MANUAL Revision 30 Jun 2009 e Mobile VE OT a KE 0 Bod FEB GEn Revision Date Comme Copyright June 2009 FOR TECHNICAL SUPPORT Diamond Systems Corporation PLEASE CONTACT 1255 Terra Bella Ave Mountain View CA 94043 USA Tel 1 650 810 2500 Fax 1 650 810 2525 www diamondsystems com support diamondsystems com viamonp SYSTEMS CHAPTER 1 INTRODUCTION MEN 4 1 1 GENERAL DESCHIDTION cc ccc ccc ccccecceccecccceccececcuccuceccuccucuccuuauceucuccueaecsuaucuceusucaucuecseueceusueaecaececcuuaueaeceueueaeceeaass 4 1 2 FEATURES EE 5 1 3 SPECIFICATIONS EE 6 CHAPTER 2 CONFIGURATION AND INSTALLATION c0cceccecesceccecescnccecescnscecescnscecesensensesenseneesensenseseneesecseesensensneeaess 7 PRA TROD enge 7 2 4 1 Main Input Power Connechor n 8 24 2 OID EE 8 LAS Biot Ee ele 9 2AA A Ba ery ele EE 9 2 4 5 RS232 Serial Port INCCrLACC cccccccccccccncccscoccecaccecansececansecennecennacenonssneneauscaarecaenscannenscanaenensannaneananucsnsnnscannecansenens 9 Pate PU ER Og ON WEE 9 2 9 1 LED JUNPEr ENAN DI SADE sire cctecdacd sete dseh E E ERE EE sect 10 CHAPTER 3 USING HESC104 POWER MANAGEMENT FEATUR EG c0cceccecceccecceccnccnscescnsccscescescessencesenseseees 11 APPENDIX 1 EXTERNAL BATTERY DESIGN cccccccescesceccsceccecescnscnsne
3. 5V for digital temperature sensor and battery enable CN5 8 BE Battery Enable output 2 4 5 RS232 Serial Port Interface The HESC SER provides an RS232 serial port for remote control monitoring and datalogging The serial port connector is a two row by five pin header connector CNQ CN9 1 BL Battery Low signal output TTL level CN9 2 Not used CN9 3 TX Out RS232 output signal CN9 4 Not used CN9 5 RX IN RS232 input signal CN9 6 PF 232 Power Fail signal output RS232 signal levels CN9 7 SD 232 Shut Down signal input RS232 signal levels CN9 8 Not used CN9 9 Common CN9 10 Common HESC SER User Manual Rev A www diamondsystems com Page 9 piamonp SYSTEMS 2 5 Jumper Selection This section describes the function of each jumper the location of it the default setting and how to change it 2 5 1 LED Jumper Enable Disable These jumpers allow the LEDs to be disabled This is most likely to be used when absolute minimum power consumption must be maintained such as when operating off a limited battery source The location of each LED jumper shown is in the diagram below a e mmm LED cut trace jumpers on SMD side of HESC SER Each LED is enabled by factory default To disable any LED remove the LED jumper or cut the small PCB trace if no jumper is installed associated with the LED To re enable any LED re install the associated jumper or solder a short jumper wire betwee
4. Position 4 IGN Ignition input ie maintained contact closure 6 40V DC CN3 2 Position 5 5VDC output CN8 3 Position 6 Common CN2 1 Position 7 12VDC output CN2 2 Position 8 12VDC output CN2 3 Position 9 5VDC output Note All outputs are active low The active state of the IGN signal is programmable by using SCU utility R12 10K R50 10K GND GND Field Connection uSig Microprocessor Output GND Output Structure for PF BL amp BE HESC SER User Manual Rev A www diamondsystems com Page 8 viamonp SYSTEMS 2 4 3 Battery Connector Batteries are connected via the Weiland connector CN7 The HESC SER accepts DC battery voltages in the range 6 5V to 35VDC through the Battery Power Connector CN7 1 Battery Positive CN7 2 Common CN7 3 TH thermistor safety input CN7 4 SDA I C SMBus data input output signal CN7 5 SCL I C SMBus clock input output signal 2 4 4 Aux Battery Connector Diamond Systems battery packs such as the BAT104 NiCd BAT104 NiMh BAT104 SLA25 and BAT104 SLA45 can be directly plugged into the HESC SER through connector CN5 Connector CN5 is a two row by four pin header with the BAT104 battery packs having a mating female connector CN5 1 Battery Positive CN5 2 Common CN5 3 Battery Positive CN5 4 Common CN5 5 SDA I C SMBus data input output signal CN5 6 SCL I C SMBus clock input output signal CN5 7 5VC
5. UNI Update Progress Wille Close Figure 3 2 PF is driven active low after the main input power is removed and the debounce interval is completed or whenever there is a pending shut down of the main outputs IGN SD BL and PF can be used to signal the host CPU to prepare for shutdown It is critical that operating systems such as Linux and Windows are shutdown gracefully otherwise corruption of the OS and the file system may result The following diagram summarizes the various input conditions which generate shutdown command to the HESC SER After one of the four signals BL PF SD IGN becomes active the corresponding counter will start counting down to zero When the counter reaches zero a shutdown command is issued to switch off the HESC SER outputs immediately HESC SER User Manual Rev A www diamondsystems com Page gt iamonp SYSTEMS APPENDIX 1 External Battery Design 1 1 Battery Isolation The HESC series products allow for an external backup battery to be connected For applications where long periods of power interruption may occur a Mosfet isolation circuit should be used to prevent deep cycling the batteries Below is a circuit complete with typical component values Slow acting fuse Thermal fuse Size according to if required battery specs typ NTE8081 Bat o Di D 3 ep 5 Ser To 12C temperature 6 5G sensor KS 7 SE BATTERY 8 Pin header NDS0605 100K Reen batter
6. cnscncscesensesenscneesensensesenseneesensenseneesensensanenseas 13 ga 71 Bl Ce ae ci WG Pee nner a ng O 13 12 TIGA SENSOR INTERFACE EE 13 HESC SER User Manual Rev A www diamondsystems com Page 2 piamonp SYSTEMS PREFACE This manual is for integrators of applications of embedded systems It contains information on hardware requirements and interconnection to other embedded electronics DISCLAIMER Diamond Systems makes no representations or warranties with respect to the contents of this manual and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose Diamond Systems shall under no circumstances be liable for incidental or consequential damages or related expenses resulting from the use of this product even if it has been notified of the possibility of such damages Diamond Systems reserves the right to revise this publication from time to time without obligation to notify any person of such revisions If errors are found please contact Diamond Systems at the address listed on the title page of this document COPYRIGHT 2009 Diamond Systems No part of this document may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise without the express written permission of Diamond Systems HESC SER User Manual Rev A w
7. ination Input Output wt wt e E T r wt Enable Level 3 SMBus operation Enable HESC104 Will Begin Shutdown When Ign Pin is High Disable HESC104 Will Begin Shutdown When Ign Pin Low Enable de actvation of Batten Enable BE after shutdown Close Figure 3 1 HESC SER User ManualRevA www diamondsystems com Page piamonp SYSTEMS BL is driven low when the battery voltage is below the setpoint value of Minimum Battery Operating Voltage EEPROM variable Figure 3 2 shows this variable under the OTHER EEPROM SETPOINTS page Please note the unit of 9400 is in millivolt Input Output r Range nits Command Description Setup Charger Power Supply Enable Flags O 65535 Sec O 65535 Sec 0 65535 1 Orn U 255 7 Ticks Cycle 0 6553 5 7 0 1K 0 6553 5 7 0 1K 0 65535 7 my 0 16 Bits 0 16 Bits 0 65535 Sec Setup Minimum Battery Operating Voltage Mmmum Battery Operating Capacity Mavmum Input Power Allowed Maximum Time Before Communications Timeout Define How Many Charge Cycles to Use Minimum Battery Charging Temperature Maximum Battery Charging Temperature Minimum Daten Charging Voltage Define Which LZ Batter Temp Device ta Use 0 T herrmister Define Which LZ Ambient Temp Device to Use Q Thermister Hate at Which 120 Devices Are Polled Enables Polling for Selected LZ Device Temp Sel Future Use Future Use Future Use
8. ing voltages from 9 5 to 35V The HESC SER has advanced power management functions that allow timed on off control of the HESC SER notification of changes to main power and changes in the battery status For example the HESC SER can be programmed to power off the outputs in 60 seconds and then turn on again 12 hours later The HESC SER size is 3 55 x 3 775 inches which is the same size as the PC 104 standard and has the same mounting holes pattern as the PC 104 standard However the HESC SER does not supply the PC 104 bus connectors For a PC 104 fully compliant power supply please see the Diamond systems HESC104 All generated voltages are provided to a Phoenix header A removable plug allows the HESC SER to be easily installed The RS232 serial port is provided on a 2x5 row pin header The HESC SER can be configured to meet almost any power supply and battery charging need for embedded applications whether that be a simple 5V application or providing power for back lighted LCD panels or a full UPS un interruptible power supply configuration HESC SER User Manual Rev A www diamondsystems com Page 4 Se doaucong SYSTEMS 1 2 FEATURES eDC to DC converter for embedded applications e Load Dump transient suppression on input power supply eOperates from 6VDC to 40VDC input ePC 104 size and mounting holes e60 watt power supply outputs ey 12V 12V 5V and battery charger outputs e Temperature range 40 to 85C
9. n each of the jumper pads HESC SER User Manual Rev A www diamondsystems com Page 10 piamonp SYSTEMS CHAPTER 3 Using HESC Power Management Features Note In order to use the advanced power management features the HESC SER must have the HESC UPS Firmware loaded Please refer to the HESC UPS manual for details By monitoring and activating the following inputs and outputs the HESC SER power supply is capable of responding to changes in input supply and battery voltage to alert the host CPU of such conditions To help accomplishing this task with ease DIAMOND Systems provides a Windows based Smart Charger Utility SCU This utility is also required when changing the charge profile for different batter ies or future firmware update CN4 1 Position 1 PF Power Fail signal output CN4 2 Position 2 BL Battery Low signal output CN4 3 Position 3 SD Shut Down input ie momentary push button input CN3 1 Position 4 IGN Ignition input ie maintained contact closure Note 1 IGN and SD response to 6 40V DC input as a logic high 2 The IGN can be triggered on either a logic low or logic high of input The input polarity of the IGN is set by changing one of the Charger flags 3 Figure 3 1 is a snap shot of the SCU utility page which shows the some of charger flags When the flag is unchecked IGN reacts to a logic high and vice versa with flag checked Command Description Enable Auto kort Charging Enable Charge Term
10. ux Battery Connector CNS W y e A RRE DA oo a Serial Port LED Indicators Connector CNS Power Considerations The 5V switching regulator is rated at 12A maximum output however the 5V output supplies power to the 12 5 and 12VDC regulators To obtain the usable range of 5V output derate according to the use of 12 5 and 12VDC Use the following formulae to calculate the maximum usable output z zk zk Usable 5Voutput 12A eee I 5 5VDC current load I 12 12VDC current load 12 12VDC current load Assuming 90 percent converter efficiency actual efficiency may vary Where HESC SER User Manual Rev A www diamondsystems com Page 7 viamonp SYSTEMS 2 4 1 Main Input Power Connector Input power is connected to the HESC SER by a Molex plug and pin connector CN6 The power supply accepts DC input voltages in the range of 6VDC to 40VDC Unregulated vehicle power is connected as follows Terminal 1 hot polarity Terminal 2 Common OVDC 2 4 2 Output Power Connector Output power is available for use via Phoenix MiniCombicon connector Connectors CN2 CN3 amp CNA are immediately side by side with a nine position mating plug in mating header supplied CN4 1 Position 1 PF Power Fail signal output TTL logic level CN4 2 Position 2 BL Battery Low signal output TTL logic level CN4 3 Position 3 SD PB Shut Down input ie push button input 6 40V DC CN3 1
11. ww diamondsystems com Page 3 viamonp SYSTEMS CHAPTER 1 INTRODUCTION 1 1 GENERAL DESCRIPTION The HESC SER is a high efficiency high performance DC to DC 60 wait converter that supplies 5V DN 12V amp 12V outputs The HESC SER also includes a flash based microcontroller that supplies advanced power management smart battery charger and an RS232 serial port The HESC SER is designed for low noise embedded computer systems has a wide input range of 6 40V gt 6 1 and is ideal for battery or unregulated input applications The HESC SER is specifically designed for vehicu lar applications and has heavy duty transient suppressors 5000W that clamp the input voltage to safe levels while maintaining normal power supply operation The HESC SER is a state of the art MOSFET based design that provides outstanding line and load regulation with efficiencies up to 95 percent Organic Semiconductor Capacitors provide filtering that reduces ripple noises below 20mV The low noise design makes the HESC SER ideal for use aboard aircraft or military applications or wherever EMI or RFI must be minimized The 5VDC and 12VDC outputs are controlled by a constant off time current mode architecture regulator that provides excellent line and load transient response The HESC SER provides up to four stages of battery charging and can charge Lead Acid NiCd and NiMh batteries and is also SMBus level 3 compatible Charge currents are up to 4A and battery charg
12. y connector HESC product on products Optional remote Of pushbutton to restart SP NO HESC after battery is in isolation mode IRLR2905 IRLR2905 Size pushbuttom for max system load Parallel mosfets as required to lower IR losses Figure A1 Battery Mosfet Isolation Circuit 1 2 Digital Sensor Interface The HESC series support PC digital temperatures of Microchip TCN75 and National LM75CIM These TC are two wire devices and require connection of a bi directional data line SDA and a bidirectional clock line SCL In addition 5V power and Gnd are required Both SDA and SCL along with 5V and Gnd are available through the eight pin battery header connector see Figure A1 on HESC products SDA and SCL are also available on the five position screw terminal block see section 2 3 3 on the HESC104 n SDA VCC Sot scr ao 4 sco a GND A2 GND TCM75 Figure A2 Digital Temperature Sensor HESC SER User Manual Rev A www diamondsystems com Page 13
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