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User Manual - Clyde Space

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1. BCR Battery Charge Regulator PCM Power Conditioning Module PDM Power Distribution Module MPPT Maximum Power Point Tracker USB Universal Serial Bus ESD Electro Static Discharge TLM Telemetry EPS Electrical Power System EoC End of Charge AMUX Analogue Multiplexer ADC Analogue to Digital Converter AIT Assembly Integration and Testing 1U 1 Unit Cubesat standard size 3U 3 Unit Cubesat standard size FleXU XU FleXible Unit suitable for various satellite configurations rh Relative Humidity Wh Watt Hour Ah Ampere Hour DoD Depth of Discharge Kbits Kilobits per second Voc Open Circuit Voltage Isc Short Circuit Current 2s1p Battery configuration 2 cells in series 1 battery in parallel single string 2s2p Battery configuration 2 cells in series 2 batteries in parallel 2s3p Battery configuration 2 cells in series 3 batteries in parallel PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 3 of 44 Street Glasgow G3 8JU Related Documents No Document Name Doc Ref RD 1 Battery board User Manual TBC RD 2 CubeSat Design Specification CubeSat Design Specification Rev 12 NASA General Environmental E fe fe E i RD 3 venan ndar GSFC STD 7000 April 2005 RD 4 CubeSat Kit Manual UM 3 RD 5 Solar Panel User Document TBC
2. ARRAVA_TEMP_TELEM ARRAYA Telemetry Table 8 5 Pin out for Header SA4 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System coni qT CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Street Glasgow G3 8JU Issue D Date 26 02 2015 Page 18 of 44 Pin Name Use Power RTN r GND connection Ground Line for Temp Sensor EMI v TEMP TELEM ARRAY5 dcin meo o Power RTN et ooo GND connection Ground Line for mo o Sensor ARRAYS TEMP TELEM TEMP TELEM ARRAY5 ARRAYSTelemetry Telemetry Table 8 6 Pin out for Header SA5 Pin Name Use m Power RTN ne GND connection Ground Line for e Sensor ARRAYG TEMP TELEM TEMP TELEM ARRAY6 ARRAYGTelemetry RE Power RTN E GND connection Ground Line for ae o Sensor Bee ARRAY6_TEMP_TELEM TEMP TELEM ARRAY6 ARRAYGTelemetry Telemetry 4 5W on CS XUEPS2 42A variant Table 8 7 Pin out for Header SA6 CS XUEPS2 42 only SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System S qT CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Street Glasgow G3 8JU Issue D Date 26 02 2015 Page 19 of 44 8 3 Solar Array Harness Clyde Space supply harnesses sold s
3. User Manual FleXible Electronic Power System CS XUEPS2 41 42 Document No USM 0002 Issue D Date 26 02 2015 Name Date Signed Author 30 07 2010 ALK PAL EEA Modified 26 02 2015 P V i Approved Alan Kane 26 02 2015 Clyde Space Ltd 5B Skypark 5 45 Finnieston Street Glasgow G3 8JU U K t 44 0 141 946 4440 e enquiries clyde space com w www clyde space com Registered in Scotland No SC285287 at 123 St Vincent Street Glasgow G2 5EA SOLUTIONS FOR A NEW AGE Ti USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 2 of 44 Street Glasgow G3 8JU Document Control Issue Date Section Description of Change Reason for Change A 22 07 10 All First Draft N A B 30 07 2010 Revision Control Rev B onwards only Telemetry equation changes 11 4 ADC conversion Equations Updated Improvement of telemetry circuit accuracy C 19 01 2015 11 2 and 11 3 Section 11 2 and 11 3 Readability minor updates D 26 02 2015 Several Updates throughout to Updated hardware build being in line with current standard build standard Revision Control Product Part Number Revisions covered Notes Cubesat FleXible Electronic CS XUEPS2 42 4 Large BCRs 2 Small BCRs Power System Cubesat FleXible Electronic CS XUEPS2 41 E 4 Large BCRs 1 Small BCR Power System Acronyms and Abbreviations
4. 02 2015 Page 24 of 44 Street Glasgow G3 8JU Option 1 CLYDE SPACE EPS SEPARATION SWITCH N E DUMMY_LOAD_ BATT POS CLYDE SPACE BATTERY Figure 8 8 Switch Configuration Option 1 Option 1 accommodates the CubeSat Kit bus available switches offering two stage isolation The separation switch provides isolation of the power buses during the launch The pull pin may be used for ground based isolation of the batteries though it does not provide any isolation during launch NOTE The second generation Clyde Space EPS has zero current draw when the pull pin is removed i e there will be no current drawn from the battery while on the launch vehicle When pull pin is inserted the battery is isolated from the output of the BCRs Under these conditions if power is applied to the input of the arrays or by connecting the USB there is a possibility of damaging the system In order to mitigate this risk a Dummy Load is fitted on the EPS Option 2 CLYDE SPACE EPS SEPARATION SWITCH 1 SEPARATION WITCH 2 BATT POS Figure 8 9 Switch Configuration Option 2 Option 2 is compatible with structures incorporating two separation switches providing complete isolation in the launch configuration The dummy load is not activated in this configuration SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d C USM 0002
5. 7 Cubesat Kit Header Pin Out HEADER 1 HEADER 2 Not Connected NC NotConnected NotConnected NC NotConnected NC NotConnected NotConnected NC NotConnected Not Connected ON NC NE NN NC us TU QJ Not Connected N 9 NC 10 11 11 12 12 13 13 14 14 15 Not Connected MEE 16 16 17 17 18 18 19 19 20 20 Oohm resistor 2 2 bod ot pido R265 must fit to 21 NC Not Connected Not Connected CLK connection operate Not Connected Not Connected 22 Not Connected Not Connected Oohm resistor 2 2 a pene sles R264 must fit to 23 NC Not Connected Not Connected DATA connection operate 24 24 Not Connected 25 Not Connected 25 5V BUS 5V Power bus Regulated 5V bus 26 Not Connected 26 5V BUS 5V Power bus Regulated 5V bus 3 NC Not Connected Not Connected 27 icd 3V3 Power Regulated 3V3 BUS bus bus 28 NC Not Connected Not Connected 28 FAN 3V3 Power Regulated 3V3 BUS bus bus Ground System power 29 NC Not Connected Not Connected 29 GND connection return d connection return NC Not Connected Not Connected 31 Not Connected Not Connected USB 5 USB 54v Use to charge 32 GND Ground System power battery via USB connection return BATT Pull pin normally P 2 BATT Pull pin normally 72 E EE PCM IN Power line Peper normaly connected pin EE PCM IN Power line SEP oe Dorma connected pin 37 Dummy Load Pull pin normally Protection open pin 38 Dummy Load Pull pin normally Protec
6. ADC Channels and Conversion Equations cccccccccsseccccssceceeececseececseceeeueceteueceseecesaueceseuecetsneeetees 35 12 co cere et er Te re er err re rr er re rrr rere 37 121 Power up Down Procedure is csecccsceccacianencadenatwcaceanmncadanseueac taauendalnaduadsataiunatennaeiseeceedteroccedeaeaveastecleesenee 37 L12 2 OAM AE V TODEIEesecremtebmdet N IA Naro esa A N bodatpderu Fir sesu A E VE NRR 38 DZ Ay SD r A OO A 39 124 CONMEUPATION and Testing 39 13 Developer AIT 42 14 Compatible SysStEIS cessum tesemI uin NI UR VEI I NERINU E NIE NE NEIN ANOIA AANT HIE 44 SOLUTIONSFORANEWAGEINSPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 ajn d 1 C USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 6 of 44 Street Glasgow G3 8JU 1 INTRODUCTION This document provides information on the features operation handling and storage of the Clyde Space FleXU EPS The FleXU EPS has been designed to be flexible to your satellite s power requirements providing four large BCRs for 4 8 cell solar panel pairs and either one or two small BCRs for 2 cell solar panel pairs The FleXU EPS will integra
7. Power System Design and Performance on the World s RD 6 Most Advanced In Orbit As named Nanosatellite Warning Risk Ensure headers H1 and H2 are correctly aligned If misaligned battery positive can short to before mating boards ground causing failure of the battery and EPS If power is applied with incorrect switch Ensure switching configuration is implemented configuration the output of the BCR can be correctly before applying power to EPS blown causing failure of the EPS and subsequent damage to the battery The battery is a static sensitive system Failure Observe ESD precautions at all times to observe ESD precautions can result in failure of the battery mE Exceeding any of the stated maximum limits can Ensure not to exceed the maximum stated limits B y result in failure of the battery If not fully isolated by switch configuration or separation the battery may over discharge resulting in failure of the battery Ensure batteries are fully isolated during storage battery bus should be made to pins H2 43 44 These headers have exposed live pins which H1 and H2 pins should not be shorted at any should not be shorted at any time Particular time care should be taken regarding the surfaces these are placed on The EPS includes a number of protection circuits for the battery Operation without these protections may lead to damage of the batteries Battery should only be operated when integrated with an EPS If the
8. SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d l D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 33 of 44 Street Glasgow G3 8JU 11 2 Command Summary Table 11 1 below provides a list of the commands for the EPS The data that should accompany the commands is included in the table Descriptions of the commands follow the table Command C T comana ip Value Range Description Name Decimal Read ADC Channel Request Status Bytes status WA PDM Off Turns off the selected PDM for a short time N A N A Table 11 1 Command Summary Status The status bytes are designed to supply operational data about the I C Node To retrieve the two bytes that represent the status the command 0x01 should be sent The meaning of each bit of the status byte is shown in Table 11 2 PDM Off There may be a time when the user wishes to turn of the PDM s for a short period They may wish to do this to create a hard reset of a circuit To carry this out the command 0x02 is sent followed by the data byte The data byte has a range of 0 to 7 Bit O corresponds to the battery bus bit 1 the 5V bus and bit 2 the 3 3V bus Any combination of busses can be turned off however is should be noted that if the user switches the 3 3V PDM off the I C node will be reset Version T
9. Sun 9 2 BCR Power Stage Overview As discussed in Section 8 the EPS has six separate independent BCRs each designed to interface to two parallel solar arrays configured to have a combined output of no greater than 12W e g a body mounted panel and deployed panel with cells facing the opposite direction Four 12W BCRs interface to the main body and deployed panels with 6 8 triple junction cells in series The two small 3W BCRs can interface to strings of 2 triple junction cells in series normally on the Z axis faces Each design offers a highly reliable system that can deliver up to 9096 of the power delivered from the solar array network at full load 12W BCR power stage The 12W BCR is a BUCK converter allowing the BCR to interface to strings of four to eight cells in series This will deliver up to 9096 output at full load The design will operate with input voltages between 10V and 24V and a maximum output of 8 26V 7 4V nominal 3W BCR Power Stage Design Each 3W BCR uses a high efficiency SEPIC converter interfacing to solar arrays of two triple junction cells in series This will deliver up to 8096 output at full load The BCR will operate with an input of between 3V and 6V and a maximum output of 8 26V 7 4V nominal 4 5W BCR Power Stage Design only present on BCR6 of CS XUEPS2 424A variant The 4 5W BCR uses a high efficiency SEPIC converter interfacing to solar arrays of up to three triple junction cells in series T
10. User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 25 of 44 Street Glasgow G3 8JU Care should be taken to ensure that the switches used are rated to the appropriate current levels Please contact Clyde Space for information on implementing alternative switch or dummy load configurations 8 9 Battery connection Connection of the battery systems on the FleXU EPS is via the Cubesat kit bus Ensure that the pins are aligned and located in the correct position as any offset can cause the battery to be shorted to ground leading to catastrophic failure of the battery and damage to the EPS Failure to observe these precautions will result in the voiding of any warranty When the battery is connected to the EPS the battery will be fully isolated until implementing and connecting a switch configuration as discussed in Section 8 8 Ensure that the battery is fully isolated during periods of extended storage When a battery board is connected to the CubeSat Kit header there are live unprotected battery pins accessible H2 33 34 These pins should not be routed to any connections other than the switches and Clyde Space EPS otherwise all protections will be bypassed and significant battery damage can be sustained 8 10 Buses All power buses are accessible via the CubeSat Kit headers and are listed and described in Table 8 8 These are the only power conne
11. battery is discharged to a voltage below Do not discharge batteries below 6V 6V the cells have been compromised and will no longer hold capacity If the battery is over discharged below 6V it should not be recharged as this may lead to cell rupture If batteries are over discharged DO NOT attempt to recharge These pins are used to connect the battery to No connection should be made to H2 35 36 the EPS Any connections to the unregulated SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 Issue D Date 26 02 2015 Page 4 of 44 B o eet 1 WIGAN CIO RR MP NER DOT QUEEN 6 1 1 A Additional Information Available Online eeeeseeeeeeeeeeeeeeeeeeeee nennen nennen nnns 6 1 2 Continuous ImptroVeliBlibossusins ue iS qEun Piu E SOY UIS IN REG RAE er VEPRIO UE seus nU US ENSRIU SduU PUN RN ERUIT END EES 6 1 3 D cumMent Ice T M 6 2 Qe 7 3 Maximum Ratings ERE TR 8 4 Electrical Characteristics coisasscuncearcsonayesshetanuscnawabanneonndonassawessbaveuatdadunloebsansanaganeiameoshabonataoonceanas 9 5 Handling and Storag E NETTE OO ETT 10 54 Electro Static Discharge ESD Protection ccsssccccccccseseecccceceeeseecceeeeeeeeeeceeseaeeecece
12. hardware or software of the I C master being used as the OBC however the user should ensure that this is the case The read and write command definitions are illustrated in Table 11 1 Address Byte wht S 7 bit node address Command eas S 7 bit node address Command A A Command Parameter A W Reply MSB Reply LSB py fe S Start Condition P Stop Condition Lj Transmitted from Master OBC A Acknowledge W Write bit N Not Acknowledged R Read bit RA Transmitted from Slave TTC node Table 11 1 IC Write and Read command packets An example of using the read and write commands is provided below In this example the OBC is requesting a telemetry reading of the solar array 2 input voltage Address Byte Byte 1 Byte 2 Address 0x2B write flag Command type 0 read ADC ADC Channel 5 Array 2 V BUS slo 1 0 4 011 W o o o o 0o 0o o 0RMM000001 01 Command Delay gt 1 2ms ADC result LSB Address 0x2B read flag ADC result MSB ADC total 402 Read SI O 1 O 1 O0 1 1 1 AYT a O 0p een NU Command S Start Condition P Stop Condition Transmitted from Master OBC A Acknowledge W Write bit N Not Acknowledged R Read bit B transmitted from Slave TTC node If a read message which does not have a preceding write message is received by the telemetry node the value OxFOOO is returned All bit level communication to and from the board is done by sending the MSB first SOLUTIONS FOR A NEW AGE IN
13. l HO8 l WIL WIL l l z l l H1 32 5v USB H2 41 44 BCR_OUT Figure 7 2 Function Diagram www clyde space com Clyde Space Limited 2015 SOLUTIONS FOR A NEW AGE IN SPACE PROPRIETARY amp CONFIDENTIAL INFORMATION ajea 4d D USM 0002 User Manual FleXible Electronic Power System T CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 14 of 44 Street Glasgow G3 8JU 7 2 Autonomy and Redundancy All BCR power stages feature full system autonomy operating solely from the solar array input and not requiring any power from the battery systems This feature offers inbuilt redundancy since failure of one BCR does not affect remaining BCRs Failure of the all strings of the battery any of the CS SBAT2 xx range will not damage the BCRs but due to the MPPT will result in an intermittent interruption on all power buses approximately every 2 5 seconds Failure of one battery on the CS SBAT 20 or two batteries on the CS SBAT2 30 will not damage the BCRs and the system can continue to operate with a reduced capacity of 10Wh The rest of the power system is a robustly designed single string 7 9 Quiescent Power Consumption All power system efficiencies detailed for BCRs and PCMs takes into consideration the associated low level control electronics As such these numbers are not included in the quiescent power consumption figures The I C node is the
14. only circuitry not covered in the efficiency figures and has a quiescent power consumption of 0 1W which is the figure for the complete EPS 7 4 Mass and Mechanical Configuration The mass of the system is approximately 133g and is contained on a PC 104 size mother card and mounted daughter card compatible with the Cubesat Kit bus Other versions of the EPS are available without the Cubesat Kit bus header 85 73 95 89 SA6 only available on CS XU EPS2 42 and CS XU EPS2 42A Figure 7 3 Board dimensions mm SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 15 of 44 Street Glasgow G3 8JU 8 INTERFACING The interfacing of the EPS is outlined in Figure 8 1 including the solar array inputs connection to the switch configuration output of the power buses and communication to the I C node In the following section it is assumed that the EPS will be integrated with a Clyde Space Battery CS SBAT2 xx and or CS RBAT2 10 MSCROUT Ji PCM INE 8 Switch Configuration As Defined By User BATT POS TELEMETRY Figure 8 1 Clyde Space EPS and Battery Simplified Connection Diagram 8 1 Connector Layout The
15. should also be isolated from the BCRs during launch in order to conform to CubeSat standard RD 2 CLYDE SPACE EPS User Defined Switch Configuration BATT POS Figure 8 7 Switch connection points Dummy Load The Dummy Load is available as an additional ground support protection system providing a load for the BCRs when the pull pin is inserted using the normally open NO connection of the Pull Pin By connecting this Dummy Load to the NO pin BCR damage can be circumvented The wiring arrangement for the dummy load is indicated in Figure 8 8 The load protects the battery charge regulator from damage when the USB or array power is attached and the batteries are not connected This system is not operational during flight and is only included as a ground support protection The Clyde Space Dummy Load system has been a standard feature from revision D of the EPS onwards If the Dummy Load is required for an earlier revision please contact Clyde Space for fitting instructions Options 1 and 2 below are two suggested methods of switch configuration but are by no means exhaustive If you wish to discuss other possible configurations please contact Clyde Space SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 an d D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26
16. to initiate an event and the read command returns the result All commands start with the 7 bit slave address and are followed by two data bytes When reading data responses both data bytes should be read together A delay of at least 1 2ms should be inserted between sending a command and reading the telemetry response This is required to allow the microcontroller to select the appropriate analogue channel allow it to settle and then sample the telemetry reading In a write command the first data byte will determine the command to be initiated and the second data byte will hold a parameter associated with that command For commands which have no specific requirement for a parameter input the second data byte should be set to OxOO In a read command the first data byte represents the most significant byte of the result and the second data byte represents the least significant byte Before sending a command the master is required to set a start condition on the I7C bus Between each byte the receiving device is required to acknowledge receipt of the previous byte in accordance with the l C protocol This will often be accommodated within the SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 32 of 44 Street Glasgow G3 8JU driver
17. 8JU CS XUEPS2 42 only CS XUEPS2 42 only CS XUEPS2 42 only Issue D Date 26 02 2015 Page 36 of 44 Array 6 0 586510 x ADC 273 15 Temperature 28 Array 6 Current 2 6685293 x ADC 2115 99 Array 6 0 586510 x ADC 273 15 oC Temperature 3 3V Bus Current 6 2881776 x ADC 4994 22 mA Sense 5V Bus Current 6 2881776 x ADC 4994 22 Sense T 6 2881776 x ADC 4994 22 Current Sense k mA Table 11 3 ADC Channels SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d 1 C USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 37 of 44 Street Glasgow G3 8JU 12 TEST All EPS are fully tested prior to shipping and test reports are supplied In order to verify the operation of the EPS please use the following outlined instructions Step by step intro of how to connect and verify operation In order to test the functionality of the EPS you will require EPS Battery or simulated battery Breakout Connector with connections as per Figure 12 1 Array Input test panel solar array simulator or power supply and limiting resistor Oscilloscope Multimeter Electronic Load Aardvark l C connector or other means of communicating on the l C bus CLYDE SPACE 3U EPS 10 e SEPARATION SWITCH Array Input NE
18. Date 26 02 2015 Page 22 of 44 Street Glasgow G3 8JU HEADER 1 50 50 51 Not Connected ES 52 Not Connected 52 Table 8 8 Pin Descriptions for Header H1 and H2 NODE HEADER CUBESAT KIT NAME NOTES 5V BUS 2 25 26 5V Regulated Bus Output 3 3V BUS 2 27 28 VCC SYS 3 3V Regulated Bus Output BATT POS 2 33 34 PCM IN DUMMY LOAD 2 37 38 N C Unused connection of launch switch closed state BCR OUT 2 41 44 Output of BCRs gt Switches BCR OUT S Output of BCRs gt Switches BATTERY BUS 2 45 46 VBATT Battery Unregulated Bus Output Table 8 9 Header pin name descriptions relating CubeSat Kit names to CS names Positive Terminal of Battery not Battery Bus DO NOT CONNECT Switches N C Switches gt Input to PCMs and PDMs S S S Switches S S 1 2 3 4 5 W W W W W W SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 23 of 44 Street Glasgow G3 8JU 8 8 Switch Options The Clyde Space EPS has three connection points for switch attachments as shown in Figure 8 7 There are a number of possible switch configurations for implementation Each configuration must ensure the buses are isolated from the arrays and battery during launch The batteries
19. FORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System coni CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Street Glasgow G3 8JU Issue D Date 26 02 2015 Page 17 of 44 Name C REN NN Power RTN fe uiE GND Ground Line connection for Temp Sensor EUN oo TEMP TELEM Array1 sinn ooo Power RTN Me EE GND Ground Line connection for aa Sensor ARRAY1 TEMP TELEM TEMP TELEM Array1 AmaylTelemery Telemetry Name UC NEN ARRAY 120 zm Power RTN EN GND Ground Line connection for Temp Sensor meme n TEMP TELEM ARRAY2 Telemetry sae ARRAY 12W zm Power RTN fev GND Ground Line connection for e Sensor ARRAY2 TEMP TELEM TEMP TELEM ARRAY2 ARRAY2Telemetry Telemetry 00 Table 8 3 Pin out for Header SA2 Name Use ae ARRAY3 12W Power Line Power 0 000000 Power RTN and GND connection Ground Line for Temp Sensor Lum TEMP TELEM ARRAY3 Ae 3 E ARRAY3 Q2W 12W Power Powerline si Power sd Power RTN and GND connection Ground Line for Temp Sensor FM nv TEMP TELEM ARRAY3 Telemetry Telemetry Table 8 4 Pin out for Header SA3 Name Use je Power RTN P GND connection Ground Line for e 3 Sensor ARRAY4_TEMP_TELEM TEMP TELEM ARRAY4 ARRAYATelemetry uu Power RTN GND connection Ground Line for Temp Sensor
20. Output Voltage Output Current Operating Frequency Efficiency 5V Bus Output Voltage Output Current Operating Frequency Efficiency 3 3V Bus Output Voltage Output Current eh o l A Operating Frequency 470 480 490 kHz Efficiency 3 3V input Full Load 9596 9796 Communications 3 3V 3 33V E es s Address scheme p Ue Quiescent Operation Physical Height from top of PCB to Dimensions bottom of next PCB in stack 95 15 24 mm l Table 4 1 Performance Characteristics of the FleXU EPS2 Protocol Transmission speed vp s Bus voltage Node address Flight Power Draw Switches Configuration 1 BCR6 can tolerate inputs of up to 9 18V on CS XUEPS2 42A variant SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d C USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 10 of 44 Street Glasgow G3 8JU 5 HANDLING AND STORAGE The EPS requires specific guidelines to be observed for handling transportation and storage These are stated below Failure to follow these guidelines may result in damage to the units or degradation in performance 5 1 Electro Static Discharge ESD Protection The EPS incorporates static sensitive devices and care should be taken during handling Do not t
21. R5 3W SA6 pin 1 or pin 4 BCRG BW wy 8 wm PCS Notes Value Input Current Battery Bus 8 26V Output Current 5V Bus 3 3V Bus c ct 3 gt gt gt g W W lt 4 4 Operating Temperature 40 to 85 C Storage Temperature 50 to 100 C Vacuum 10 torr Radiation Tolerance TBC kRad Shock TBC Vibration To RD 3 Table 3 1 Max Ratings of the FleXU EPS2 1 Stresses beyond those listed under maximum ratings may cause permanent damage to the EPS These are the stress ratings only Operation of the EPS at conditions beyond those indicated is not recommended Exposure to absolute maximum ratings for extended periods may affect EPS reliability 2 De rating of power critical components is in accordance with ECSS guidelines 3 BCR 6 only available on CS XUEPS2 42 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 9 of 44 Street Glasgow G3 8JU 4 ELECTRICAL CHARACTERISTICS Description Conditions i Typical Max 12W BCR 1 4 Input Voltage Output Voltage Output Current Switching Frequency Efficiency 3W BCR 5 6 Input Voltage Output Voltage Output Current Operating Frequency Efficiency Unregulated Battery Bus
22. SM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 31 of 44 Street Glasgow G3 8JU 11 TELEMETRY AND TELECOMMAND The telemetry system monitors certain stages of the power system and allows a small degree of control over the PDM stages The telemetry system transfers data via an lC bus The telemetry system operates in slave mode and requires an I C master to supply commands and the clock signal Control systems within the EPS offer the user the ability to temporarily isolate the EPS buses from the on board computer systems ARRAY Sense voltage VBAT PDM Sensing Current Sensing 5V PDM Current ARRAY Sense n voltage i anco mM Sensing 3 3V ARRAY Sense Current PDM voltage 8 pa BCR6 Sense gt x N cC x current jd temperture 2 FC databus PC NODE ees Signal line Control line Figure 11 1 Telemetry functional diagram 11 1 12C Node All communications to the Telemetry and Telecommand TTC node are made using an I C interface which is configured as a slave and only responds to direct commands from a master I C node no unsolicited telemetry is transmitted The 7 bit I C address of the TTC Node is factory set at Ox2B and the l C node will operate at up to 100kHz bus clock Command Protocol Two message structures are available to the master a write command and a read command The write command is used
23. TML CVCM WVR Application 2 1B31 Acrylic Humiseal 3 89 0 11 Conformal Coating 3 DC6 1104 Dow Corning 0 17 0 02 Adhesive fixing on modifications 4 Stycast 4952 Emerson amp 0 42 0 17 0 01 Thermally Cuming Conductive RTV 5 PCB material FR4 0 62 0 1 Note worst case on NASA out gassing list Solder Resist CARAPACE 0 95 0 02 0 31 EMP110 or or 0 995 Or 0 001 XV501T 4 7 Solder Sn62 or Sn63 Tin Lead Flux Alpha Rosin Note ESA Flux RF800 Recommended ROLO Table 6 1 Materials List Part ame eJ Manufacturer Contact Insulator cr DF13 6P 1 25DSA 50 Hirose Gold Plated Polyamide Solar Array Connectors ESQ 126 39 G D Samtec Gold Plated Black Glass Filled CubeSat Kit Polyester Compatible Headers DF13 6S 1 25C Hirose N A Polyamide Crimp Housing Harness for Solar Arrays sold separately DF13 2630SCFA 04 Hirose Gold Plated N A Harness for Solar Arrays sold separately Table 6 2 Connector Headers 6 2 Processes and Procedures All assembly is carried out and inspected to ESA Workmanship Standards ECSS Q ST 70 O8C and ECSS Q ST 70 38C SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 SPACE USM 0002 User Manual FleXible Electronic Power System Adel T CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 12 of 44 Street Glasgow G3 8JU 7 SYSTEM DESCRIPTION The Clyde Space Fle
24. XU EPS is optimised for Low Earth Orbit LEO missions with a maximum altitude of 850km The EPS is designed for integration with spacecraft that have multiple solar panels which may be configured in a number of different ways with a maximum of four pairs of 4 8 cell panels and two pairs of 2 cell panels one 2 cell and one 3 cell for the CS XUEPS2 42A variant of the EPS Pairs should be arranged so that at any given time the panel pair cannot output any greater than 12W for the large panels and 3W for the small panels 4 5W on SA6 for the CS XUEPS2 42A variant of the EPS The EPS can accommodate various solar panel configurations and has been designed to be versatile please consult our support team if you have specific requirements for connecting the EPS to your spacecraft The Clyde Space EPS connects to the solar panels via 5 6 independent Battery Charge Regulators BCRs Each BCR can be connected to two solar arrays in parallel provided the connected panels cannot output a power greater than 12W for BCRs 1 4 and 3W for BCRs 5 and 6 4 5W on SA6 for the CS XUEPS2 42A variant of the EPS There are a number of possible configurations that can be used depending on the deployment configuration Please contact Clyde Space to discuss possible configurations Each of the BCRs has an inbuilt Maximum Power Point Tracker MPPT This MPPT will track the dominant panel of the connected pair the directly illuminated panel The output of all BCRs are t
25. ble Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 42 of 44 Street Glasgow G3 8JU 13 DEVELOPER AIT AIT of the EPS with other CubeSat modules or subsystems is the responsibility of the CubeSat developer Whilst Clyde Space outlines a generic process which could be applicable to your particular system in this section we are not able to offer more specific advice unless integration is between other Clyde Space products or those of compatible products see Table 14 1 AIT is at the risk of the developer and particular care must be taken that all subsystems are cross compatible Throughout the AIT process it is recommended that comprehensive records of all actions be maintained tracking each subsystem specifically Photo or video detailing of any procedure also helps to document this process Comprehensive records are useful to both the developer and Clyde Space in the event of any anomalies complete and rapid resolution will only be possible if good records are kept The record should contain at least e Subsystem and activity e Dates and times of activity start finish key milestones e Operator s and QAs e Calibration of any equipment e Other subsystems involved e Method followed e Success condition or results e Any anomalous behaviour Before integration each module or element should undergo an acceptance or pre integration review to ensure that the develope
26. circuitry moves the solar array operation point away from the maximum power point of the array drawing only the required power from the panels The excess power is left on the arrays as heat which is transferred to the structure via the array s thermal dissipation methods incorporated in the panels The operation of these two modes can be seen in Figure 9 1 9 4 i r 1 2 end of charge voltage i pom 8 5 i voltage at 8 2V H i 1 8 Jj 0 8 7 5 4 0 6 7 lt o a 6 5 taper charge end of 04 3 discharge z gt voltage YU 6 0 2 constant current 55 1 charge again constant current discharge 0 5 charge mode on orbit charge current is proportional to solar panel illumination 0 2 4 5 4 conditions 4 0 4 0 5000 10000 15000 20000 25000 30000 Time s Figure 9 1 Tapered charging method SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System cS qT CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 27 of 44 Street Glasgow G3 8JU The application of constant current constant voltage charge method on a spacecraft is described in more detail in RD 6 In this document there is on orbit data showing the operation and how the current fluctuates with changing illumination conditions and orientation of the spacecraft with respect to the
27. connector positions are shown in Figure 7 3 and described in Table 8 1 Function SAS CS XUEPS2 42A variant EPS CS XUEPS2 42 and CS XUEPS2 42A only SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System tuni qT CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Street Glasgow G3 8JU Issue D Date 26 02 2015 Page 16 of 44 Table 8 1 Connector functions 8 2 Solar Array Connection The EPS has 5 6 connectors for the attachment of solar arrays This interface accommodates inputs from the arrays with temperature telemetry for each Max Cells E CLYDE SPACE EPS Figure 8 2 Solar Array Configuration HIROSE DP12 6P 1 25 DSA connector sockets are used on the EPS These are labelled SA1 SA6 SA1 SA4 are routed to BCR1 BCR4 respectively These BCRs are capable of interfacing to 12W panels and should be harnessed to arrays with between 4 8 triple junction solar cells in series SA5 SA6 route to BCR5 BCR6 respectively each of which are 3W BCR6 is 4 5W on CS XUEPS2 42A variant channels that should be harnessed to the small arrays The array lengths should be the same on joined panels with 2 cells each 3 cells possible on SA6 with CS XUEPS2 42A variant aN UAOO Figure 8 3 Solar Array Pin Numbering SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL IN
28. ctions that should be used by the platform since they follow all battery and bus over current protections All IC communications can are accessible via the CubeSat kit header See Section 11 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d m D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 26 of 44 Street Glasgow G3 8JU 9 TECHNICAL DESCRIPTION This section gives a complete overview of the operational modes of the EPS It is assumed that a complete Clyde Space system EPS Batteries and Solar panels is in operation for the following sections 9 1 Charge Method The BCR charging system has two modes of operation Maximum Power Point Tracking MPPT mode and End of Charge EoC mode These modes are governed by the state of charge of the battery MPPT Mode If the battery voltage is below the preset EoC voltage the system is in MPPT mode This is based on constant current charge method operating at the maximum power point of the solar panel for maximum power transfer EoC Mode Once the EoC voltage has been reached the BCR changes to EoC mode which is a constant voltage charging regime The EoC voltage is held constant and a tapering current from the panels is supplied to top up the battery until at full capacity In EoC mode the MPPT
29. down This is controlled by a comparator circuit with hysteresis In the event of the battery discharging to 6 2V slightly above the 6 1V that results in significant battery degradation the EPS will shut down the supply buses This will also result in the C node shutting down When a power source is applied to the EPS e g an illuminated solar panel the battery will begin charging immediately The buses however will not reactivate until the battery voltage has risen to 7V This allows the battery to charge to a level capable of sustaining the power lines once a load is applied It is recommended that the battery state of charge is monitored and loading adjusted appropriately turning off of non critical systems when the battery capacity is approaching the lower limit This will prevent the hard shutdown provided by the EPS Once the under voltage protection is activated there is a monitoring circuit used to monitor the voltage of the battery This will draw approximately 2mA for the duration of shutdown As the EPS is designed for LEO orbit the maximum expected period in under voltage is estimated to be 40mins When ground testing this should be taken into consideration and the battery should be recharged within 40mins of reaching under voltage otherwise permanent damage may be sustained SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d 1 C U
30. e Array 2 Current 2 6685293 x ADC 2115 99 Array 2 0 586510 x ADC 273 15 Temperature C C C co C Co Array 3 Voltage 0 0216486 x ADC 25 0947 Array 3 Current 2 6685293 x ADC 2115 99 Array 3 0 586510 x ADC 273 15 Temperature Array 3 Current 2 6685293 x ADC 2115 99 7 m m e RA Array 3 0 586510 x ADC 273 15 Temperature Array 4 Voltage 0 0216486 x ADC 25 0947 m D 3 Array 4 Current 2 6685293 x ADC 2115 99 Array 4 0 586510 x ADC 273 15 Temperature Array 4 Current 2 6685293 x ADC 2115 99 Array 4 0 586510 x ADC 273 15 Temperature Array 5 Voltage 0 0216486 x ADC 25 0947 Array 5 Current 2 6685293 x ADC 2115 99 Array 5 0 586510 x ADC 273 15 Temperature Array 5 Current 2 6685293 x ADC 2115 99 Array 5 0 586510 x ADC 273 15 Temperature Array 6 Voltage 0 0216486 x ADC 25 0947 Array 6 Current 2 6685293 x ADC 2115 99 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 IB on C HB m Co oe C 7 N IB C N HP N W A A A A A C A A A A A N UJ NA DA C Ul m m V m m V m m 6 V m m V m m V CS XUEPS2 42 only m d A CS XUEPS2 42 only USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Street Glasgow G3
31. ections of the battery cells within the battery system e g 2s1p indicates a single string of two cells in series 2 Will require some alteration to MPPT Please contact Clyde Space SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015
32. ee i y P DUMMY LOAD ULL PIN ELECTRONIC LOAD BATT POS BATTERY Figure 12 1 Suggested Test Setup The breakout connector should be wired with the switch configuration to be used under mission conditions 12 1 Power up Down Procedure The order of assembly should follow the order detailed below e Breakout connector assembled with switches set to launch vehicle configuration as shown in Figure 12 1 Fit Breakout connector to EPS Connect battery to stack Connect electronic load no load to buses Remove Pull Pin Activate Separation Switch Connect array input When powering down this process should be followed in reverse SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System coni qT CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 38 of 44 Street Glasgow G3 8JU 12 2 Solar Array Input There are 3 options for the array input section e Asolar array e Asolar array simulator e Abenchtop power supply with current limiting resistor When using a solar array or solar array simulator the limits should not exceed those outlined in Table 12 1 Isc mA Table 12 1 solar array limits When using a power supply and resistor setup to simulate a solar panel the required setup is shown in Figure 12 2 Array Input CLYDE SPACE XU EPS Power Supply Se
33. eparately to connect the solar panels to the EPS comprising two Hirose DF13 6S 1 25C connected at each end of the cable one end connects to the EPS with two halves of the harness connecting to opposing solar panels Clyde Space solar arrays use Hirose DF13 6P 1 25H as the interface connector to the harness 8 4 Temperature sensing interface Temperature sensing telemetry is provided for each solar array connected to the EPS A compatible temperature sensor LM335M is fitted as standard on Clyde Space solar arrays for non Clyde Space panels refer to section 8 5 The output from the LM335M sensor is then passed to the telemetry system via on board signal conditioning Due to the nature of the signal conditioning the system is only compatible with zener based temperature sensors i e LM335M or equivalent Thermistor or thermocouple type sensors are incompatible with the conditioning circuit CLYDE SPACE EPS Figure 8 4 Temperature sensor block diagram 8 5 Non Clyde Space Solar Arrays When connecting non Clyde Space solar arrays care must be taken with the polarity Pins 1 2 and 3 are for array and pins 4 5 and 6 relate to the opposite array Cells used should be of triple junction type If other cells are to be interfaced please contact Clyde Space SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 Pp USM 0002 User Manual FleXible Electronic Power S
34. eseuaneeeeeeeeeas 10 S2 General Handling sea Tm 10 Did Shipping and SPOLdBB Gies ci i a a a EAA RETA 10 6 Materials and PrOCESSES snis csneccncannaesdsnacensdoaacinrsionanndeershaconicuswnasaencdsamesusonanceneoncusadoanasdonsdadans 11 bu IVA Se SSS sastoan E Ea eE eTa aae A a E ceetecene 11 62 Processes and Procedure S pias cinco nec ire E ENEE T 11 7 System Description ssesssessessessessrrsrrssrsseesresressesseosresreosesseosresreeseoseeseoseosseeseoseesreereeseeseeee 12 7 1 System Overview ssssssesssessesssessersressessresrrssessresseessresersseesersseesereseesrrsseeserssersreeseessesserssessereseesereseest 13 75 2 Autonomy and Regubddlib ueuerasscstsea ui ek keiner EEr NENA EEEE ESEE AE E EANES EENES 14 7 3 Quiescent Power Consumption ssccscesssissrisiepesier is eaen ieran IAEE EE NNE EEE AEE EE S EKSAN UN ai 14 7 4 Mass and Mechanical Configuration ssesisrescssscisrcrrrsicrerrrcirsserrraressrssirserrissrarsrrirsserrioseisisdrsisraratsias 14 8 Ini M a RR EE A A E E E A A A A 15 8 1 CONECTO LVO EOE 15 8 2 Solar Array Connection REM 16 Soa SPAN INES r TN 19 8 4 Temperature sensing INTEFFACE ccccccccsssccccsssecceceeseececeeseccessuueecesseaeeeessuaeecessueaeceesaeeeceesaeaeeessaganses 19 8 5 Non Clyde Space Solar ArrayS ccccsssscccccssccecsesseccccessecccseeececsuaseceesueeceesueseceeseeueceessaaeceesaueeceesaggeses 19 8 6 CubeSat Kit Compatible Headers s
35. h I C Overflow No I C Overflow Overflow D ui Write Bit cleared when read Received Message to Long IC Write Collision No I C Write Collision T Occurred I2C Error Bit cleared IC Error No I C Errors isi Occurred when read Table 11 2 Status Bytes SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 35 of 44 Street Glasgow G3 8JU 11 8 ADC Channels and Conversion Equations Each of the analogue channels when read returns a number between 0 1023 To retrieve the value of the analogue signal this number ADC is to be entered into an equation When the equation is used the value calculated is the value of the input analogue signal Table 11 4 contains example equations of the conversions of each of the channels To get more accurate equations a full calibration test should be carried out Signal Approx Conversion Equations Units Notes Array 1 Voltage 0 0216486 x ADC 25 0947 V Array 1 Current 2 6685293 x ADC 2115 99 Array 1 0 586510 x ADC 273 15 Temperature Array 1 Current 2 6685293 x ADC 2115 99 Array 1 0 586510 x ADC 273 15 Temperature Array 2 Voltage 0 0216486 x ADC 25 0947 Array 2 Current 2 6685293 x ADC 2115 99 Array 2 0 586510 x ADC 273 15 Temperatur
36. he firmware version number can be accessed by the user using this command Please contact Clyde Space to learn the version number on your board WatchDog The Watchdog command allows the user to force a reset of the I C node If the user detects or suspects an error in the operation of the l C node then this command should be issued When issued the l C node will reset and return to an initial state SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 34 of 44 Street Glasgow G3 8JU Byte Bit Description If Low 0 If High 1 Note Brown Reset No Brown Out Bit cleared Brown Out Reset Occurred Occurred Reset Occurred when read Power Reset Power Bit cleared P R m DISCUS PII Occurred m Ped Watchdog Reset Bit cleared 5 Watchdog Reset Occurred No Watchdog Reset B Occurred when read External Oscillator External 4 Oscillator bit x B S failure MSB Not Used ree as ADC Result N B ADC Result Not Ready ADC Result Ready C Result Not Bit cleared Ready when read Last Command Unknown Command Value Last Command Value OK Value Out of Range Unknown Command Type Last command OK Last Command Bit cleared Unknown when read i LE Received Messages Last Message Correct Length incorrect Lengt
37. hen connected together and via the switch network described in Section 7 2 supply charge to the battery Power Conditioning Modules PCMs and Power Distribution Modules PDMs via the switch network The PCM PDM network has an unregulated Battery Voltage Bus a regulated 5V supply and a regulated 3 3V supply available on the satellite bus The EPS also has multiple inbuilt protection methods to ensure safe operation during the mission and a full range of EPS telemetry via the l C network These are discussed in detail in Sections 10 and 11 respectively Figure 7 1 Some Possible Array Configuration SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 oO 41 Uu gt un il oO O A YL O il 41 UO a LLI E 2 gt x lt a LL To il oO Ww USM 0002 N ki T T N un a LLI un UO 5B Skypark 5 45 Finnieston Street Glasgow G3 8JU Page 13 of 44 Date 26 02 2015 Issue D System Overview 7 1 Wadangoz 9poN el UNDER VOLTAGE CTRL DBuisues uang He qA lt lt co O o cp n oz OnE ND YS 2 lo l FOIT Dopa em 85 O N II ai E al Lr SM I lt a MAAAAAL Le x E H2 29 31 32 GND ADYVHO JO QN3 zp zSd3nX So uo Auo 9uog ONISN3S ee ci l GHog ONISN3S e AVHHV
38. his will deliver up to 8096 output at full load The BCR will operate with an input of between 3V and 9 18V and a maximum output of 8 26V 7 4V nominal 9 3 MPPT Each of the BCRs can have two solar arrays connected at any given time only one array can be illuminated by sunlight although the other may receive illumination by albedo reflection from earth The dominant array is in sunlight and this will operate the MPPT for that BCR string The MPPT monitors the power supplied from the solar array This data is used to calculate the maximum power point of the array The system tracks this point by periodically adjusting the BCRs to maintain the maximum power derived from the arrays This technique ensures that the solar arrays can deliver much greater usable power increasing the overall system performance SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 28 of 44 Street Glasgow G3 8JU Increasing Temperature Maximum Power Point 2 3 Array Current Increasing Temperature Array Voltage Figure 9 2 Solar Array Maximum Power Point The monitoring of the MPP is done approximately every 2 5 seconds During this tracking the input of the array will step to o c voltage as s
39. hown in Figure 9 3 Noise Filter Off 400rns I EE atm oe Figure 9 3 Input waveform with Maximum Power Point Tracking 9 4 5V and 3 3V PCM The 5V and 3 3V regulators both use buck switching topology regulators as their main converter stage The regulator incorporates intelligent feedback systems to ensure the voltage regulation is maintained to 196 deviation The efficiency of each unit at full load is approximately 9696 for the 5V PCM and 9596 for the 3 3V PCM Full load on each of the regulators is a nominal output current of 4A Each regulator operates at a frequency of 480 kHz SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 29 of 44 Street Glasgow G3 8JU 10 GENERAL PROTECTION The EPS has a number of inbuilt protections and safety features designed to maintain safe operation of the EPS battery and all subsystems supplied by the EPS buses 10 1 Over Current Bus Protection The EPS features bus protection systems to safeguard the battery EPS and attached satellite sub systems This is achieved using current monitors and a shutdown network within the PDMs Over current shutdowns are present on all buses for sub system protection These are solid state switches that monitor the current and shutdown a
40. hown in Table 13 2 ID Requirement Procedure Result X Success Compliance iteri criteria eae ain SYS 0030 The system mass shall TEST 01 0 957 kg X lt 1kg PASS be no more than 1 kg SYS 0040 The error LED remains TEST 02 LED flashing LED off FAIL off at initialisation Table 13 2 Compliance matrix example All procedural plans carried out on the EPS should conform to the test setups and procedures covered in Section 12 During testing it is recommended that a buddy system is employed where one individual acts as the quality assurance manager and one or more perform the actions working from a documented and reviewed test procedure The operator s should clearly announce each action and wait for confirmation from their QA This simple practice provides a useful first check and helps to eliminate common errors or mistakes which could catastrophically damage the subsystem Verification is project dependant but should typically start with lower level subsystem specific requirements which can be verified before subsystems are integrated in particular attention should be paid to the subsystem interfaces to ensure cross compatibility Verification should work upwards towards confirming top level requirements as the system integration continues This could be achieved by selecting a base subsystem such as the EPS OBC or payload and progressively integrating modules into a stack before structural integration Dependent upon the specif
41. ic systems and qualification requirements further system level tests can be undertaken When a subsystem or system is not being operated upon it should be stowed in a suitable container as per Section 5 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 44 of 44 Street Glasgow G3 8JU 14 COMPATIBLE SYSTEMS Compatibility Notes CubeSat Kit Bus CubeSat Kit definition pin compatible ual Non standard Wire Connector User defined Connector Other Connectors Please contact Clyde Space Clyde Space Battery Systems 10W hr 30 W hr Lithium lon Polymer CS SBAT2 10 20 30 CS RBAT2 10 Lithium Polymer 8 2v 2s1p to 253p Batteries More strings can be connected in parallel to increase capacity if required Lithium lon 8 2v 2s1p to 2s3p More strings can be connected in parallel to increase capacity if required Clyde Space 3W solar array Connects to BCRs 4 amp 5 via SA4 amp 5 Clyde Space 12W solar array Connects to BCR 1 4 via SA1 4 12W triple junction cell arrays Other array technologies Any that conform to the input ratings for Voltage and Current CubeSat 3U structure with deployable Structure ISIS CubeSat 3U compatible with deployable Table 14 1 Compatibilities 1 Refers to series and parallel conn
42. measured with a multimeter By increasing the load on each of the buses you will be able to see the current trip points activation as discussed in Section 10 1 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d q C USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 40 of 44 Street Glasgow G3 8JU Undervoltage Protection When using a simulated battery it is possible to trigger the undervoltage protection Using the same test setup as detailed above with a simulated battery if the voltage is dropped to below 6 2V the undervoltage will be activated This can be observed by the power buses shutting down Note This test takes the battery to 10096 DoD and should always be followed by a charge cycle BCR Testing In order to test the operation of the BCRs the separation switches should be moved to flight configuration as shown in Figure 12 5 with the pull pin still removed Once this is done the array input can be connected CLYDE SPACE EPS BCR OUT SEPARATION 4 SWITCH 7 BCR wem Array Input DUMMY LOAD PULL PIN BATT POS ELECTRONIC LOAD BATTERY Figure 12 5 Test set up in Flight Configuration To check the operation of the BCR MPPT an oscilloscope probe should be placed at pin 1 of the active solar array connector n
43. ot at the power supply The wave form should resemble Figure 12 6 Noise Filter Off 400rns I BEE atm oe Figure 12 6 Waveform of Solar Array Input SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d 1 C USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 41 of 44 Street Glasgow G3 8JU EoC Operation Using the test setup detailed in Figure 12 5 the EoC operation can be demonstrated By raising the voltage of the simulated battery above 8 26V the EoC mode will be activated This can be observed using an ammeter coming from the Array input which will decrease towards OA it will never actually reach OA closer to 10mA as the BCR low level electronics will still draw form the array 5V USB Charging Figure 12 7 shows the test setup for the 5V USB charging CLYDE SPACE EPS 5V USB TeWeljM SEPARATION J Charging H1 32 SWITCH N Power Supp 5V 1 2A DUMMY LOAD L PULL PIN BATT POS ELECTRONIC LOAD BATTERY Figure 12 7 5V USB charge setup This setup should only be used for top up charge on the battery not for mission simulation testing SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d C USM 0002 User Manual FleXi
44. ouch the EPS without proper electrostatic protection in place All work carried out on the system should be done in a static dissipative environment 5 2 General Handling The EPS is designed to be robust and able to withstand flight conditions However care must be taken when handling the device Do not drop the device as this can damage the EPS There are live connections between the battery systems and the EPS on the CubeSat Kit headers All metal objects including probes should be kept clear of these headers Gloves should be worn when handling all flight hardware Flight hardware should only be removed from packaging in a class 100000 or better clean room environment 5 9 Shipping and Storage The devices are shipped in anti static vacuum sealed packaging enclosed in a hard protective case This case should be used for storage All hardware should be stored in anti static containers at temperatures between 20 C and 40 C and in a humidity controlled environment of 40 6096rh The shelf life of this product is estimated at 5 years when stored appropriately SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 11 of 44 Street Glasgow G3 8JU 6 MATERIALS AND PROCESSES 6 1 Materials Used Material Manufacturer
45. r is satisfied that the subsystem meets its specification through analysis inspection review testing or otherwise Activities might include e Satisfactory inspection and functional test of the subsystem e Review of all supporting documentation e Review of all AIT procedural plans identifying equipment and personnel needs and outlining clear pass fail criteria e Dry runs of the procedures in the plan Obviously testing and analysis is not possible for all aspects of a subsystem specification and Clyde Space is able to provide data on operations which have been performed on the system as detailed in Table 13 1 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 43 of 44 Street Glasgow G3 8JU Performed on Availability Functional Moduesuppied Providedwithmodule calibration Module supped Providedwithmodule Vacuum Performed onmodule prototype mma Thermal Performed on module prototype mma f Simulation amp modeling Not performed Notavallble Table 13 1 Acceptance test data Following this review it is recommended the system undergoes further testing for verification against the developer s own requirements Commonly requirement compliance is presented in a compliance matrix as s
46. ssseeesssseeeeeeeeeen nennen nennen nnns sn annees nnne nnns 20 5 7 Cubesat Kit Header Pin DUE siiis oui ter nadlesknxtctostaxtsberanvt aa eaa ctio Enr aE a tuse eaaa een RUN a 21 S8 WIRE UN OO enc RE 23 8 9 Balterv Oe UNO Dio onse atc chu ncscensainae senna twaies ea cue aan sauceouacausuvb gi NM IMPIUM M NEM ERN Su AN CURE 25 of EO I E 25 9 TE GIG SC FIOM ME mme 26 OU Charee MeMo Me Emm 26 9 2 BCR Power Stage OQ VOLVIGW xuntvio SQUE ecw E EIRDOY REDI SuGE E sauna gs req en E uuPRINDUEMR B HA UN EN TEN PR Sud AN dM bees 27 9 3 uu ee 27 2A E105 N ROM M 28 10 General O10 GC EOIN REN RO E 29 LO Over Current BUS PROTOCUOMN i doce piv mus Forne rey Rx E Uu endl Pur FD YU cuPI IE S EvE DA UEM FUR P EEUU DIPENDE eee 29 10 2 Battery Under Voltage Protection insect ede rne RORIS E E TI EE PN En EP EE a N Quid Rb vanteens E FU quu a HOS 30 11 Telemetry and Felecoriftidlitl use vieni a xtluobkS SQUE DEUM NRNUS SU RUM PU SR SUA RRUREC URINE ME SNP Id iBUU EROS TR TORUM ud 31 de ed TECNO RR ETUR 31 SOLUTIONSFORANEWAGEINSPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 Issue D Date 26 02 2015 Page 5 of 44 25 o at 11 2 Command SUEDE y ererken nrar EE FRED Fa Mu ER XN EAE CR EERUMURERUUERE RUE E EOE UH v pX ERE ID E NI I EREEUE 33 11 3
47. t limits V 20V ELM NA Array Input CLYDE SPACE XU EPS Power Supply Set limits V 6V EM NA Figure 12 2 Solar Panel using power supply SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 39 of 44 Street Glasgow G3 8JU 12 3 Battery Setup The system should be tested with a battery in the system This can be done using a Clyde Space Battery by stacking the boards or by using a power supply and load to simulate the behavior of a battery This setup is shown in Figure 12 3 CLYDE SPACE EPS BATT POS Electronic Power Load Supply Set to 0 5A draw 7 74V 1 2A BATTERY Figure 12 3 Simulated Battery Setup 12 4 Configuration and Testing The following section outlines the procedure for performing basic functional testing PCM Testing In order to test the PCMs power must be applied to the PCM_IN connection In order to do this the Pull Pin should be removed connection the battery as shown in Figure 12 4 CLYDE SPACE EPS BCR_OUT SEPARATIO SWITCH DUMMY LOAD L PULL PIN No Input BATT POS c oO m O LLI l LLI BATTERY Figure 12 4 Test set up with Pull Pin Removed In this configuration all buses will be activated and can be
48. t predetermined load levels see Table 10 1 The bus protection will then monitor the fault periodically and reset when the fault clears The fault detection and clear is illustrated in the waveform in Figure 10 1 SYSTEM EVENT TEST SYSTEM VER CURRENT EUNT SHUTDOWN TEST PERIOD CLEARS PERIOD RESUME i3 p BUS VOLTAGE NORMAL AAN EANAN SSES KX 6000 gees a AAAS S S252 AUS hteteteto OX XP SS oD iets xX x Mete SS MM en teftes DO POCO OC OF LCC CAA eere 79 9 9 9 9 9 9 9 LEVEL d NORMAL 1 Oost on OPERATION state Ret iate Me es sales Oy eee SKS Pesce OPERATION Ve Oe RSA Lo ogpe xd Recent secon Oo 25 BN N 2 2555 D Sel Ml Shutdown period Shutdown period Shutdown period Figure 10 1 Current protection system diagram Bus Period Approximate Duration ms Shutdown period Battery Bus Test period shutdown period 5V Bus Test period 30 shutdown period 3 3V Bus 30 Test period Table 10 1 Bus protection data SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 30 of 44 Street Glasgow G3 8JU 10 2 Battery Under voltage Protection In order to prevent the over discharge of the battery the EPS has in built under voltage shut
49. te with a suitable battery and solar arrays to form a complete power system for use on a CubeSat or Nanosat Switch Configuration As Defined By User i c node BATT_POS Seps BCR6 only on CS XUEPS2 42 and CS XU EPS2 42A Figure 1 1 System Diagram 1 1 Additional Information Available Online Additional information on CubeSats and Clyde Space Systems can be found at www clyde space com You will need to login to our website to access certain documents 1 2 Continuous Improvement At Clyde Space we are continuously improving our processes and products We aim to provide full visibility of the changes and updates that we make and information of these changes can be found by logging in to our website http www clyde space com 1 3 Document Revisions In addition to hardware and software updates we also make regular updates to our documentation and online information Notes of updates to documents can also be found at www clyde space com SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 19 d D USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 SPACE 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 7 of 44 Street Glasgow G3 8JU 2 OVERVIEW This is the second generation of Clyde Space CubeSat Electronic Power System developed by our team of highly experienced Spacecraft Power S
50. tion open pin 39 Not Connected Not Connected 40 Not Connected int PP SS pins SS pins SS pins SS pins 45 Battery EET Output to battery Bus bus Not Connected Not Connected 46 Eu un ade Not Connected Not Connected 47 Not Connected Not Connected NC Not Connected Not Connected 48 Not Connected Not Connected Not Connected Not Connected 49 Not Connected Not Connected CON E VU NC NC NC NC NC NC NC NC C i EB 6S QJ N O Not Connected Not Connected W Ww Not Connected Not Connected W A O Not Connected Not Connected QJ ui O Not Connected Not Connected E O Not Connected Not Connected QJ N Not Connected Not Connected QJ 0 Not Connected Not Connected Data for 12C communications Not Connected Not Connected ie ite O IC DATA I C data A ary O Not Connected Not Connected Clock for I C 12C clock in communications 43 I C CLK Z C Not Connected Not Connected A A Z O Not Connected Not Connected n ui A Z ziz zZ Z Z zZ zZ Z O O O O A gt gt 2 C zZ A A o N n O SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D
51. ystem CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 20 of 44 Street Glasgow G3 8JU 8 6 CubeSat Kit Compatible Headers Connections from the EPS to the bus of the satellite are made via the CubeSat Kit compatible headers H1 and H2 as shown in Figure 8 6 12C DATA 12C CLK H2 1 3 5 7 9 Ej e n 16 P m w 15 5V BUS 5V BUS 3 3V BUS 3 3V BUS GND GND USB 5V BATT POS PCM IN R265 NF BATT POS PCM IN DUMMY LOAD N C BCR OUT DUMMY LOAD N C BCR OUT E BAT BUS R255 NF BAT BUS ole Pl eT eB iejo lw fw wl wow ininininjnj eleleljlel re J j reiuwi julj clj i5iuwi iuj covcolj nr el uli iuj juwljieljtulj iuljctul wi Cn B 5 m wlw lw lol rn it nl nitro fe le le le le Figure 8 5 CubeSat Kit Header Schematic _H2 ja Hl BCR OUT BAT BUS 3 3V BUS GND POS PCM IN 5V BUS wow Y ox RTSTTTe s s s u v s B t psiz snss ms ajos BnnnpmepEEBEREEEOBOUEE FIBEEBSPPBEBEBBBETSREEB CODE USB NN CHARGING DUMMY LOAD 12C DATA N2C CLK Figure 8 6 EPS Connector Pin Identification SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 21 of 44 Street Glasgow G3 8JU 8
52. ystems and Electronics Engineers Since introducing the first generation in 2006 Clyde Space has shipped over 120 EPS and Batteries to a variety of customers in Europe Asia and North America The second generation EPS builds on the heritage gained with the first generation whilst increasing power delivery capability by approximately 5096 Furthermore we have implemented an ideal diode mechanism which ensures that there will be zero draw on the battery in launch configuration Clyde Space is the World leading supplier of power system components for CubeSats We have been designing manufacturing testing and supplying batteries power system electronics and solar panels for space programmes since 2006 Our customers range from universities running student led missions to major space companies and government organisations SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2015 USM 0002 User Manual FleXible Electronic Power System CS XUEPS2 41 42 5B Skypark 5 45 Finnieston Issue D Date 26 02 2015 Page 8 of 44 Street Glasgow G3 8JU 3 MAXIMUM RATINGS OVER OPERATING TEMPERATURE RANGE UNLESS OTHERWISE STATED BCR Value Cc E i i ix i i c il lix SA1 pin 1 or pin 4 BCR1 12W 25 SA2 pin 1 or pin 4 BCR2 12W SA3 pin Lor pina BCRS 12W Input Voltage SM4 pin Lor pin BCRA 12W SA5 pin 1 or pin 4 BC

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