rtd UPS25 User manual

UPS25
Uninterruptible power supply and
Ni-Mh/Ni-Cd charger unit
User’s Manual
BDM-610020008
Rev. C
I
IS SO O9 90 00 01 1 a an nd d A AS S9 91 10 00 0 C Ce er rt ti if fi ie ed d

UPS25 2 RTD Embedded Technologies, Inc
UPS25
Uninterruptible Power Supply
User’s Manual
RTD Embedded Technologies, INC.
103 Innovation Blvd.
State College, PA 16803-0906
Phone: [phone]
FAX: [phone]
E-mail
[e-mail]
techsu[email protected]
web site
http://www.rtd.com

UPS25 3 RTD Embedded Technologies, Inc
Revision History
10/08/2000 HW Release 1.0
10/07/2001 Name of company corrected
Rev A New manual naming convention
Rev B Removed reference to EFAN; Included hot-swap warning
Rev C Removed information about J12
Published by:
RTD Embedded Technologies, Inc.
103 Innovation Blvd.
State College, PA 16803-0906
Copyright 1999, 2002, 2003, 2004, 2005 by RTD Embedded Technologies, Inc.
All rights reserved
Printed in U.S.A.
The RTD Logo is a registered trademark of RTD Embedded Technologies. cpuModule and utilityModule are trademarks of
RTD Embedded Technologies. PS/2, PC/XT, PC/AT and IBM are trademarks of International Business Machines Inc. MS-DOS,
Windows, Windows 95, Windows 98 and Windows NT are trademarks of Microsoft Corp. PC/104 is a registered trademark of PC/104
Consortium. All other trademarks appearing in this document are the property of their respective owners.

UPS25 4 RTD Embedded Technologies, Inc
TABLE OF CONTENTS
CHAPTER 1 - INTRODUCTION ............................................................................... 7
Features........................................................................................................................................................................7
Some of the key features of the UPS25 include: ...................................................................................................7
Power supply unit........................................................................................................................................................8
Charger unit.................................................................................................................................................................8
Host interface and control..........................................................................................................................................8
Mechanical description...............................................................................................................................................8
Connector description.................................................................................................................................................8
What comes with your board .....................................................................................................................................9
When you need help..................................................................................................................................................10
CHAPTER 2 - BOARD SETTINGS......................................................................... 11
Factory-Configured Jumper Settings......................................................................................................................11
Charger control (Factory setting: C/2, top off charge enabled).......................................................................15
CHAPTER 3 - BOARD INSTALLATION................................................................. 16
Board installation......................................................................................................................................................16
General installation guidelines: ...........................................................................................................................16
Installation integrated with a PC/104 module stack:............................................................................................16
External power connections......................................................................................................................................18
CHAPTER 4 - HARDWARE DESCRIPTION.......................................................... 20
Current Limit.......................................................................................................................................................21
Charger power converter .........................................................................................................................................21
Ni-Mh/Ni-CD Battery Pack and Thermistor........................................................................................................22
Ni-Mh\Ni-Cd battery charger ..............................................................................................................................23
Discharging Ni-Mh/Ni-Cd battery pack ..............................................................................................................23
Charger mode configuration- solder blobs B2 and B3...........................................................................................24
Power switching circuitry.........................................................................................................................................25
CHAPTER 5 - BOARD OPERATION AND PROGRAMMING................................ 28
Defining the Memory Map .......................................................................................................................................28
BA+0 Control register (Read and Write).........................................................................................................28
BA+1 Status register (Read)...........................................................................................................................29
BA+1 Status register (Write)..........................................................................................................................29
Programming the UPS25 ..........................................................................................................................................29
Clearing and setting bits in an I/O port...................................................................................................................30
INTERRUPTS...........................................................................................................................................................30
What is an interrupt? ...........................................................................................................................................30
Interrupt request lines..........................................................................................................................................31
8259 Programmable Interrupt Controller ............................................................................................................31
Interrupt Mask Register (IMR)............................................................................................................................31
End-of-Interrupt (EOI) Command.......................................................................................................................31
What exactly happens when an interrupt occurs?................................................................................................32

UPS25 5 RTD Embedded Technologies, Inc
Using Interrupts in your Program........................................................................................................................32
Writing an Interrupt Service Routine (ISR).........................................................................................................33
The following C example shows what the shell of your ISR should be like:.......................................................34
Saving the Startup Interrupt Mask Register (IMR) and interrupt vector .............................................................34
Common Interrupt mistakes.................................................................................................................................35
Example on Interrupt vector table setup in C-code: ............................................................................................36
CHAPTER 6 - UPS25 SPECIFICATIONS .............................................................. 37
Host interface.............................................................................................................................................................37
Power supply specifications......................................................................................................................................37
Charger and batteries...............................................................................................................................................37
Electromechanical .....................................................................................................................................................37
CHAPTER 7 - RETURN POLICY AND WARRANTY ............................................. 38
Return Policy.............................................................................................................................................................38
LIMITED WARRANTY.................................................................................................. 40

UPS25 6 RTD Embedded Technologies, Inc
List of Illustrations and Tables
.............................................................................................................................................................. Illustrations
Fig. 2-1 UPS25 Board layout showing jumper locations
Fig. 2-2 Base address jumpers illustrating address 300h
Fig. 2-3 Interrupt jumpers from left to right: IRQ 2,5,7,10,11,12,15
Fig. 2-4 Charger control, solder blobs, located near the left side of the PC/104
bus connector
Fig. 3-1 UPS25 integrated in a RTD PC/104 cpuModule stack together with a
HPWR104 power supply module
Fig. 3-2 UPS25 power supply connections
Fig. 4-1 Block diagram of the UPS25
Fig. 4-2 Discharging jumper
Fig. 4-3 Charger configuration, solder blobs B2 and B3
Fig. 4-4 Trip point adjustment trim pots for VIN and BATT levels
Fig. 4-5 I/O interface connector
...................................................................................................................................................................... Tables
Table 2-1 Factory configured jumper settings
Table 2-2 Base address jumper settings UPS25
Table 4-1 Charger status LED functional description
Table 4-2 I/O connector pin outs

UPS25 7 RTD Embedded Technologies, Inc
Chapter 1 - INTRODUCTION
This user’s manual describes the operation of the UPS25 versatile uninterruptible
power supply unit for automotive and industrial applications.
Features
Some of the key features of the UPS25 include:
• Compatible with RTD power supplies
• Wide input voltage range 10-40V DC
• Battery currents to 5 Amps
• Maximum 20W charge power with adequate cooling 75% total efficiency
• -40 to +85C ambient operating temperature
• Battery backup
• 8 Ni-MH battery cells, 25 Watt 30 min backup time
• 1500 mAh 9,6V nominal battery voltage
• 24 Watt 30 min backup time
• Discharge -10 to 65°C battery temperature
• Charge 0 to 40°C
• 8 Ni-Cd battery cells, 25 Watt 20 min backup time
• 1000 mAh 9,6V nominal battery voltage
• 24 Watt 20 min backup time
• Discharge -20 to 65°C battery temperature
• Charge 10 to 40°C
• Thermistor feedback charging process
• Complete software controlled charging process
• Main power fail interrupt with Software controlled shutdown of backup
• Adjustable backup voltage trip level
• Fully PC/104 compliant
• Part numbers:
• UPS25-1 Ni-MH battery version
• UPS25-2 Ni-Cd battery version
The following paragraphs briefly describe the major features of the UPS25. A more
detailed discussion is included in Chapter 4 (Hardware description). The board’s
installation is described in Chapter 2 (Board Installation).

UPS25 8 RTD Embedded Technologies, Inc
Power supply unit
The UPS25 uninterruptible power supply unit is designed to provide a complete
backup system for your embedded computer and its peripherals. Battery
charging power is generated using a wide input voltage range (8 to 40V DC) step
down converter with a maximum charging output power of 25W. Battery charging
power is converted from this output using a second step-up DC/DC converter.
This scheme will enable charging of the batteries at +12V, while operating at an
input voltage of 10V. The UPS25 input is protected against reverse voltage up to
40V, and is over voltage protected using a 5 Watt 40 V zener diode.
Charger unit
While the main system power is present the onboard battery charger may charge
the external battery pack. However charging may be disabled by software by
writing to the appropriate charger control bit. Charging will not take place if any of
the following conditions are met: 1) main power is below 10V, 2) battery
temperature is out of limits, 3) battery is already charged, 4) battery error exists.
Host interface and control
The UPS25 can be controlled and monitored from software. A host interrupt may
be generated to indicate that the main power supply is below 10V and that the
system is powered from the battery pack. This interrupt can be used to start
required actions. The state of the UPS25 can be polled using status bits
indicating battery voltage level, charger state and battery temperature state.
Mechanical description
The UPS25 is designed on a PC/104 form factor. An easy mechanical interface
to both PC/104 and EUROCARD systems can be achieved. Stack your UPS25
directly on a PC/104 compatible power supply using the onboard mounting holes
and standoffs.
Connector description
All power connections are made using "cable plug" type terminal blocks. This
enables removing connections from the board without opening the cables from
the terminal blocks. Power must be removed before connecting or disconnecting
batteries. Hot swapping the battery pack may damage the UPS25.

UPS25 9 RTD Embedded Technologies, Inc
What comes with your board
Your UPS25 package contains the following items:
• UPS25 board with mating connectors for the supported power connections
• User's manual
Note: Software and drivers can be downloaded from our website.
If any item is missing or damaged, please send an EMAIL to RTD Embedded
Systems, Inc. sales service department at <[e-mail] >.

UPS25 10 RTD Embedded Technologies, Inc
Using this manual
This manual is intended to help you install your new UPS25 module and get it
working quickly, while also providing enough detail about the board and it's
functions so that you can enjoy maximum use of it's features even in the most
demanding applications.
When you need help
This manual and all the example programs will provide you with enough
information to fully utilize all the features on this board. If you have any problems
installing or using this board, contact our Technical Support department at
<[e-mail]>. When sending us an Email request please include the
following information: Your company's name and address, your name, your
telephone number, and a brief description of the problem.