User Manual - Clyde Space
Contents
1. n 39 123 Power up Dowh Proced re iere eee e i EE E YEN RE URL e Ee eee n pe un nae n 39 12 2 Solar Array InpUt iE te Ho EC A ERE ees E Cure ave HE EE iene 40 pcc CINES HR 41 124 Configuration and Testing niece tei Re D edge aaa 41 13 Developer p 45 14 Compatible cu 1 47 SOLUTIONS FOR A NEW AGE IN SPace Www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 6 of 47 Glasgow G20 OSP UK 1 INTRODUCTION This document provides information on the features operation handling and storage of the Clyde Space 3U EPS The 3U EPS is designed to integrate with a suitable battery and solar arrays to form a complete power system for use on a 3U CubeSat SOLAR m 8 ARRAYS z SOLAR REG p ARRAYS EN B3v EM I CUm F USB 5V SOLAR ARRAYS itc node TELEMETRY 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 and2. GND z GND 6 788313 x ADC Count 5V Bus Current 5366 1616 mA 6 788313 x ADC Count 3 3V Bus Current 5366 1616 mA GND GND Z Array 0 163 x ADC count 110 338 C Temperature 2 7153 x ADC Count Z Array Current 2146 464646 mA Table 11 3 ADC Channels SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ qT EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 39 of 47 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 e Battery or simulated battery e Breakout Connector with connections as per Figure 12 1 e Array Input test panel solar array simulator or power supply and limiting resistor e Oscilloscope e Multimeter e Electronic Load e Aardvark lC connector or other means of communicating on the I C bus CLYDE SPACE 3U EPS BCR OUT SEPARATION 4 SWITCH m Array Input v DUMMY LOAD PULL PIN e a 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
3. 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 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 1 2 end of charge voltage i constant battery amp 5 4 i i voltage at 8 2V i i 8 4 0 8 75 4 r 0 6 z c g t w 6 5 4 taper charge end of 0 4 o 5 discharge 5 gt voltage o 6 f 0 2 pei current 55 4 charge again constant current discharge 0 5 charge inode on orbit charge current is proportional to solar panel illumination F 0 2 4 5 4 conditions 4 d i Hm 04 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 Limite
4. This MPPT will track the dominant panel of the connected pair the directly illuminated panel The output of the three BCRs are then 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 I C network These are discussed in detail in Sections 10 and Error Reference source not found respectively SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ Cas EPS 2G 3U Helix Building WSSP Glasgow G20 0SP UK Issue B Date 25 09 2014 Page 13 of 47 Z Array Y Array Nd X Array X Array Y Array Z Array Figure 7 1 Array Configuration SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U i i Helix Building WSSP Issue B Date 25 09 2014 Page 14 of 47 Glasgow G20 OSP UK 7 1 System Overview H1 43 12C CLOCK
5. User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS Author Approved Clyde Space Ltd Helix Building Kelvin Campus West of Scotland Science Park Glasgow G20 OSP UK 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 Name Stephen Charlick 25 09 2014 Alan 25 09 2014 2G 3U Document No USM 0007 Revision B Date 25 09 2014 Signed SOLUTIONS FOR A NEW AGE IN SPACE USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Issue B Date 25 09 2014 Page 2 of 47 Helix Building WSSP Glasgow G20 0SP UK Document Control Issue Date Section Description of Change Reason for Change A 14 02 2011 All Sections First Draft N A Section 8 2 Update to connector part Incorrect part number number for Array specified in Rev A of connector on EPS document B 25 09 2014 Table 11 3 Update to theoretical Rev B of this document equations for reflects current build level of telemetries product Rev C Revision Control Product Part Number Revisions covered Notes Cubesat 3U Electronic Power 25 00221 s System 2x16V 8W 5V 3W BCR Acronyms and Abbreviations BCR Battery Charge Regulator PCM Power Conditioning Module PDM Power Distribution Module
6. B User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Date 25 09 2014 Page 47 of 47 Helix Building WSSP Glasgow G20 OSP UK 14 COMPATIBLE SYSTEMS Compatibility CubeSat Kit Bus CubeSat Kit definition pin compatible stacking 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 2s3p Batteries More strings can be connected in parallel to increase capacity if required Lithium lon 8 2v 2s1p to 2s3p m More strings can be connected in parallel to increase capacity if required Other Batteries Please contact Clyde Space Solar Arrays Clyde Space 3W solar array Connects to BCR 3 via SA3 Clyde Space 8W solar array Connects to BCR 1 2 via SA1 2 3W triple junction cell arrays 2 in series connection 8W triple junction cell arrays 6 8 in series connection Other array technologies Any that conform to the input ratings for Voltage and Current Structure Pumpkin CubeSat 3U structure ISIS CubeSat 3U compatible Other structures Please contact Clyde Space Table 14 1 Compatibilities 1 Refers to series and parallel connections of the battery cells within the battery system e g 2s1p indicates a single string of two cells in
7. H1 41 12C DATA UNDER VOLTAGE 12C BUFFER H2 27 28 3 3V BUS H2 25 26 5V BUS H2 45 46 BATTERY BUS W TLM conditioning 3 3V PCM H2 35 36 PCM IN H2 29 31 32 GND H1 32 5v USB H2 41 44 BCR OUT 3W SEPIC BCR END OF CHARGE 8W BUCK BCR SENSING SENSING SENSING Figure 7 2 Function Diagram SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 CLYDE gt USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC q Helix Building WSSP Issue B Date 25 09 2014 Page 15 of 47 Glasgow G20 0SP UK 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 as the 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 i
8. 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 e Fit Breakout connector to EPS e Connect battery to stack e Connect electronic load no load to buses e Remove Pull Pin e Activate Separation Switch e 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 40 of 47 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 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 3U EPS Power Supply Set limits V 20V 12 1 2A 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 2010 USM 0007 User Manual 25 00
9. 2 Processes and Procedures All assembly is inspected to ESA Workmanship Standards ECSS Q ST 70 08C and ECSS Q ST 70 38C SOLUTIONS FOR A NEw AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 d Cas USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC Helix Building WSSP Issue B Date 25 09 2014 Page 12 of 47 Glasgow G20 0SP UK 7 SYSTEM DESCRIPTION The Clyde Space 3U 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 six or less body mounted solar panels i e one on each spacecraft facet 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 three independent Battery Charge Regulators BCRs These are connected as shown in Figure 7 1 and Figure 7 2 with panels on opposing faces of the satellite connected to the same BCR e g X array and X array are connected to BCR1 Y and Y to BCR2 and Z and Z to BCR3 In this configuration only one panel per pair can be directly illuminated at any given time with the second panel providing a limited amount of energy due to albedo illumination Each of the BCRs has an inbuilt Maximum Power Point Tracker MPPT
10. 3 3V BUS BATT BCROUT BAT BUS 5V BUS P ejeje H2 refs o o o n o CHARGING DUMMY LOAD 2C DATA 12C 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 22 of 47 Glasgow G20 0SP UK 8 7 Cubesat Kit Header Pin Out HEADER 1 HEADER 2 Name Use Notes Pin Name Use Notes Not Connected Not Connected Not Connected Not Connected N Not Connected 9 9 N Not Connected 10 10 T 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 Oohm resistor 21 Alt IC clock connection R265 must fit to 21 NC Not Connected Not Connected operate 22 Not Connected Not Connected Not Connected Not Connected Oohm resistor 23 Alt lC data connection R264 must fit to 23 NC Not Connected Not Connected operate 24 24 25 ME oves 5V Power bus Regulated Sv bus 26 EE 5V 8US 5V Power bus Regulated 5v bus 3 27 NC Not Connected Not Connected 27 d OWE Regulated 3V3 bus BUS bus pi NC Not Connected Not Connected 28 gt gt Jm WEB Regulated 3V3 bus BUS bus 29 NC Not Connected Not Connected 29 GND Ground PAT connection return 30 NC Not Connected Not Connected 30 GND Ground System power connection return 31 32 USB 5 USB 54v Use to charge GND Ground System power battery
11. Cells Max Cells CLYDE SPACE 3U EPS Y Solar Array Figure 8 2 Example Solar Array Configuration HIROSE DF13 6P 1 25 DSA connector sockets are used on the EPS These are labelled SA1 SA3 SA1 SA2 are routed to BCR1 BCR2 respectively These BCRs are capable of interfacing to 8W panels and should be harnessed to arrays with between 6 8 triple junction solar cells in series SA3 routes to BCR3 which is a 3W channel that should be harnessed to the small arrays The array lengths should be the same on joined panels with 2 cells each g000000 aNV ROD Figure 8 3 Solar Array Pin Numbering SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI Cc EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 19 of 47 Glasgow G20 0SP UK Pin Name Use E E power 2 GND Ground ine Power RTN and GND connection for Temp Sensor FEM YARRAY_TEMP_TELEM YArray Telemetry VARRAY AW power GND Ground Line Power RTN and GND connection for Temp Sensor YARRAY_TEMP_TELEM VArray Telemetry Table 8 2 Pin out for Header SA1 Pin Name Use ETEENEN Power GND ex inne Power RTN and GND connection for Temp Sensor SXARRAY TEMP TELEM XARRAY Telemetry ARRAY W power GND Groundiiine Power RTN and GND connection for Temp Sensor XARRAY TEMP TELEM ARRAY Telemetry Tabl
12. 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 SOLUTIONS FOR A NEW AGE IN SPACE PROPRIETARY amp CONFIDENTIAL INFORMATION www clyde space com Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U i Helix Building WSSP Issue B Date 25 09 2014 Page 3 of 47 Glasgow G20 0SP UK 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 RD 3 Varfistten standard GSFC STD 7000 April 2005 RD 4 CubeSat Kit Manual UM 3 RD 5 Solar Panel User Document TBC Power System Design and RD 6 Performance on the World s Most Asha
13. accurate equations full calibration test should be carried out ADC Approx Conversion Equations Channel 0 10 11 12 13 14 15 16 17 18 19 20 GND 2 7153 x ADC Count Y Array Current 2146 464646 mA Y Array 0 163 x ADC count 110 338 C Temperature Array Pair Y 0 021668284 x ADC Count v Voltage 25 06218798 2 7153 x ADC Count Y Array Current 2146 464646 mA Y Array 0 163 x ADC count 110 338 C Temperature Array Pair X 0 021668284 x ADC Count v Voltage 25 06218798 2 7153 x ADC Count X Array Current 2146 464646 mA X Array 0 163 x ADC count 110 338 oc Temperature Array Pair Z 0 021668284 x ADC Count v Voltage 25 06218798 2 7153 x ADC Count Z Array Current 2146 464646 mA Z Array 0 163 x ADC count 110 338 oc Temperature GND 2 7153 x ADC Count X Array Current 2146 464646 mA X Array 0 163 x ADC count 110 338 C Temperature GND s GND s Battery Bus 6 788313 x ADC Count m Current 5366 1616 GND GND ii GND SOLUTIONS FOR A NEW AGE IN SPACE PROPRIETARY amp CONFIDENTIAL INFORMATION www clyde space com Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Glasgow G20 0SP UK Issue B Date 25 09 2014 Page 38 of 47 GND GND GND
14. microcontroller Additional Hardware Further required hardware includes an oscillator and an lC bus extender The oscillator provides a robust clock signal for the microcontroller The bus extender provides greater robustness to signal noise on the lC bus during integration and operations 11 2 12C Command Interface All communications to the Telemetry and Telecommand TTC Node are via an I C interface The TTC Node is configured as a slave and only responds to direct commands from a master I C node No unsolicited telemetry is transmitted A maximum 400Kbit bus speed is supported with typical bus speeds of 100Kbit The address of the TTC Node is factory set The address is Ox2B SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC mM as EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 34 of 47 Glasgow G20 0SP UK Message Formats Two message structures are available to the master a write command and a read command The write command is used 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 The first data byte should be the command The second byte represents the data that is used as part of the command An example of the data is the analogue to digital channel to read An example of a r
15. of the buses you will be able to see the current trip points activation as discussed in Section 10 1 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 100 DoD and should always be followed by a charge cycle SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 43 of 47 Glasgow G20 OSP UK 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 a Lj Array Input DUMMY_LOAD PULL PIN LJ BATT_POS 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 not at the power supply The wave form should resemble Figure 12 6 Noise Filter Off 400rns Figure 12 6 Wavef
16. 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 www clyde space com 1 3 Document Revisions In addition to hardware and software updates we also update 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 7 of 47 Glasgow G20 OSP UK 2 OVERVIEW This is the second generation of Clyde Space CubeSat Electronic Power System developed by our team of highly experienced Spacecraft Power Systems and Electronics Engineers Since introducing the first generation in 2006 Clyde Space has shipped over 120 EPS to customers in Europe Asia and North America The second generation EPS builds on the heritage gained with the first whilst adding over 50 additional power delivery capability Furthermore we have also implemented an ideal diode mechanism to ensure 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 so
17. series 2 Will require some alteration to MPPT Please contact Clyde Space SOLUTIONS FOR A NEW AGE IN SPACE PROPRIETARY amp CONFIDENTIAL INFORMATION www clyde space com Clyde Space Limited 2010
18. with an input of between 3V and 6V 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 Increasing Temperature PAn AAE a aai Maximum Power Point Array Current Increasing Temperature Vmpp Vo c Array Voltage Figure 9 2 Solar Array Maximum Power Point SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC mM qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 30 of 47 Glasgow G20 OSP UK 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 shown in Figure 9 3 Noise Filter Off Figure 9 3 Input waveform with Maximum Power Point Trac
19. 221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U f Helix Building WSSP Issue B Date 25 09 2014 Page 41 of 47 Glasgow G20 OSP UK 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 SP ACE BATT POS H2 33 34 Power Supply 7 74V 1 2A Electronic Load Set to 0 5A draw 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 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC mM qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 42 of 47 Glasgow G20 OSP UK CLYDE SPACE EPS BCR OUT SEPARATION 4 SWITCH a lt No Input DUMMY_LOAD a BATT_POS BATTERY Figure 12 4 Test set up with Pull Pin Removed In this configuration all buses will be activated and can be measured with a multimeter By increasing the load on each
20. 3 Not Used Reads as 0 4 Oscillator Bit External Oscillator External i running Oscillator failure Watchd Reset Bit cl d 5 Watchdog Reset Occurred No Watchdog Reset M HE Rao Occurred when read Power On Reset No Power On Bit cleared i Fewer OR Reser Derren Occurred Reset Occurred when read 7 Bin Sut Reset Oct rred Brown Out Reset No Brown Out Bit cleared Occurred Reset Occurred when read 0 PC Error I2C Error Bit cleared Occurred when read I2C Write 1 l C Write Collision No IC Write Collision Collision B Occurred lc Overfl 2 C Overflow No I C Overflow 27M Occurred Received M Last Messa 3 Received Message to Long ndis SEE c np di Correct Length incorrect Length 4 7 Not Used Reads as 0 Table 11 2 Status Bytes SOLUTIONS FOR A NEW AGE IN SPACE PROPRIETARY amp CONFIDENTIAL INFORMATION www clyde space com Clyde Space Limited 2010 USM 0007 Issue B User Manual 25 00221 2x8W Buck 1x3W SEPIC Date 25 09 2014 EPS 2G 3U Page 37 of 47 Helix Building WSSP Glasgow G20 OSP UK 11 4 ADC Channels 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
21. 47 4 ELECTRICAL CHARACTERISTICS Description Conditions Min Typical WED Unit 8W BCR 1 amp 2 Input Voltage lt ale nO 8 26 1 2 2 lt Output Voltage fo gt Output Current U1 u1 R o N N u gt Switching Frequency KHz Efficiency 16 5V input Full Load 90 92 3W BCR 3 Input Voltage V Output Voltage 8 26 V Output Current D A Operating Frequency 170 180 KHz Efficiency 6V input Full Load 8096 Unregulated Battery Bus 8 26 lt Output Voltage e N Output Current Operating Frequency 8 26V input Full Load 98 5 99 99 5 Efficiency 5V Bus 5 05 29 lt Output Voltage gt Output Current kHz L ps 5V input Full Load 96 3 276 3 3 Operating Frequency 9 Efficiency 3 3V input Full Load ps qi Transmission speed I 100 Bus voltage ee 3 26V 83V 3 33V Quiescent Operation Flight Configuration of Power Draw Switches 0 1 Ww L W L Operating Frequency 9896 Efficiency 3 3V Bus 3 333 2 9 lt Output Voltage gt Output Current 5 80 5 2 4 kHz 9 9796 Communications Protocol T Kbits Physical Height from top of PCB to Dimensions bottom of next PCB in stack 95 15 24 mm Weight m e s s Table 4 1 Performance Characteristics of the 3U EPS SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Spac
22. C Helix Building WSSP Issue B Date 25 09 2014 Page 26 of 47 Glasgow G20 OSP UK Option 2 CLYDE SPACE 3U SEPARATION SWITCH 1 SEPARATION 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 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 3U 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 al
23. Not Connected Not Connected Not Connected SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 23 of 47 Glasgow G20 0SP UK HEADER 1 HEADER 2 Pin ETT Use Notes Pin Name Use Notes 50 Not Connected Not Connected 50 Not Connected Not Connected 51 Not Connected Not Connected 51 Not Connected Not Connected 52 Not Connected Not Connected 52 Not Connected Not Connected Table 8 5 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 3 3V Regulated Bus Output BATT POS 2 33 34 SWO Positive Terminal of Battery not Battery Bus DO NOT CONNECT PCM IN 2 35 36 SW1 Switches gt Input to PCMs and PDMs DUMMY LOAD 2 37 38 SW2 Switches gt N C 2 39 40 SW3 Switches N C Unused connection of launch switch closed state BCR OUT 2 41 44 SWA Output of BCRs gt Switches BCR OUT 2 41 44 SW5 Output of BCRs gt Switches BATTERY BUS 2 45 46 VBATT Battery Unregulated Bus Output Table 8 6 Header pin name descriptions relating CubeSat Kit names to CS names SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 CLYDE qT USM 0007 User Manual 25 00221 2x8W Buc
24. Sat 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 developer 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 subsyst
25. d 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ qT EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 29 of 47 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 Sun 9 2 BCR Power Stage Overview As discussed in Section 8 the EPS has three separate independent BCRs each designed to interface to two parallel solar arrays on opposing faces of the satellite Two 8W BCRs interface to the panels in the X and Y axes and a third smaller 3W BCR interfaces to the panel on the Z axis Each design offers a highly reliable system that can deliver 90 8W BCR or 80 3W BCR of the power delivered from the solar array network at full load 8W BCR power stage The 8W BCR is a BUCK converter allowing the BCR to interface to strings of six to eight cells in series This will deliver up to 90 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 80 output at full load The BCR will operate
26. e 8 3 Pin out for Header SA2 Pin Name Use Notes EB s 2 GND Ground Line Power RTN and GND connection for Temp Sensor 3 ZARRAY_TEMP_TELEM ZARRAY Telemetry Telemetry E 5 GND ee ee Power RTN and GND connection for Temp Sensor ZARRAY_TEMP_TELEM ZARRAY Telemetry Table 8 4 Pin out for Header SA3 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 20 of 47 Glasgow G20 OSP UK 8 3 Solar Array Harness Clyde Space supply harnesses sold separately 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 s
27. e Limited 2010 d ras USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC Helix Building WSSP Issue B Date 25 09 2014 Page 10 of 47 Glasgow G20 OSP UK 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 touch 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 robust and designed 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 3 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 contai
28. ead command would be e The master transmits the slave address with write flag command type 0x00 and data ADC channel e The slave acts on the commands sets the correct channel and reads the analogue to digital converter e The master transmits the slave address with read flag e The slave responds with a two byte value If a read message does not have a preceding write message the value OxFOOO is returned All bit level communication to and from the board is done by sending the MSB first If both bytes are not read then the system may become unstable ADC The lC node acts as a multi channel Analogue to digital convertor which allows the board to supply sensor data to the user When the command is received a delay approximately 1 2ms is inserted to allow the analogue reading to settle After this delay the result can be retrieved The result is a 10 bit value with the first byte received containing the two most significant bits and the second byte received the remaining 8 bits MSB LSB LTT TT HAA EEE First byte AC Pd Second byte Used bits Figure 11 2 ADC 10bit data packet To retrieve a sensor reading the following procedure should be used Send 0x00 followed by OxOX where X represents the channel number in Hex format This instructs the IC node that the user wishes to retrieve a sensor value and which sensor to take the reading from After a small delay approximately 1 2ms the user can issue a read command and the res
29. em 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC mM as EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 46 of 47 Glasgow G20 OSP UK Performed on WZIELA Functional Calibration Vacuum Therma Simulation amp modelling Not performed Not available 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 shown in Table 13 2 Requirement Procedure Result X Success criteria Compliance pass fail SYS 0030 The system mass TEST 01 0 957 kg X 1kg PASS shall be no more than 1 kg SYS 0040 The error LED TEST 02 LED LED off FAIL remains off at flashing initialisation sysooso EI Table 13 2 Compliance matrix example All procedural plans carried ou
30. ensors i e LM335M or equivalent Thermistor or thermocouple type sensors are incompatible with the conditioning circuit CLYDE SPACE EPS 1 5V Ref 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 2010 gt gt USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U g Helix Building WSSP Issue B Date 25 09 2014 Page 21 of 47 Glasgow G20 OSP UK 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 5 H2 5VBUS pzp 3 5V BUS 3 3V BUS EBP 3 27 GND P 22 GND USB 5V 31 3 3V BUS BATTPOS 4 3 33 BATTPOS PCMIN 4 3 35 PCM IN DUMMY LOAD D 37 DUMMY LOAD Nc gt 29 NIC BCR OUT 41 BCR OUT 43 BATBUS MEP 45 R255 NF 12C DATA 12C CLK BAT BUS Figure 8 5 CubeSat Kit Header Schematic H2 H1
31. he telemetry system transfers data via an I C bus The telemetry system operates in slave mode and requires an 1 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 Sensing VBAT t ARRAY Sense Current PDM voltage e Canca JE CUIRRRAY Sense RE temp voltage CRQCane AMUX ap p me POM CUTARRAY Sense t voltage gt _ gt emp current BCR3 Sense Sensing 3 3V temperture Current PDM C data bus 2 PV NODE Signal line Control line Figure 11 1 Telemetry functional diagram 11 1 I Node The I C Node is based on the Microchip PIC16F690 The device node is configured to act as a single channel analogue to digital converter The microcontroller controls the analogue multiplexer that routes the signals from the sensors The PIC16F690 program is designed to operate as a slave sensor node on the I C bus The program will select and then convert the desired signal data from the telemetry network on demand There is also a control feature that can briefly shutdown PDMs within the EPS The following sections briefly describe the hardware that is used Analogue Multiplexer A 32 channel analogue multiplexer is used for selecting the correct sensor signal The multiplexer is controlled from the
32. ically and reset when the fault clears The fault detection and clear is illustrated in the waveform in Figure 10 1 SYSTEM EVENT TEST SYSTEM OVER CURRENT SHUTDOWN TEST PERIOD CLEARS PERIOD RESUME EVENT a BUS VOLTAGE onm AX m 1 LEVEL Ree Ba S FERATO HR T m OPERATION AA Ki kj k NORMAL pi BESI ei BEN ZARN d Shutdown period Shutdown period Shutdown period Figure 10 1 Current protection system diagram Bus Period Approximate Duration ms Shutdown period 650 Battery Bus Test period 60 Shutdown period 585 5V Bus Test period 30 Shutdown period 525 3 3V Bus Test period 30 Table 10 1 Bus protection data SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 32 of 47 Glasgow G20 0SP UK 10 2 Battery Under voltage Protection In order to prevent the over discharge of the battery the EPS has in built under voltage shutdown 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 shutdown the supply buses This will also result in the 1 C node shutting down When a power source is app
33. k 1x3W SEPIC Helix Building WSSP Issue B Date 25 09 2014 Page 24 of 47 Glasgow G20 OSP UK 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 should also be isolated from the BCRs during launch in order to conform to CubeSat standard RD 2 CLYDE SPACE 3U User Defined Switch 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 on all revisions of the EPS2 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 n
34. king 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 95 for the 3 3V PCM Full load on each of the regulator have a nominal output current of 2 5A which is upgradable to 4 5A 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 31 of 47 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 shut down 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 at predetermined load levels see Table 10 1 The bus protection will then monitor the fault period
35. l protections will be bypassed and significant battery damage can be sustained SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ qT EPS 2G 3U i Helix Building WSSP Issue B Date 25 09 2014 Page 27 of 47 Glasgow G20 OSP UK 8 10 Buses All power buses are accessible via the CubeSat Kit headers and are listed and described in Table 8 5 These are the only power connections that should be used by the platform since they follow all battery and bus over current protections All C 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC mM as EPS 2G 3U Helix Building WSSP Glasgow G20 0SP UK Issue B Date 25 09 2014 Page 28 of 47 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
36. lar 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Glasgow G20 0SP UK Issue B Date 25 09 2014 Page 8 of 47 3 MAXIMUM RATINGS OVER OPERATING TEMPERATURE RANGE UNLESS OTHERWISE STATED BCR Value Unit tey fes Ce KA EWA Eua Value Unit mh mA lt lt lt lt lt lt Operating Temperature ps Storage Temperature IC Vacuum 10 torr Radiation Tolerance kRad Shock TBC Vibration Table 3 1 Max Ratings of the 3U EPS 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 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Glasgow G20 0SP UK Issue B Date 25 09 2014 Page 9 of
37. lied 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC MZ as EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 33 of 47 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 T
38. med Advanced In Orbit Nanosatellite Risk gt Warning Ensure headers H1 and H2 are correctly aligned before mating boards If misaligned battery positive can short to ground causing failure of the battery and EPS gt Ensure switching configuration is implemented correctly before applying power to EPS If power is applied with incorrect switch configuration the output of the BCR can be blown causing failure of the EPS and subsequent damage to the battery Observe ESD precautions at all times The battery is a static sensitive system Failure to observe ESD precautions can result in failure of the battery Ensure not to exceed the maximum stated limits Exceeding any of the stated maximum limits can result in failure of the battery Ensure batteries are fully isolated during storage If not fully isolated by switch configuration or separation the battery may over discharge resulting in failure of the battery gt gt gt b No connection should be made to H2 35 36 These pins are used to connect the battery to the EPS Any connections to the unregulated battery bus should be made to pins H2 43 44 H1 and H2 pins should not be shorted at any time These headers have exposed live pins which should not be shorted at any time Particular care should be taken regarding the surfaces these are placed on Battery should only be operated when integrated with an EPS The EPS includes a n
39. n the following section it is assumed that the EPS will be integrated with a Clyde Space Battery CS SBAT2 10 20 30 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC CLYDE qT EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 17 of 47 SOLAR ARRAYS SOLAR ARRAYS USB 5V SOLAR ARRAYS i c node i c node TELEMETRY Figure 8 1 Clyde Space EPS and Battery Simplified Connection Diagram 8 1 Connector Layout The connector positions are shown in Figure 7 3 and described in Table 8 1 Connector Function SA1 Solar Array connector for 8W arrays SA2 Solar Array connector for 8W arrays SA3 Solar Array connector for 3W arrays H1 Cubesat Kit bus compatible Header 1 H2 Cubesat Kit bus compatible Header 2 Table 8 1 Connector functions SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI as EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 18 of 47 8 2 Solar Array Connection The EPS has three connectors for the attachment of solar arrays This interface accommodates inputs from the arrays with temperature telemetry for each Max
40. neral Man GWA waza cza iwa Wini RO REIN aes IERI ads 10 5 3 Shipping and Storages e Baa dodal aaa aa pd el cette stern ena uot sie e AZ ARES 10 6 Materials and Processes eesessissesesesseeee eene enne nennen iasad aaa nnne ns 11 61 Materials Used oreet ten e e A c tende Ded egre ep cua EA A e ev e NR d 11 6 2 Processes and Procedures itecto du ite ied eei te a EO sin de ace d iiiI 11 7 System PI Te gToid o o eT 12 7 1 VECES lig 14 7 2 Autonomy and Redurndantcy s iere etse hin eee ee VR TERR Re S 15 7 3 Quiescent Power Consumption ee eeeeee eee enea aaa aaa nnne ennt nnn n nnne aaa aaa nennt nnnnnens 15 7 4 Mass and Mechanical Configuration eese eene nnne nnne nnn nnns 15 8 ou zig oi ttr H 16 8 1 Connect r E Tero ewa iid EC SA 17 8 2 Solar Array Connection iste tite A AW PAW AAU A A PPU iw 18 8 3 SolarArray NatnESS oc aceti ridet cea teme RI retine a Ea a O herido a Edad 20 84 Temperat re sensing Interface ie hie Rae rte eco ees 20 8 5 Non Clyde Space Solar ArrayS csccsssccsssesssecssecsssecseceseecsseecseeceseeseneccseesssecseeseaeesseeceaseseesseesseeeees 20 8 6 CubeSat Kit Compatible Headers nennen nennen nennen nnne nennen nnns 21 8 7 Cubesat Kit Header Pin QUE ee aa each rente e ve ute eee e Evan FEX Ee Exe ree 22 8 8 Switch OPthons cise ridge HERES CREE RO ccd s
41. ners 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 11 of 47 Glasgow G20 OSP UK 6 MATERIALS AND PROCESSES 6 1 Materials Used Material Manufacturer TML CVCM WVR Application 2 1B31 Acrylic Humiseal 3 89 0 11 Conformal Coating 3 DC 6 1104 Dow Corning 0 17 0 02 Adhesive fixing on modifications MER 4952 Emerson 8 Thermally Conductive RTV PCB material Note worst case on NASA out gassing list Solder Resist CARAPACE 0 95 0 02 0 3 EMP110 or or 0 995 Or 0 001 XV501T 4 7 Solder Sn62 or Sn63 Tin Lead Flux Alpha Rosin Low activity flux Flux RF800 ROL to avoid 0 corrosion Table 6 1 Materials List Part Used Manufacturer Contact Insulator Type 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 Crimp Harness for Solar Arrays sold separately Table 6 2 Connector Headers 6
42. o 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 2010 CLYDE qT USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC Helix Building WSSP Issue B Date 25 09 2014 Page 25 of 47 Glasgow G20 OSP UK Option 1 CLYDE SPACE 3U SEPARATION SWIT CH PULL PIN 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 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 CLYDE az USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPI
43. 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 0x0002 is sent followed by the data byte The data byte has a range of O 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 The 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 IC node If the user detects or suspects an error in the operation of the I C node then this command should be issued When issued the 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Issue B Date 25 09 2014 Page 36 of 47 Helix Building WSSP Glasgow G20 0SP UK Description If Low 0 If High 1 0 Unknown Command Type Last command OK ee ao ee Unknown when read Last Command Bie eared 1 Unknown Command Value Last Command Value OK Value Out of when read Range ADC Result Not Bit cl d 2 ADC Result Not Ready ADC Result Ready S baba Ready when read
44. orm of Solar Array Input 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 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Helix Building WSSP Glasgow G20 OSP UK Issue B Date 25 09 2014 Page 44 of 47 CLYDE SPACE 3U EPS 5V USB BCR OUT SEPARATION Charging 4 SWITCH m Power Supply eH j 4 5V 1 2A L DUMMY_LOAD PULL PIN a BATT_POS BATTERY Figure 12 7 Waveform of Solar Array Input 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 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC mM as EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 45 of 47 Glasgow G20 0SP UK 13 DEVELOPER AIT AIT of the EPS with other Cube
45. s a robustly designed single string 7 3 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 lC node is the 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 83g and is contained on a single PC 104 size card compatible with the Cubesat Kit bus Other versions of the EPS are available without the Cubesat Kit bus header 2 SAMTEC CONNECTOR 6 39 C D ESQ 12 4 PLATED THRU HOLES O32 83 19 Figure 7 3 Mechanical Diagram SOLUTIONS FOR A NEw AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC CLYDE qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 16 of 47 Glasgow G20 OSP UK 8 INTERFACING The interfacing of the EPS is outlined in SOLAR CC ARRAYS JC SOLAR ARRAYS USB 5V SOLAR C ARRAYS 907 i c node i c node YYYYY TELEMETRY 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 I
46. s cd de cade ede ace Nec ee eere er eee 24 8 9 Battery Connection P 26 MIENTO 27 9 Technical descrlptlOn s ouieo nien oro ctae ed neto nonae ch nena Rn annee ddwaeahandsasessecetedaccasaeubeadeaces 28 9 1 Charge Meth Od M PIEC 28 9 2 BCR Power Stage Overview cccccesssccceeeteeeeneeeeeeeeeenseneceeesessnenaneeeneseseaaaesenesesenaaeaeeeseenssnenseenenees 29 9 3 uer EE G EEE 29 9 4 DV and 3 3V PCM E E 30 10 General PROTECTION iere ee eevee ctacecevestoetsaccssdadhvesiecaseetediunectucednvcstlsaleeivectnexsatdencetecedie 31 10 1 Over Current BUS Protection iret terere orent iyasa a EN apa SEM ein Ik eoe 31 10 2 Battery Under voltage Protection a si eere deed wada dota enact 32 11 Telemetry and Telecommand esses ener th natas isses tennis 33 MEL RR T TT 33 SOLUTIONS FOR A NEW AGE IN SPace Www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Issue B Date 25 09 2014 Page 5 of 47 Hia Mg 112 IG Command literface us eee i ei nc Fete ENDE E EN D 33 11 3 Command Summary rici este neget pens idl esa de dae ela so pesa vepe adc RA YE 35 TL4 ADCCh liels rt ett ete A W W eI E W FUR wa ee tees asi DERE cea 37 12 Erie
47. t 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 specific 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 2010 USM 0007 Issue
48. ult will be transmitted The most significant byte is sent first followed by the least significant byte The result received should then be entered into the conversion equations covered in a further section which calculates the requested parameter If the reading is not yet ready OxFOOO is returned This process should be followed for all ADC channels SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC AMI qT EPS 2G 3U Helix Building WSSP Issue B Date 25 09 2014 Page 35 of 47 Glasgow G20 OSP UK 11 3 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 e dT axes Lui Value Range Description Decimal Name Decimal 0 ADC Read ADC Channel 1 N A Request Status Bytes 7 2 PDM Off 0 a Request Firmware Version Watchdog Causes a soft reset of the micro Turns off the selected PDM for a short time Table 11 1 Command Summary Status The status bytes are designed to supply operational data about the IC 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
49. umber of protection circuits for the battery Operation without these protections may lead to damage of the batteries Do not discharge batteries below 6V If the battery is discharged to a voltage below 6V the cells have been compromised and will no longer hold capacity gt P gt P If batteries are over discharged DO NOT attempt to recharge If the battery is over discharged below 6V it should not be recharged as this may lead to cell rupture SOLUTIONS FOR A NEW AGE IN SPACE PROPRIETARY amp CONFIDENTIAL INFORMATION www clyde space com Clyde Space Limited 2010 USM 0007 User Manual 25 00221 2x8W Buck 1x3W SEPIC EPS 2G 3U Issue B Date 25 09 2014 Page 4 of 47 ek 1 IntrodACtIO a a oO cage GE a needs Lead awe das EdG costes 6 11 Additional Information Available Online eueee eee aaa aaa nnt nennen 6 1 2 Continuous Improvement iie aaa Deere labs sni chance gea a ice epa SR MS oe E NER ERE ra aaaea arataa 6 1 3 Document REVISIONS c ps reo A tu ts eae tho rea eene yk A de ee SUE SEL bo ESAE Saa i ee La SSR as SSE paries 6 2 edi S 7 3 Maximum Ratings Oo SAYS 8 4 Electrical Characteristics itcr t eere e ith Oden habei sito Al ASA Paki 9 5 Handling and storage seisnesid ieena t nasaia e ia aa aia SE nq a ea EN vg aun 10 5 1 Electro Static Discharge ESD Protection nnne 10 5 2 Ge
50. via USB connection return 33 NC Not Connected Not Connected ETT Power line PPR we POS connected pin 34 NC Not Connected Not Connected BATT Power line Pulpin normally POS connected pin D wW Ne wW Ne Not Connected Not Connected Not Connected Not Connected Not Connected Not Connected NC NC NC NC NC NC c Not Connected Not Connected N N N N N N N N on ow fs 0 DU n C c c C s 5 35 NC Not Connected Not Connected PCM IN Power line pand RADY connected pin 36 NC Not Connected Not Connected PCM IN Power line SPO connected p Dummy Load I pin normally 37 NC Not Connected Not Connected DL Protecti 38 NC Not Connected Not Connected Dummy shag Pulls normaly Protection open pin 39 Not Connected Not Connected Not Connected Not Connected 40 Not Connected Not Connected Not Connected Not Connected s s Data for I C C t PP PME C DATA PC data ROPA BCR OUT Power line n communications SS C int PP 42 NC Not Connected Not Connected BCR OUT Power line SITIO pon SS pins C t PP LEE C CLK PC clock CoA E BCR OUT Power line See eo communications SS pins C t PP 44 NC Not Connected Not Connected BCR OUT Power line RA pon SS pins Batt Output to batt 45 Not Connected Not Connected R Sy Bat Power Bus dx d Bion u 46 Not Connected Not Connected gn Bat Power Bus A 47 Not Connected Not Connected Not Connected Not Connected 48 Not Connected Not Connected Not Connected Not Connected 49 Not Connected
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