User manual - DV Industrial Computer
Contents
1. Output Rail Current Max Current Peak Regulation lt 5 seconds 5Vsb SAS 6 5A 3 5V SAS 6 5A 3 3 3V 5A 6A 2 5 12V 2A 2 5A 3 12V 0 1A 0 2A 2 Total current on 5Vsb and SV rails Maximum Power at 12 5V Input engine is off Output Rail Current Max Current Peak Regulation lt 5 seconds 5Vsb 5A 6A 3 5V 5A 6A 3 3 3V 5A 5 5A 2 5 12V 2A 254 3 12V 0 1A 0 2A 2 Total current on 5Vsb and SV rails Maximum Power at 10 5V Input engine cranks or deep discharge Output Rail Current Max Current Peak Regulation lt 5 seconds 5Vsb 4 5A 5 5A 4 5V 4 5A 5 5A 4 3 3V 4 5A 5A 3 5 12V 1 5A 2A 4 12V 0 1A 0 2A 2 5 Total current on 5Vsb and SV rails INPC DP022 Automotive PSU Connection NOTICE Use the DP022 only with low power motherboards all VIA C3 C7 CPUs and Pentium M CoreDuo that use V core from the 5V rail Do not use general purpose motherboards or 5 25 CDDs as they tend to use a lot of current on the 12V rail It s desirable to use 2 5 drives SlimCDDs or FlashDisks as they use only current from the 5V rail Do not connect a Car Battery Charger directly to the DP022 The DP022 has several wires that need to be installed in various places When installing always double check the polarity of your wires with a voltmeter NEVER use the cigarette plug as a power source often the contac2. LED Buzzer Status Off No sound Deep Sleep 0 005sec Blink 5sec Off No sound faint clicks Sleep 0 005sec Blink lsec Off No sound faint clicks StandBy On No sound PowerOn 0 1sec Blink Ssec Off 0 1sec Beeps Sleep Over Temperature 0 1sec Blink lsec Off 0 1sec Beeps Sleep PSU Overload or Fault Input Voltage must go low or r command must be sent to clear a fault INPC DP022 Automotive PSU 6 Serial Line RS232 Notice The DP022 PSU operates completely independent of computer s software and serial line connection The DP022 that is connected to control computer by serial line operates as a terminal device with fixed connection 9600 8 bit no parity 1 stop bit Usually computer acts as initiator of data communication the host The computer can send commands and data to the DP022 The DP022 responds by data block to the most commands sent from computer The DP022 realizes a likeness of ANSI VT100 terminal by means of subset of commands with extensions for WatchDog timer temperature and voltage measurement channel and so on Input from serial line is latched by incoming buffer of 23 byte size String with 24 bytes and more will be wrapped The DP022 starts parsing after receiving of CR Ox0d or LF Ox0Oa symbol or after overflowing of input buffer 23 bytes Note that parameters such as timeout for the WatchDog timer are in ASCII digits so 12 is represented by the characters 1 and 2 not by a single byte with
3. 22k GND Black E NC T_SIGNAL 5V Rea GND 5V Red 6 Beste CC CC ie E OO ei O ell Te JP See 32 JPL INPUT POWER DEFAULTS SINR Pin Description PUWER 2 IGNITION JP2 RESET SWITCH Description SOUT lt TR gt 3 GND BATTERY lt gt RESET SW JP3 POWER SWITCH in Description 4 PWR SW INPC DP022 Automotive PSU JP9 20 18 17 14 13 Je 11 oO OW FT GOSS OO Operation VEHICLE MODE If ignition is OFF and IGNITION is LOW 0 Volts then nothing happens and the DP022 stays in Sleep mode LED Blinks as 0 005sec On 5sec Off Buzzer faint clicks The DP022 is waiting for ignition signal The user steps into the automobile and turns on the key IGNITION goes HI 12 Volts and as a result the DP022 wakes up from Sleep Mode The DP022 waits for 2 seconds then turns on the 5Vsb rail Buzzer sounds shortly and after another second the DP022 sends an ON signal to the motherboard via the 2 wires connected to the JP3 and to the motherboard s Power On header The motherboard will turn ON and your system should start booting Ignition is ON during driving Your comput
4. state and switches into StandBy state t get current value of temperature Press three keys t and Enter As a response the DP022 sends two values of temperature that aree separeted by 7 symbol slash First value is measured by remote thermistor second is measured by internal DP022 thermistor You can control temperature on the fly by sending this comand periodically INPC DP022 Automotive PSU 12 Iy get current values of input and output voltages Press three keys v and Enter As a response the DP022 sends five values of voltages that are separated by symbol slash First value is input voltage nominal value is 13 5V second value is 5Vsb third 12V fourth 5V and fifth 3 3V Values have sent in millivolts You can control voltages on the fly by sending this comand periodically w get current value of counter of WatchDog timer Press two keys w and Enter As a response the DP022 sends current value of counter of WatchDog timer in ticks each tick is 0 3s long W set current value of counter of WatchDog timer Press two keys W and then type the value of ticks from 0 to 255 each tick is 0 3s long and finish with Enter As a response the DP022 sends symbol slash and just entered value which allows to check accuracy of setting Support and warranty Standard Hardware Warranty 1 Year Installation support 30 days via email INPC DP022 Automotive PSU 13
5. INPC DP022 55W Smart Automotive PSU 10 19Volt Input ALL INFORMATION IN THIS USER MANUAL IS PRELIMINARY AND SUBJECT TO CHANGE R 1 0 May 2007 DV Industrial Computer Ltd Wide input range 10 19V Suitable for automotive applications Suitable for battery powered applications Complete with start up shut down control user adjusted saved in EEPROM Compatible with most ITX boards equipped with a 20pin ATX connector Silent operation fanless no moving parts Temperature control Low heat dissipation efficiency over 88 Chassis mountable measurements 36x170x31 Connection via COM port with computer Before you start This device should be attached and tuned by specialized personnel only after familiarizing with current manual Please take a moment and read this manual before you install the DP022 in your vehicle Often rushing into installing the unit can result in serious damage to your DP022 converter computer and probably your car electrical system The DP022 converter has several wires that need to be installed in various places When installing always double check the polarity of your wires with a voltmeter INPC DP022 Automotive PSU 1 Introduction This manual is intended for firmware release 1 0 The firmware release number is written on the label stick on the MCU inside the device and also this number can be obtained by a proper command sent through the serial line All registered trademarks are the pro
6. ault state if input voltage does not exceed Low Voltage Threshold The Low Voltage Threshold value is being stored in EEPROM GI set new value of Low Voltage Threshold Press keys G l and then type value of millivolts from 9000 to 1500 and finish with Enter You can check accuracy of setting by gl command get Lower Voltage Threshold gh get Voltage Threshold Hysteresis Press four keys g h and Enter As a response the DP022 sends value of Voltage Threshold Hysteresis in millivolts In case if the DP022 has been switched to Sleep PSU Overload or Fault state and this error was caused by dropping of input voltage below Low Voltage Threshold value and if the input voltage stays less than sum of Low Voltage Threshold and Voltage Threshold Hysteresis the DP022 will stay in Sleep PSU Overload or Fault state If input voltage rises over sum of Low Voltage Threshold and Voltage Threshold Hysteresis the DP022 will switch into StandBy state The Low Voltage Threshold value is being stored in EEPROM INPC DP022 Automotive PSU 11 Gh set new value of Voltage Threshold Hysteresis Press keys G h and then type value of millivolts from 500 to 4000 and finish with Enter You can check accuracy of setting by gh command get Voltage Threshold Hysteresis h get list of commands Press two keys h and Enter As a response the DP022 sends firmware release number and list of commands l get launching voltages table Press two keys l and En
7. e the DP022 will operate as dumb PSU This will bypass the Startup Shutdown sequence and battery protection Connect GND and POWER of JP1 connector with heavy gauge wire directly to the automotive batteries and terminals GND may also be connected with heavy gauge wire to the Chassis if desired Apply 12 Volts to IGNITION by turning on the ignition or by flipping a switch and you re ready to go The DP022 can be tested in the lab before being installed into the vehicle Certain details need to be noted for proper bench testing When connecting bench power use between 12 to 16 Volts DC to POWER and GND BATTERY terminals for best results The best way to do successful bench testing is to use an adequately sized 12V battery Bringing in the battery from the car or using an extra one that has at least a 10 AmpHour capacity will be sufficient in most cases To aid in bench testing do not connect IGNITION anywhere The DP022 will operate as dumb PSU with button POWER control INPC DP022 Automotive PSU 4 l l A Fp JP8 210 min 200 min eM LA A JPI POWER BUTTON JP8 ATX OUT JP9 HDD OUT Wire Color Col Description I 12V Yellow JP8 ATX OUT Des Wire Col or y gt 33V ae JP7 EXTERNAL LED SC SE i GND Black CS ON Greer GND Black GND Black 1 THERMISTOR
8. eeds to be powered at all times The power consumption in the suspend mode is few Watts Motherboard No matter how big your car battery is it will eventually drain your vehicle battery in a matter of days The DP022 is addressing these issues by cutting off the 5VSB rail after a pre defined amount of time timing settings The DP022 monitors battery voltage to protect against deep discharge When battery level drops below predefined value for more than predefined time the DP022 will shut down and re activate only when the input voltage is gt predefined value will still consume a few hundred milliwatts needed to monitor computer ON OFF status All power supplies AN e WW S ON OFF RESET 20pin ATX connector switch switch Of course there is a traditional PC PSU mode setting with no ignition control shutdown logic bypassed and it can be used in non vehicle computer applications INPC DP022 Automotive PSU 2 Input Characteristics lutput Connector 2 pin PWL3 Minimum Input Operating voltage 10V 8 5V for less than 0 01sec Maximum Input Operating voltage 19V 25V for less than 0 01sec Maximum Input Current Sleep Mode 10mA Maximum Input Current Deep Sleep Mode ImA Range of Adjustable Lower Voltage Threshold 10 15V Range of Countdown Timer 1 60 minutes Output Power Characteristics Output Connector ATX Power 20 pin Molex P N 39 01 2200 Maximum Power at 13 5V Input engine is running
9. er will remain ON playing MP3s doing GPS Navigation etc The automobile goes to the gas station and the driver turns off the key and IGNITION goes LOW The DP022 now starts the Countdown Timer T1 The driver gets back in the car starts the car and the computer keeps playing the MP3s without a hiccup The user then drives home and turns off the car for the night IGNITION goes low and the Countdown Timer T1 starts The DP022 waits for STANDBYDELAY then Countdown Timer T1 expires The DP022 then sends a pulse again over JP3 pins to shutdown the computer The shutdown pulse was successful and the computer turned off Standby The Countdown Timer T2 starts The DP022 waits for SLEEPDELAY then Countdown Timer T2 expires The DP022 then goes to Sleep mode and preserves battery power While in Deep Sleep or Sleep mode the DP022 constantly monitors your car battery voltage levels preventing deep discharge situations by automatically shutting down until battery levels reach safe levels again DUMB MODE The DP022 behaves as a regular ATX PSU with button Power On Off Of course the DP022 monitors battery voltage to protect against deep discharge and monitors temperature and outputs You can monitor these parameters via serial line in DUMB MODE as well as in VEHICLE MODE Also the WatchDog timer can be used So it seems that the DP022 is not a regular ATX PSU LED Buzzer Status Codes
10. flow is displayed on terminal window In the clear terminal window enter the first command h help press keys h and then Enter As a response the controller sends firmware release number and list of commands that are supported in Monitor mode e PSU HyperTerminal E 5 x File Edit Yiew Call Transfer Help Del 2 3 cls ei B100 set standBy dolay 10sec from H to 65000 Zch get standBy timer Caunter value cs get Sleep timer Counter value Ze get slEEp delay E100 set slEEp delay 10sec from O to 65000 Zo get low voltaGe threshold G12000 set low voltaGe threshold 12000mY from 10000 to 15000 h this Help l Launching diagram m get current Mode n get Number of firmware version r Reset error status switch to Standby mode Ze get current Status t get standBy Temperature values Zu get Volatage values w get Watchdog value W100 set Watchdog value 10 tics from H to 255 gt Connected 0 00 15 TTY 9600 8 N 1 co caps NUM Capture Print echo If you see this list all settings have been made correct and you can continue with study of commands The commands have friendly interface to interact with terminal program NOTICE The commands that start with symbol slash are focused to be used with dedicated programs of course you can use them with terminal program Some of commands answer with asked value but some of commands do not All answers tha
11. mmand that can be sent with delay of some time will result in another value with difference that corresponds to delay from first command point es get counter value of T2 timer Press four keys c s and Enter As a response the DP022 sends current value of T2 timer counter in seconds At the moment when the DP022 switches into StandBy state T2 timer starts decrementing counter value count down Therefore second command that can be sent with delay of some time will result in another value with difference that corresponds to delay from first command point le get SLEEPDELAY Press three keys e and Enter As a response the DP022 sends current value of SLEEPDELAY initial value for T2 timer in seconds This value should be loaded into counter of T2 timer when the DP022 switches into StandBy state After that T2 timer starts time countdown The DP022 switches to Sleep state when T2 timer expires The SLEEPDELAY value is being stored in EEPROM JE set new value of SLEEPDELAY Press two keys E and then type value of seconds from 0 to 65000 at finish with Enter You can check accuracy of setting by Je command get SLEEPDELAY If you set SLEEPDELAY to 0 then the DP022 will switch to StandBy state at no time gl get Low Voltage Threshold Press four keys g 1 and Enter As a response the DP022 sends value of Low Voltage Threshold in millivolts The DP022 switches into Sleep PSU Overload or F
12. ms Accessories Communications The dialog window appears on the screen Let us name our connection as PSU arbitrary name Enter a name and choose an icon for the connection Name gt PSU Enter details for the phone number that you want to dial Country region United States 1 Area code fi Phone number Comec usio Cancel INPC DP022 Automotive PSU 8 And set up COM3 properties COM3 Properties Port Settings Bits per second Data bits fe H Parity None DI Stop bits ns Flow control Hardware zl Restore Defaults Cancel Apply Click on File button in main menu of Hyper Terminal program and click on item Properties in pop up menu In dialog window PSU Properties select bookmark Settings and select the following properties PSU Properties ConnectTo Settings Function arrow and ctrl keys act as Terminal keys Windows keys Backspace key sends Ge Dh Del Cti H Space Ctrl H Emulation v Terminal Setup Telnet terminal ID TELETYPE 33 Backscroll buffer lines 500 7 Play sound when connecting or disconnecting Input Translation ASCII Setup Cancel INPC DP022 Automotive PSU 9 When Hyper Terminal configuration has been finished everything is ready to dialog with the controller Commands that are entered on terminal keyboard are sent to the controller PSU via serial port while input data
13. perty of their respective owners Overview The DP022 is a fully compliant ATX power supply designed to power a low power PCs from a single 12V power source The DP022 power supply has an MCU that controls and monitors various functions of the power supply operation Also it realizes voltages monitoring temperature monitoring and communication via COM port with computer As well the MCU realizes a WatchDog timer to supervise the computer A LED indicator and buzzer in the power supply continually Battery report the power system status and health It is also used ay for troubleshooting There are four main operating modes RS232 COM of the DP022 Deep Sleep Sleep Standby Power On en The DP022 has user selectable MCU driven timing Button settings allowing you to choose various ignition shutdown vehicle computer timing schemes GND settings These settings are user adjusted and saved in EEPROM These settings allow to overcome the main EE problems of vehicle computer power supplying One of and ATX gd most difficult tasks of operating a computer in a vehicle power logic GE is power consumption while the computer is OFF Even if E Ss LED your computer is totally OFF standby mode a computer 4 3 3V 12V 12V provide 5Vsb ON standby so that the motherboard can issue at least a PSON signal When the computer is in the suspend sleep mode it will consume even more power because the RAM n
14. t have started with symbol are tailed with symbol carriage return line feed and prompt symbol gt a display all Press two keys a and Enter As a response the DP022 sends current value of temperature output voltages input voltage value of Lower Voltage Threshold contents and initial values of Timers T1 and T2 current operating mode and status b get STANDBYDELAY Press three keys b and Enter As a response the DP022 sends current value of STANDBYDELAY initial value for T1 timer in seconds This value should be loaded into counter of T1 timer when IGNITION goes low After that T1 timer starts time countdown The DP022 switches to StandBy state when T1 timer expires The STANDBYDELAY value has been saved in EEPROM INPC DP022 Automotive PSU 10 B set new value of STANDBYDELAY Press keys B and then type value of seconds from 0 to 65000 and finish with Enter You can check accuracy of setting by b command get STANDBYDELAY If you set STANDBYDELAY to 0 then the DP022 will switch to StandBy state immediately after circuit IGNITION has gone low cb get counter value of T1 timer Press four keys c b and Enter As a response the DP022 sends current value of T1 timer counter in seconds At the moment when IGNITION goes low while the DP022 is being in PowerOn state T1 timer starts decrementing counter value count down Therefore second co
15. ter As a response the DP022 sends the 20 row table with values of voltages that were measured at the moment of starting the DP022 Table contains 20 batches of voltages measured with ms time slots each batch reflected in separate row At the start there was 20ms period to control This table helps to evaluate load that has been connected to the DP022 m get current mode of operation Press three keys m and Enter As a response the DP022 sends numeric value that corresponds to current mode of operation either 0 OT DUMB MODE has been set or 1 if VEHICLE MODE has been set n get firmware release number Press three keys n and Enter As a response the DP022 sends firmware release number s get current state Press three keys s and Enter As a response the DP022 sends numeric value that corresponds to current state The correspondence table looks as following Value Status Explanation 0 PowerOn Switched on all rails have been activated 2 StandBy Switched off only 5Vsb rail has been activated 6 Sleep Switched off any rail has not been activated 7 Deep Sleep Switched off any rail has not been activated 8 Sleep Over Temperature Switched off any rail has not been activated 9 Sleep PSU Overload or Fault Switched off any rail has not been activated r reset error state and switch to StandBy state Press two keys r and Enter As a response the DP022 resets the error
16. the value of 12 Also characters are case sensitive so W and w are two different commands WatchDog timer The WatchDog timer is designed to overpass a computer hanging up Usually computer almost never hangs up However if it hangs up and gets stuck usually there is nobody at the site to press the reset or nobody knows where the stuck computer is because there were no problem with it for a long time The WatchDog timer is used just for such situations It automatically restarts the computer that is hung up To restart computer the WatchDog timer closes circuit between pins 1 and 2 of J11 connector The WatchDog timer is off after starting of the DP022 To switch it on the command WW should be sent and timeout number of ticks one tick is 0 3 seconds should be set by indicating required W which is a value between 0 and 255 The driver program needs to set the timeout periodically to avoid the WatchDog hits and following reset contacts closing Detailed information about WatchDog is given in the further sections INPC DP022 Automotive PSU 7 Using the serial line of the DP022 in MS Windows MS Windows XP for example Assume that computer has available COM3 port that should be set as 9600 8 bit no parity 1 stop bit operation As a dialog application let us use Hyper Terminal that is included in MS Windows To get it ready open the folder Communications and run Hyper Terminal click on Start button and then Progra
17. ts are not capable of delivering high current to your PC Connect a 2 pin jumper cable between JP2 and the motherboards Reset header This will allow the DP022 to reset the motherboard by simulating a reset button press POLARITY MATTERS HERE Connect a 2 pin jumper cable between JP3 and the motherboards Power On header This will allow the DP022 to turn on and off the motherboard by simulating a power button press POLARITY MATTERS HERE JP6 is a 10 pin polarized connector that is used for connection via serial line RS 232 to the COM port of the computer The DP022 uses the RTS CTS hardware handshaking of serial line flow control However the DP022 ignores signal on RTS line assuming that control computer is always ready to receive data Therefore really only four wire link is required SG Signal Ground SIN RD Serial Input Read of data SOUT TR Serial Output Transmit of data CTS Clear To Send Connect a 10 pin flat ribbon cable to COM port connector of your control computer RT1 2 pin connector is used to connect remote 0 4m temperature sensor thermistor Place remote thermistor at CPU heatsink of your computer Connect the ATX Power Connector JP8 to the motherboard and any peripherals to JP9 connector AT THE END Connect the IGNITION pin2 of JP12 to the switched 12 Volt supply wire ignition circuit or fuse box Do not connect IGNITION anywhere if you use the DP022 as a non vehicle PSU In this cas
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