Micro Technic Micronix PV-5127 User's Manual
Contents
1. Connection number in KL3 Function 1 GND 2 GND 3 12V out 4 5V out 5 5V out KL KL3 1 Mains 9 2 GND S e 3 GND 4 Battery 6 we Ext sensor H N 10 T T Segera 2 2 RS IE NN _ E E 9 a Charge current AQ 5 6 0 5A xa as5 0 A 3j lt 5 CN X3 zii S CN3 CNIO 89 og C Jumpers shown in their factory default positions Page 29 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Thermal considerations When installing the Micronix PV 5127 in a PC 104 stack some considerations about convection must be made For the power supply to work properly certain temperature limits must not be exceeded Several factors will affect the temperature raise in the PV 5127 the delivered power the convection inside the cabinet the input voltage mains and the ambient temperature Tests have shown that if the temperature at the top of the electrolytic capacitors do no2. pin9 0 x5V 7 _ 4 Cold LED On LED 9 Mains LED e 4 Mode Red LED cm Heat t NO Hee Mode Green LED pint pin2 To PV 5127 CN2 RS232 connector CN3 This connector is documented in the UPS Control section Page 9 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS ATX connector CN10 The ATX connector holds the three ATX signals P5 ON GOOD and 5V Standby The layout of this connector is shown in the schematic The function of the individual ATX signals is shown in the table ATX signal no Function GND 1 System GND i 2 For factory use only 3 For factory use only Bd 4 For factory use only 5 For factory use only i 6 For factory use only 5V STB 7 5V Standby PWR_GOOD 8 This pin is 3 3V when 5V and 12V is OK PS ON 9 This pin must be pulled low in order to start PV 5127 GND 10 System GND Ext sensor connector J2 This connector is for an external ambient system temperature sensor see section System temperature The input is designed for the Infineon KTY11 5 temperature dependent resistor Infineon ordering code Q62705 K245 Mating connector for J2 is Molex 7880 2 A ready made sensor with a 40 cm
3. 919 ems ntium 10 PC 104 BUS CONNECTOR CN1 a 11 SYSTEM TEMPERA TUR Evite 12 UPS CONT ROE Eo 14 SIGNAL A tis 14 J E nece EE e EIE EE 15 RS232 Status signals gate du edd ee d N EE dent 16 RS232 Sh tdown signal died Reged teri A Hee ded se e de Me Hee dioe reden 16 PG IQA INTEREBACE 5 ier ioter er eee eee er eve eee iste eese iube Set eee eec edere CR RET reve eae ee ee ee uev 17 SOBEWARE COMPATIBILITY E REPRE E IU IE 19 BATTERY MONITOR AND CHARGER e esee eese ee ee een osea etta Pes seta Pee seen ee seen Pese ee ense ette ases ee to 20 BATTERY VOLTAGES 3 corte tive ceto ett esee ated e vem eese dec 20 L EAD ACID CHARGER ov E E A toe ive vol evaded Sav eaae e ve 20 ATX STATE MACHINES iore se se esee o eon eoe UR ve e v epa 22 THE MAIN DC DC CONVERTER AND 3V S TB See ee Eve eR Ue PE xe SAEI PE Ve E eR Ye 22 OUTPUTS xenon EGER nda tet Ure VR 22 THEATX ON OFF STATE ERE e Te ee Pure Ee eee ET exe ee PET E ERN eave ia 23 THESOFIOBESTATEMACG
4. y BSE 4 Bos Ha Sz mc SE gt a S 2E ATX CNIO a Page 30 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Differences between PV 5127 and PV 5127A The PV 5127 is available in a version without UPS and battery charger The ordering code for this product is PV 5127A These things are different in this version The mains voltage range is nominally 10 35V instead of 18 35V The mains monitor reports mains failure at mains voltage below 9 0V and mains OK at above 9 5V instead of 16 5V and 17 5V respectively The battery charger is omitted The input selector circuit is omitted J1 for battery temperature sensor is omitted CN3 for RS232 UPS communication is omitted Block diagram of the PV 5127A it Mains 104 GND Q On board sensor External sensor Je Simulate 10 C m ots T lt PC104 ISA BUS gt 7 5127 Schematic P XIII 5V standby PW OK 3 3V gt PS UN Page 31 of 31
5. The main 5V and 12V outputs are available in the PC 104 connector so you don t need to use the KL3 outputs when drawing smaller currents The maximum allowed current through the PC 104 connector is 2A per pin Using all three 5V pins in parallel together with at least three GND pins allows a maximum of 5V 6A There is one 12V pin allowing max 12V 2A For larger currents you must use the KL3 power connector PC 104 power pins gt 0 o gt ar O ar O O 832 At A32 CO C19 Dow BONN 079 S o 22 The ATX signals 5V STB PS ON GOOD are not available in PC 104 connector The PC 104 bus is also used for software UPS status and power off see the UPS Control section The software interface uses the following signals PC 104 pin Function A2 507 506 4 505 5 504 A6 503 7 502 8 501 9 500 11 A22 SA9 A23 SA8 A24 SA7 A25 SA6 A26 SA5 A27 5 4 A28 SA3 A29 SA2 A30 SA1 A31 B13 IOW B14 IOR Page 11 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS System
6. Users Manual amp Installation Guide PV 5127 Power supply module with UPS RS232 Status signals The Battery low and Mains failure signals together can tell three different states Mains failure Battery low Status 0 0 Running normally on mains power 1 0 Mains alarm running on battery The CPU is advised to shut down if mains power doesn t come back within reasonable time This time should be configured in the UPS monitoring software Critical alarm The CPU is advised to shut down immediately This happens in two situations e During mains failure and the battery is critically low When the system is too hot RS232 Shutdown signal When the CPU activates the Shutdown signal for one second the PV 5127 immediately turns off the 5V and 12V power and if mains is not present also 5 STB Pulses shorter than one second have no effect For details please see the section ATX and Softoff state machines UPS shutdown via rs 232 24V Mains Mains LED Mains fail l IL LLL LL LL B g RS 232 CTS Te RS 232 CD 5V 12V 5V STB arx Shutdown from CPU RS 232 DTR Battery voltage w timd for system to shutdown 9 5V ae Batt LED e E _ discharge charge Internal sofety shutdown Page
7. B Y current amp z 24 0 5 5 Cold LED m 1 04 sy 5 lt 1 cD Batt Low 2 8 Fan oN 7 Hot LED je 5 3 A RTS UPS active 6 5 Batt D t o NY 259 NEUE LE 3 in DN Eu bi 5 6 CTS Mains alarm 4 3 Heat n 1 7 DTR UPS shutdown Su R UPS shutolown GND 5 9 10 CN3 CNIO Note 1 System temperature Notera pat ery on board temperature sensor 1 i x Nowe er Batter ui 3 in pos On board A PC 104 connector Disable ure Mount a jumper on ST3 in Leave J2 unconnected 1 Mating connector Molex 7880 2 GND 0000 2 Mating connector Molex 7880 2 Power input connector KL2 Using battery Leave Jl unconnected Power into PV 5127 Mains and battery is supplied through KL2 that is a four pole removable screw clamp connector The layout of this connector is printed in the silkscreen on the heatsink Power output connector KL3 Power out of PV 5127 5 and 12V is applied to that is a five pole removable screw clamp connector The layout of this connector is printed in the silkscreen on Output voltage indicators the heatsink Three green LEDs indicate presence of the output voltages 5V 5V Standby and
8. 12V Page 8 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Heater and fan control and external LEDs connector CN2 Status for PV 5127 can be shown on external LEDs These must be connected to CN2 by a 10 position ribbon cable with a mating connector Furthermore the 5V Standby and logical outputs for the external heating element and the external fan are placed in this connector The layout of this connector is shown in the schematic to the left of the connector The function of the individual LEDs is shown in the table LED name Pin no Function GND 1 System GND Mode Green LED 2 See note Heat On 3 Logical output for external heat element 3 3V when active Mode Red LED 4 See note Battery LED 5 See section Battery monitor and charger Mains OK LED 6 On when mains supply OK Hot LED 7 See section UPS control Fan On 8 Logical output for external fan 3 3V when active Cold LED 9 See section UPS control STB 10 standby is active when the main converter is on Note Mode Green LED and Mode Red LED are intended for use with a two color red green LED When both Mode LEDs are on you get yellow The possible colors are Mode LED color Function Green On both 5V and 12V are Yellow Standby only 5V Standby is on Off Off main DC DC converter is off The LEDs should be connected like this
9. 20 C to 70 C at 0 5 m s airflow Storage temperature 40 C to 85 C Humidity 20 to 90 non condensing Cyclic humidity ETS 300 019 2 5 or equal Vibration 10 1000 Hz sinus and random 1 1 5G RMS EN Sustained vibration 60068 2 34 amp 60068 2 36 Shock IEC 60068 2 27 amp 60068 2 29 Size W x L x H 90 x 96 x 15mm Page 26 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Mechanical layout The schematic on this page shows the dimensions for PV 5127 dimensions are in mm ion CO Co TS 960 0 I 90 8 fo 90 8 86 3 g5 S i 85 3 SS LE S E S 666 ur 1 H S NS Em i 60 3 b 22 E Siue m gt 2 aa 14 CNIO 3 1 0 5 54 0000 7 4 E is e ES e 27 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Installation guide Precautions to ESD Please note
10. 2538 read only RS232 STATUS 254h read write SHUTDOWN 255h Reserved 256h Reserved 257h Reserved SIGNATURE port 250h read only This port always reads as 37h Software can read this register to verify the presence of a PV 5127 adapter STATUS port 251h read only 0000bmss This port contains the following read only status information bits 55 STATUS bit 1 0 System temperature according to the internal or external system temperature sensor ss 00 Too cold ss 01 Cool ss 10 Warm ss 11 Too hot m STATUS bit 2 Mains present m 0 Mains voltage not present running on battery m 1 Mains voltage present Page 17 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS b STATUS bit 3 Battery present b 0 Battery not present empty or disconnected b 1 Battery present BAT STATUS 252h read only nnOcctvv This port contains the following read only battery status information bits vv BAT STATUS bit 1 0 Battery voltage See the section Battery monitor and charger vv 00 Empty or low vv 01 Medium vvz10 Full vv 11 Disconnected t BAT_STATUS bit 2 Battery temperature according to the battery temperature sensor input When using the PV 1075 NiMH battery module the sensor should be disconnected and this bit always reports battery too hot t 0 Battery temperature OK charger enabled t 1 Battery too hot charger disabled BAT_STATUS bit 4 3
11. changed page 27 Page 4 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS General information Ordering codes PV 5127 S PV 5127A S S Stack through PC 104 connector Available models Model no Description PV 5127 S 75W PC 104 Power Supply Module 5V 12V 18 35V input supply with UPS Battery charger PV 5127A S 75W PC 104 Power Supply Module 5V 12V 10 35V input supply Accessories These accessories must be ordered separately if needed Model no Description PV 5127 TW40 External temperature sensor for system and battery temperature CDB 9F RS232 ribbon cable for simple signalling UPS protocol PV 5127 TW40 length 40cm PV5127 J1 J2 CDB 9F Female ping pinto pin __ pins length 30cm oo immi oo x 7 E pint pin2 colored wire ping pini To PV5127 CN3 To CPU RS 232 port Page 5 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Description The Micronix PV 5127 is a high efficiency PC 104 power supply for embedded vehicular and automotive systems applications It will withstand extended temperatures and the shock and vibration of mobile equipment Micronix PV 5127 has an input supply range of 18 35V PV 5127 10 35V which is
12. Charger status cc 00 Charger off When using the PV 1075 the charger is always off cc 01 Reserved cc 10 Charger on trickle charging cc 11 Charger on fast charging nn BAT_STATUS bit 7 6 Battery type With the current firmware the only possible value is 01 nn 00 Reserved nn 01 Lead Acid or PV 1075 NiMH battery module nn 10 Reserved nn 11 Reserved RS232 STATUS port 253h read only uuuu0000 This port contains the following read only status bits They reflect the status of the pins in the RS232 connector whether input from the CPU or output by the PV 5127 four signals are active high i e 1 signal active O signal inactive Note that RTS UPS active has no function apart from being readable in this port RS232 STATUS bit 4 CD Lobat Output from the PV 5127 RS232 STATUS bit 5 CTS Mainsfail Output from the PV 5127 RS232 STATUS bit 6 RTS UPS active Input into the PV 5127 RS232 STATUS bit 7 DTR Shutdown Input into the PV 5127 SHUTDOWN port 254h read write This port holds the current state of the Softoff state machine Please see the section and Softoff state machines Possible values are Page 18 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS 00h SOFT OFF first half of 2 second delay FEh SOFT ON FFh SOFT OFF second half of 2 second delay or SOFT TEMPBAD Other values DELAY delayed shutdown in progress value remaining s
13. convenient for automotive and low voltage applications Intelligent back up battery charger with temperature protection of your battery pack Additionally it has a built in fan heat control Micronix PV 5127 has support for three ATX signals PWR GOOD PS ON and 45V Standby Micronix PV 5127 supports sealed lead acid batteries and the Micronix PV 1075 PC 104 NiMH battery pack Block Diagram GND q T Input selector circuit Power switch GND y n x Lj gt gt A A GND Lead Acid Batter 3 y Battery 2 Charger Std trickle Un Level control logic gt U_batt_sense Mains 5V standby 5 7 Battery_status amp Batt LED gt 28 E Cold LED On board sensor Lon t 4 Hot_LED Simulate 10 4 lt System temperature e T s prises E Mode Green LED Fon 4 3 3V Heot Un 33 V5 UPS_shutoown DTR C UPS_active RTS 5V standby PW DK 3 3v PS UN Mains CTS Battery low CD GND lt 104 ISA BUS gt Env le V5127_Block dwg PV 5127 is built around a high efficiency DC DC converter that converts the incoming DC voltage to 5V 15A This output is used for 5V Standby and is a
14. located in the CN10 connector and the system temperature status ON is active low it is active when pulled low to OV and inactive when high or left floating e The state machine starts up in OFF when the main DC DC converter starts It changes to ON when PS ON is active and the system temperature is OK cool or warm This means that the CPU cannot turn itself on when the temperature is not OK 100 cold or too hot e It stays in ATX_ON as long as PS ON is active Even if the system temperature becomes too cold or too hot it stays in ON as long as PS ON is active This means that the CPU won t suddenly be turned off if the temperature becomes bad but it can decide to do a controlled shutdown and power off when it sees the temperature status When PS ON goes inactive it changes to OFF If your CPU cannot control the PS ON input you can make it permanently active by placing a jumper in CN10 The Softoff state machine The Softoff state machine is intended for use with UPS monitoring software such as the Windows 2000 XP UPS service The Softoff state machine is controlled by the RS232 Shutdown DTR signal the system temperature status and software commands through the PC 104 bus This state machine is useful when your CPU does not support the 5 ON signal With this state machine you can perform a shutdown using an RS232 handshake signal see the section RS232 and through a software comm
15. power switch to the main 5V output and through a step up DC DC converter to the 12V output The power switch controls when to turn on the 5V 12V outputs The main DC DC converter turns on when mains appears and stays on as long as mains is present When the converter is on the CPU can turn on and off the 5V 12V output using PS ON depending on temperatures etc When mains disappears the converter stays on as long as the 5V 12V output is on and the battery is OK gt 9 5V That is when running on battery the converter is turned off when the CPU turns itself off to conserve battery capacity until mains comes back or when the battery 15 empty to protect the battery against deep discharging The 5V 12V outputs The power switch which turns on and off the 5V 12V outputs is controlled by two state machines implemented in the control logic the ATX on off state machine and the Softoff state machine Both state machines must be in their state for the power switch to turn on When either state machine goes to an off state the 5V 12V outputs turn off and if mains is not present the main DC DC converter also turns off Page 22 of 31 Users Manual 8 Installation Guide PV 5127 Power supply module with UPS The ATX on off state machine The ATX on off state machine has two states ATX OFF and ATX ON Only in the ATX ON state can the 5V 12V outputs be turned on The state machine is controlled by the PS ON input
16. that the Micronix PV modules must be handled with respect to ESD Electrostatic Discharge Electrostatic Discharge to the PV modules must be avoided Before removing the module from the protection bag the user must be discharged using a grounded wrist ribbon Settings and connections ST1 To set the fast charge current to 1A install a jumper at ST1 factory default To set the fast charge current to 0 5A remove jumper at ST1 J1 Connect an external temperature sensor at J1 i e PV 5127 TW40 if the battery temperature is to be supervised during the charging process The battery temperature control can be disabled by installing a jumper at J1 factory default Leave STI unconnected when PV 5127 is used with a PV 1075 battery module See section Connectors and Battery monitor and charger ST3 Connect a jumper in position On board sensor if the system temperature is to be measured by the on board sensor If the system temperature is to be measured by an external sensor leave ST3 unconnected To disable the system temperature control install a jumper in the position 102 factory default J2 Connect an external temperature sensor at J2 i e PV 5127 TW40 if the system temperature is to be supervised by an external sensor Otherwise leave J2 unconnected See section Connectors and System temperature CN2 If external LED indicators or the heater and fan control outputs are used connect these through CN2 Otherwi
17. the CPU to get UPS status information and to turn off power The CPU can get status information through the RS232 and the PC 104 interface and it can perform a software controlled power off through the ATX PS ON signal through an RS232 signal and through the PC 104 interface PS ON signal Two of ATX functions that are supported in PV 5127 are 5V STB and PS ON These signals are placed in connector CN10 In the figure below the relationship between Mains OK PS ON and 5 STB is illustrated Mains OK j PS ON 5V STB 5V 12V po 00 In this figure the system temperature and the battery voltage are assumed to be OK For the full details involving these conditions please see the ATX and Softoff state machines section 1 5V STB turns on when mains turns on 2 The CPU can turn itself on and off using PS_ON and since mains is on the 5V STB also stays on 3 When mains disappears while the CPU is on it continues running on battery 4 When the CPU turns itself off while mains isn t present everything including 5V STB is turned off to conserve battery power It stays off until mains comes back PS LIN GND jumper in this position will activate PS UN Page 14 of 31 Users Manual amp Ins
18. 16 of 31 Users Manual 8 Installation Guide PV 5127 Power supply module with UPS PC 104 interface The PV 5127 has a software interface where the CPU can read status information and perform a power off through the PC 104 bus The power off can be delayed up to 253 seconds so that the UPS monitoring can start the delayed power off then start a shutdown of the operating system and the actual power off happens after the operating system has finished shutting down When a delayed power off has been initiated the software can later cancel or modify it This means that the delayed power off can be used as a software watchdog If the software e g once every second starts a power off specifying a delay of 10 seconds the system is continuously kept on If because of a software error the refreshing of the delayed power off stops the PV 5127 will power off the system in 10 seconds If mains is present and the system temperature is OK the PV 5127 will turn on again two seconds later ensuring a clean reboot This interface is used by the PV 5127 UPS minidriver for Windows 2000 XP You only need the following information if you want to write your own UPS monitoring or watchdog software To the CPU the PV 5127 appears as a fixed block of eight I O addresses at 250h 257h It doesn t use any memory addresses IRQs or DMA channels Address Read write Function 250h read only SIGNATURE 251h read only STATUS 252h read only
19. 67 ur MICRONIX PC 104 POWER SUPPLY PV 5127 PV 5127A POWER SUPPLY MODULE WITH UPS amp BATTERY CHARGER User Manual amp Installation Guide VERS 1 1 5127 ver 15 1 DOC M5236DM Users Manual amp Installation Guide PV 5127 Power supply module with UPS Table of contents TABLE OB CONTENIS ROC suastees oascadssdesssssdsesesusdscstesssdeseusbasevens 2 REVISION HISTORY Secs vec ca aepo toe 4 GENERAL INFORMATION coco se ee ees sooo ee vo 5 ORDERING CODES eerte to teri sche eve toot e yere 5 Paesi 5 DESCRIPTION oT 6 BLOCK DIAGRAM 6 CONNECTORS assscicsdecksssisdesedcsdsivacdecssseasedachaundddeseascasavtewecsensccsdeaseces sdeveccnsssseudesoasescssbaseess sdevedsousevencedeeseicedscudeadsvesscsecsantes 8 POWER INPUT CONNECTOR KL2 cem tite eee bt e emen te s eee ay tates e ce me eo fee ce e EHE E 8 POWER OUTPUT CONNECTOR KL3 aeiiae aeaaee aape Eea SEERE e Ee o EEEE EE paR a aeaa aeta esie 8 OUTPUT VOLTAGE INDICATORS a a e ebbe a a a 8 HEATER AND FAN CONTROL AND EXTERNAL LEDS CONNECTOR 9 232 reiten abe a wei ete ee 9 n I 10 EXT SENSOR CONNECTOR 12 sre meet 10 BATT SENSOR CONNECTOR e DB EB BER eres reete 10
20. HINE e reete eese Lo ede gue t uee sunk E eee estne votis neo Do 23 TECHNICAL DATA Noa eene 25 MECHANICAL LAYOUT P 27 WVULQEGU LUUD 27 I EVEDECVVLOTEG BUT D M 28 28 SETTINGS AND CONNECTIONS 28 EE 28 2 of 31 Users Manual 8 Installation Guide PV 5127 Power supply module with UPS Td REL M RE 28 AVIS GT R 28 DD RCM 28 eae 28 GINS 28 CES 28 hon EET 29 THERMAL CONSIDERATIONS e eene veo o veo Po Loo eue 30 DIFFERENCES BETWEEN PV 5127 AND 5127 asses e eese en ases e sete 31 BLOCK DIAGRAM OF THE PV 512 T ise eerte eee eee poete eb ive eoe esty tete bey ee iet en esee tae bey ee ve e ue 31 Page 3 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Revision history Revision number Reason for change Date 1 0 Initial revision 23 Mar 04 1 1 Error in mechanical layout 21 Oct 05
21. and through the PC 104 bus see the section PC 104 Interface If you leave the RS232 DTR unconnected it is by default inactive The state machine has four states SOFT ON SOFT DELAY SOFT OFF and SOFT TEMPBAD SOFT ON and SOFT DELAY are the states i e only in these states can the 5V 12V be turned on SOFT OFF and SOFT TEMPBAD are the off states where the 5V 12V is guaranteed to be off Page 23 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS It can be illustrated like this PC 104 delayed shutdown command Pd i e SOFT DELAY delay in 0 253 seconds progress De PC 104 cancel E Bom delayed shutdown pss ps temp OK delay expired RS232 active temp E N delay expired SOFT OFF delay in not SOFT_TEMPBAD 2seconds progress p _ 22 Hume Oe The state machine starts up in TEMPBAD when main DC DC converter starts In this state the 5V 12V cannot be turned on It stays in this state as long as the system temperature is 100 cold or too hot SOFT ON This is normal state The RS232 DTR Shutdown is monitored and if it is active for one second power is turned off by going to OFF Pulses shorter than one second are ignored In SOFT_ON the CPU can issue a delayed shutdown command through the PC 104 bus SOFT DELAY T
22. cable and connector is available as the PV 5127 TW40 accessory Batt sensor connector J1 This connector is for an external battery temperature sensor or a jumper see section Battery monitor and charger The input is designed for the Infineon KTY 11 5 temperature dependent resistor Infineon ordering code Q62705 K245 Mating connector for J1 is Molex 7880 2 A ready made sensor with a 40 cm cable and connector is available as the PV 5127 TW40 accessory From the factory a jumper is installed disabling the battery temperature control Pinheader ST3 This pinheader is for configuring the System temperature measurement see section System temperature You can mount a jumper in the 10 C position in the On board sensor position or you can leave it unconnected The factory default is a jumper in the 10 C position Jumper position ST3 Input for System temperature No jumper installed Sensor connected to J2 Jumper on On board sensor On board sensor Leave J2 unconnected Jumper on 10 C Simulate 10 C Leave J2 unconnected Factory default Page 10 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS PC 104 bus connector CN1 The PC 104 connector is for connecting the PV 5127 to the CPU and other PC 104 boards There is a female connector on the top and pins on the bottom so that you can mount other PC 104 boards both above and below the PV 5127
23. econds until SOFT OFF Software normally won t read the values and FFh since the 5V 12V is off at this time Writing 00h will turn off power immediately and it will stay off for at least two seconds You shouldn t write FFh since this will turn power off for only one second and this might not be enough for a CPU to reboot cleanly Writing FEh will cancel a delayed shutdown in progress Writing other values will initiate or modify a delayed shutdown with the value being the number of seconds until SOFT OFF Software compatibility Windows NT 4 0 The PV 5127 RS232 interface is directly compatible with the Windows NT 4 0 UPS service using the CDB 9F cable It can monitor the three statuses Normal Mains alarm Critical alarm and use the RS232 Shutdown signal to power off Windows 2000 and XP The UPS service in these operating systems can monitor the three statuses Normal Mains alarm Critical alarm through RS232 but it cannot power off the PV 5127 with the Shutdown signal This is because the UPS service is terminated during shutdown so it cannot activate the Shutdown signal when shutdown is complete To power off the PV 5127 after a shutdown under Windows 2000 and XP you must use either the PS ON signal with an ATX compatible CPU or PC 104 interface Using the PS ON signal ensures that power is turned off exactly when the operating system has finished shutting down The PC 104 interface is used by the PV 5127 UPS minidriv
24. er available at http www micro technic com pv5127 This method does not use an RS232 port or cable Linux Several UPS monitoring daemons exist which use the simple or dumb signalling protocol on a serial port Examples are apcupsd http www2 apcupsd com When using the CDB 9F cable you should specify UPSCABLE 940 0020B Network UPS Tools http www networkupstools org When using the CDB 9F cable you should specify genericups upstype 2 Other daemons Make sure that you use the right handshake signals since no single standard exists for which handshake are used for which function and adapt either the software configuration or the cable accordingly With some UPS hardware you can experience a deadlock problem if mains power comes back after the UPS monitoring software has decided to shut down the operating system This happens if the UPS monitoring software is unable to turn off power after the operating system has finished shutting down because mains power has come back This cannot happen with the PV 5127 because it always turns off power for at least two seconds after a power off command through RS232 or PC 104 even if mains power is present Page 19 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Battery monitor and charger Battery voltages The PV 5127 monitors the voltage of the battery as long as the main DC DC converter is on The voltage status cont
25. he 5V 12V is still on but the delayed shutdown timer is running The delay can be cancelled by software returning to SOFT ON SOFT OFF The 5V 12V is turned off for two seconds ensuring that the CPU is cleanly rebooted after it has decided to shut down even if mains is present If mains isn t present the main DC DC converter is also turned off so everything stays off until mains comes back SOFT TEMPBAD If mains is present it moves from OFF to SOFT TEMPBAD after two seconds If the system temperature is OK cool or warm it then moves immediately to SOFT ON If the system temperature is either 100 cold or too hot it stays in SOFT TEMPBAD until either the temperature becomes OK or mains disappears whereby everything is turned off until mains comes back Note that the PV 5127 does not have a very accurate clock You should expect deviations of 10 from the nominal times in SOFT DELAY and SOFT OFF Page 24 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Technical data Power supply Input voltage PV 5127 S 18 35Vdc with UPS and charger PV 5127A S 10 35Vdc without UPS and charger Output Voltage 1 5 8A Ripple noise 100 Line regulation 1 Load regulation 5 Output Voltage 2 12Vdc Ripple noise 150 Line regulation 1 Load regulation 5 Output Voltage 3 5V Sta
26. monitoring software on the CPU can get UPS status information through the RS232 port and the PC 104 bus and it can perform a software controlled power off through the ATX signal PS ON the RS232 port and the PC 104 bus See the section UPS control Page 7 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Connectors The PC 5127 is equipped with nine connectors Phoenix type MSTB 2 5 5 ST On board temperature sensor N Phoenix type MSTB 2 5 4 ST 2s X A CEU 2 e SEP em p N 6 S lt 7 6 3 5 5 4 Battery KTY11 5 cp ibd 2 T ix Je Ext sensor a 2 LH nm i e J2 ST3 see note 1 Jue es 5 ae fi 5 Dutput voltage indicators see note 2 118 ST C unde H z E e ens e E 5 j
27. ndby 1A Output power 75W max Efficiency 5V 91 12V 81 Overload protection Short circuit and overload protected UPS Battery Charger Battery type 12V Lead Acid or NiMH PV 1075 Lead Acid charge Fast charge Constant current 0 5 or 1A Trickle charge Constant voltage 13 6V Battery protection Input for temperature sensor Temperature control Internal or external ambient temperature sensor Logical outputs for external fan and heater 3 3V when on Alarm to CPU when temp too high via RS232 and PC 104 ATX signals Input PS_ON Outputs PWR_GOOD 5V Standby RS232 Interface Handshake signals Mains failure Battery Low Shutdown High temperature alarm Activates Mains failure and Battery Low Software Supported by Windows NT and Linux PC 104 Interface Power 5V 12 Status Software readable mains battery and temperature status Shutdown Software shutdown delayed 0 253 sec Software UPS service for Windows 2000 and XP available Logic outputs Fan_ON Heat_ON and PWR_GOOD Output high voltage min 2 4V 4 0mA Output high voltage typ 3 3V Vo Output low voltage max 0 4V 8 0mA Page 25 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Environmental specifications Operating temperature
28. onnected Temperature controlled charging Constant charge voltage 13 6V x Constant charge current 0 5 1A Battery Constant charge vol tage current 0 5 1A Batt Batt 99 Temp 45 fast charge no charge fast charge trickle charge no charge trickle charge Page 21 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS ATX and Softoff state machines The PV 5127 provides several ways to turn on off power ATX compatible CPUs can turn themselves on and off using PS ON and UPS monitoring software on CPUs without PS ON can turn off using either a RS232 handshake signal or a software command through the PC 104 bus Regardless of the method the system temperature ensures that the CPU can only be turned on when the system temperature is OK but it is allowed to stay on if the temperature later becomes too cold or too hot The system temperature circuit can be bypassed using a jumper that effectively tells the PV 5127 that the temperature is always OK The main DC DC converter and 5V STB The main DC DC converter converts the input voltage from mains or the backup battery to 5V The output of the converter is directly connected to the 5V STB output so whenever the converter is on the 5V STB is present It also powers the internal control logic When off the power consumption is minimal The output of the converter is also connected through a
29. per at STI ST1 installed ST1 removed Fast charge current 1A Fast charge current 0 5A After reaching 14 7V the charger goes into trickle charge mode In this mode the battery is supplied with a constant voltage of 13 6V When the battery voltage falls below 13 0V the charger returns to fast charge mode Charging a lead acid battery while it is too hot may damage it The PV 5127 has an input J1 for connecting an external battery temperature sensor The sensor if used should be physically Page 20 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS mounted directly on the battery The charging is disabled when the temperature according to this sensor rises above 55 C and enabled when it falls below 45 C The J1 input has the following function Installed on J1 Charger function Disabled See note A jumper Enabled factory default A KTY11 5 sensor Enabled when not too hot Note When using the PV 5127 with a PV 1075 NiMH battery module you must disable the PV 5127 charger by leaving J1 unconnected You can connect a Battery LED to the CN2 connector The LED shows these statuses Battery LED Meaning Off Battery voltage OK medium or full If mains is present and the charger is enabled the charger is in trickle charge mode otherwise it is off Flashing Charger is in fast charge mode Steady on Battery error This indicates that the battery is either empty low or disc
30. rols the charger the RS232 alarm output the battery LED and it can be read through PC 104 The possible ranges are Range Thresholds Empty Below 9 5V Low Between 9 5V and 10 75V 11 25V Medium Between 10 75V 11 25V and 13 0V 14 7V Full Between 13 0V 14 7V and 15 0V Disconnected Above 15 0V There is hysteresis when moving between some of the ranges The notion 10 75V 11 25V denotes the lower and upper hysteresis levels so that the change from low to medium happens when the voltage rises above 11 25V but to change from medium to low the voltage must drop below 10 75V When empty and running on battery power is immediately turned off to protect the battery against complete discharge This is the safety shutdown feature Empty can also mean that no battery is connected When low and running on battery a Critical alarm is reported through RS232 The medium and full ranges control the charging mode see below The disconnected state happens when the charger is on and there is no battery connected Lead acid charger The PV 5127 has an integrated lead acid battery charger that will maintain the UPS battery as long as the mains voltage is present The battery charger has three modes of operation Fast charge trickle charge and off In the fast charge mode the battery charger will deliver a constant current to the battery as long as the battery voltage has not reached 14 7V This current can be programmed by a jum
31. se leave CN2 unconnected See section Connectors CN3 If the simple signalling protocol is to be used for the UPS control connect a suitable cable i e CDB 9F between CN3 and a COM port on the CPU Otherwise leave CN3 unconnected See section UPS Control CN10 If your CPU has a 5V Standby power input and a PS_ON output connect them to the corresponding pins in CN10 ATX Otherwise place a jumper on the two leftmost pins in CN10 to permanently activate PS_ON factory default See section Connectors and section UPS Control Page 28 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS KL2 Connection of mains and battery voltage are made via KL2 as shown in the table Connection in KL2 Function 1 Mains in 2 Mains in 3 Battery in 4 Battery in Connect mains input to pin 1 and 2 To use a lead acid backup battery connect it to pin 3 and 4 otherwise leave pin 3 and 4 unconnected To use a NiMH Nickel Metal Hydride battery for back up a Micronix PV 1075 can be integrated in the PC 104 stack In this case see documentation supplied with PV 1075 for connection of mains and battery KL3 Output power can be supplied from connector KL3 This should be used if the output current exceeds the PC 104 connector limits see section 104 connector or if you need power for devices that are not powered through the PC 104 bus
32. t exceed 105 C the PV 5127 is thermally safe This table shows the relationship between Uin and Tcap Uin V Tamb max C 10 67 60 75 18 72 55 75 24 74 53 75 30 86 41 75 figures in table match ambient temperature equal to 22 C without forced cooling A raise in ambient temperature must be added to Tcap This gives the max ambient temperature Tamb max 105 22 These figures are given in the table If the PV 5127 is placed in an ambient temperature that is higher than indicated in the table the system integrator must arrange forced cooling Temperature experiments have shown that a min airflow parallel to the surface of the heat sink of 0 5m s is adequate for max load at ambient temperatures up to 84 C For durability reasons it is recommended not to use PV 5127 at ambient temperatures exceeding 70 C at full load direction Airflow Teap 4 alt 1 ie 3 GND Y aL Q Se 4 Battery GND 2 ud d gt ML Bee sensor z GND 1 D J 10 x Qo lt 7 On board 2 We m Oo 0 o m gt Charge current c 0 5A
33. tallation Guide PV 5127 Power supply module with UPS RS232 The PV 5127 has a connector CN3 labelled RS232 that can be connected to an RS232 port on the CPU The PV 5127 provides two handshake outputs with status information and one handshake input for controlling shutdown The RxD and TxD signals are not used the only used signals are Ground and the three handshake signals The three signals are compatible with the simple signalling or basic signalling protocol used by other UPS units The 10 connector CN3 is designed to be used with a simple ribbon cable ending in a DB9 female connector to be plugged into a DB9 male RS232 connector on the CPU CDB 9F Female pinto ping pind length 30cm n pint ping colored wire pin6 AX pini To PV 5127 To CPU RS 232 port The signals use normal RS232 voltage levels Inactive 0 10V active 1 10V In the table shown inputs are indicated by 1 and outputs by o PV 5127 CN3 CPU RS232 DB9 Pin Function Pin RS232 Function 1 Battery low o 1 CD Battery low i 2 2 3 3 4 UPS active i see note 4 DTR Shutdown o 5 5 GND GND 6 Mains failure o 6 7 Shutdown i 7 RTS UPS_active o 8 8 CTS Mains failure i 9 GND 9 10 Note The UPS_active signal is currently unused by the PV 5127 Page 15 of 31
34. temperature The PV 5127 has a temperature measuring circuit that can control an external fan and heater and prevent the CPU from starting if the temperature is too low or too high It monitors the system temperature as long as 5V STB is on As system temperature sensor you can use the onboard sensor or an external sensor of type Infineon KTY 11 5 connected to J2 labelled Ext sensor If you don t want any temperature control you can also configure it to a simulated 10 C which effectively disables the temperature control The circuitry checks for four different temperature ranges 100 cold cool warm and too hot Range Thresholds Too cold Below 0 C 3 C 0 C 3 C and 15 18 Warm Between 15 C 18 C and 47 C 55 C Too hot Above 47 C 55 There is hysteresis when moving between the ranges The notion 0 C 3 C denotes the lower and upper hysteresis levels so that the change from foo cold to cool happens when the temperature rises above 3 C but to change from cool to too cold the temperature must fall below 0 C Similarly for the threshold between cool and warm at 15 C and 18 C and between warm and too hot at 47 C and 55 C For testing purposes the too cold and too hot ranges can be simulated To simulate too cold mount a jumper on J2 instead of a sensor To simulate 100 hot leave both J2 and ST3 unconnected The temperature ranges are used for these func
35. tions CPU start Cold Hot Range allowed Heater Fan Critical alarm LED LED Too cold No On Off No Flashing Off Cool Yes Off Off No Off Off Warm Yes Off On No Off Off Too hot No Off On Yes Off Flashing Page 12 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS Note that the heater and fan outputs are logical outputs that become 3 3V when they are active If necessary the user must provide driving circuitry to drive an actual heater and fan The positions of the two outputs in CN2 are shown here Ping Fon 3 If the temperature is too cold or too hot the CPU cannot be turned on until it changes to cool or warm But if it the CPU is on and the temperature later changes to too cold or too hot the CPU continues running If the temperature changes to too hot and you are using UPS monitoring software with the RS232 status signals a critical alarm mains failure and low battery is signalled prompting the monitoring software to shut down immediately UPS monitoring software that reads status information through the PC 104 can also detect this condition and react accordingly Page 13 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS UPS Control The PV 5127 provides several methods for
36. vailable at CN2 and CN10 A power switch is used for turning on off the output voltages 5V and 12V under software control and by the safety shutdown function The mains power and backup battery are connected to KL2 The input selector circuit always selects the highest of the two voltages If the mains voltage drops below the battery voltage the backup battery immediately takes over Page 6 of 31 Users Manual amp Installation Guide PV 5127 Power supply module with UPS The mains supply is continuously monitored There is hysteresis on the mains monitor so that a mains failure is reported when the mains voltage drops below 16 5V and mains is reported OK when the voltage rises above 17 5V 24V Pom input to main DC DC converter 16 5 13 6V Battery voltage Gall chargedye mains voltage Mains LED The connected lead acid backup battery is maintained by an integrated battery charger fast charge and trickle charge Using an external battery temperature sensor you can disable the charging if the battery is too hot See the section Battery monitor and charger The PV 5127 can also monitor the system ambient temperature and prevent the CPU from starting if it is too cold or too hot and advise it to shut down if it is too hot The system temperature can also be used to control an external fan and heating element See the section System temperature UPS
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