Micro Technic Micronix PV-5127, Installation And User Manual

Page 1: ... 6615 3000 Fax 45 6615 3077 E mail support micro technic com Website www micro technic com MICRONIX PC 104 POWER SUPPLY PV 5127 PV 5127A POWER SUPPLY MODULE WITH UPS BATTERY CHARGER User Manual Installation Guide VERS 1 1 DOC M5236DM ...

Page 2: ...XT SENSOR CONNECTOR J2 10 BATT SENSOR CONNECTOR J1 10 PINHEADER ST3 10 PC 104 BUS CONNECTOR CN1 11 SYSTEM TEMPERATURE 12 UPS CONTROL 14 PS_ON SIGNAL 14 RS232 15 RS232 Status signals 16 RS232 Shutdown signal 16 PC 104 INTERFACE 17 SOFTWARE COMPATIBILITY 19 BATTERY MONITOR AND CHARGER 20 BATTERY VOLTAGES 20 LEAD ACID CHARGER 20 ATX AND SOFTOFF STATE MACHINES 22 THE MAIN DC DC CONVERTER AND 5V STB 22...

Page 3: ...stallation Guide PV 5127 Power supply module with UPS Page 3 of 31 J1 28 ST3 28 J2 28 CN2 28 CN3 28 CN10 28 KL2 29 THERMAL CONSIDERATIONS 30 DIFFERENCES BETWEEN PV 5127 AND PV 5127A 31 BLOCK DIAGRAM OF THE PV 5127A 31 ...

Page 4: ... Installation Guide PV 5127 Power supply module with UPS Page 4 of 31 Revision history Revision number Reason for change Date 1 0 Initial revision 23 Mar 04 1 1 Error in mechanical layout changed page 27 21 Oct 05 ...

Page 5: ...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 ...

Page 6: ... in fan heat control Micronix PV 5127 has support for three ATX signals PWR_GOOD PS_ON and 5V Standby Micronix PV 5127 supports sealed lead acid batteries and the Micronix PV 1075 PC 104 NiMH battery pack Block Diagram 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 available at CN2 and CN10 A power...

Page 7: ...erature 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 temperatu...

Page 8: ...e 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 5V and 12V is applied to KL3 that is a five pole removable screw clamp connector The layout of this connector is printed in the silkscreen on the heatsink Output voltage indicators Three green LEDs indicate presence of the output voltages 5V 5V...

Page 9: ...en_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 5V_STB 10 5V standby is active when the main DC DC converter is on Not...

Page 10: ...Molex 7880 2 A ready made sensor with a 40 cm 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 KTY11 5 temperature dependent resistor Infineon ordering code Q62705 K245 Mating connector for J1 is Molex 7880 2 ...

Page 11: ... 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 The ATX signals 5V STB PS_ON and PWR_GOOD are not available in the PC 104 connector The PC 104 bus is also used for software UPS statu...

Page 12: ...d Below 0 C 3 C Cool Between 0 C 3 C and 15 C 18 C Warm Between 15 C 18 C and 47 C 55 C Too hot Above 47 C 55 C 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 too 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 ...

Page 13: ... 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...

Page 14: ...ON These signals are placed in connector CN10 In the figure below the relationship between Mains OK PS_ON and 5V STB is illustrated 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...

Page 15: ...lling or basic signalling protocol used by other UPS units The 10 pin 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 The signals use normal RS232 voltage levels Inactive 0 10V active 1 10V In the table shown inputs are indicated by i and outputs by o PV 5127 CN3 CPU RS232 DB9 Pin Function Pin...

Page 16: ...e time This time should be configured in the UPS monitoring software 1 1 Critical alarm The CPU is advised to shut down immediately This happens in two situations 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 ...

Page 17: ...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 IRQ...

Page 18: ...s 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 ...

Page 19: ...te 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 the 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 minidriver available at http w...

Page 20: ...an 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 vo...

Page 21: ...ult 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 other...

Page 22: ... When off the power consumption is minimal The output of the converter is also connected through a 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 th...

Page 23: ...es 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 ATX_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...

Page 24: ...ing 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 SOFT_OFF to SOFT_TEMPBAD...

Page 25: ... 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...

Page 26: ...perating temperature 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 60068 2 36 Shock IEC 60068 2 27 60068 2 29 Size W x L x H 90 x 96 x 15mm ...

Page 27: ...Users Manual Installation Guide PV 5127 Power supply module with UPS Page 27 of 31 Mechanical layout The schematic on this page shows the dimensions for PV 5127 All dimensions are in mm ...

Page 28: ...t 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 10 C factory default J2 Connect an external temperature sensor at J2 i e PV 5127 TW40 if the system temperature is to be supervised...

Page 29: ...nd 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 PC 104 connector CN1 or if you need powe...

Page 30: ...shows the relationship between Uin and Tcap Uin V Tcap C Tamb max C Pout W 10 67 60 75 18 72 55 75 24 74 53 75 30 86 41 75 All figures in the table match an 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 Tcap 22 These figures are given in the table If the PV 5127 is placed in an ambie...

Page 31: ...V 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 omi...