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

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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

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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).

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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.

UPS25 11 RTD Embedded Technologies, Inc
Chapter 2 - BOARD SETTINGS
The UPS25 board has jumper settings, which can be changed to suit your application
and host computer configuration. The factory settings are listed and shown in the
diagram at the beginning of this chapter. Make sure you completely study and
understand this chapter before making changed to these settings.
Factory-Configured Jumper Settings

UPS25 12 RTD Embedded Technologies, Inc
Table 2-1 below illustrates the factory jumper setting for the UPS25. Figure 2-1 shows
the board layout of the UPS25 and the locations of the jumpers. The following
paragraphs explain how to change the factory jumper settings to suit your specific
application.
Table 2-1 Factory configured jumper settings (Please see figure 2-1 below for more
detailed locations)
JUMPER NAME DESCRIPTION NUMBER OF JUMPERS FACTORY SETTING
BASE Base Address 3 300
IRQ Host interrupt 7 N.C.
B2/B3 blobs Charger control 3+3 C/2, Top off charge
enabled
Fig. 2-1 UPS25 Board layout showing jumper locations
Battery trip adjust
Input trip adjust
Address Jumpers
Interrupt Jumpers

UPS25 13 RTD Embedded Technologies, Inc
Base address jumper (Factory setting: 300h)
The UPS25 is I/O mapped into the memory space of your host computer. The
board occupies a consecutive memory window of 2 bytes starting from the base
address.
The most common cause of failure when you are first setting up your
module is address contention. Some of your computers I/O space is already
occupied by other devices and memory resident programs. When the UPS25
attempts to use it's own reserved memory addresses (which are being already
used by another peripheral device) erratic performance may occur and the data
read from the board may be corrupted.
To avoid this problem make sure you set up the base address by using the three
jumpers marked “J14”, this allows you to choose from a number of different
addresses in your host computer’s I/O map. Should the factory-installed setting of
300h be incompatible to your system configuration, you may change this setting
to another using the options illustrated in Table 2-2 (overleaf). The table shows
the jumper settings and their corresponding values in hexadecimal form. Ensure
that you verify the correct location of the base address jumpers. When the
jumper is removed it corresponds to a logical "0", connecting the jumper to a "1".
When you set the base address of the module, record the setting inside the back
cover of this manual.

UPS25 14 RTD Embedded Technologies, Inc
BASE ADDRESS JUMPER SETTINGS UPS25
Base address
Hex
Jumper settings
A8 A7 A6
200 0 0 0
240 0 0 1
280 0 1 0
2C0 0 1 1
300 1 0 0
340 1 0 1
380 1 1 0
3C0 1 1 1
0 = JUMPER OFF 1 = JUMPER CLOSED
Table 2-2 Base address jumper settings UPS25
Fig. 2-2 Base address jumpers illustrating address 300h

UPS25 15 RTD Embedded Technologies, Inc
Host interrupt (Factory setting: Not Connected)
The header connector, shown in Figure 2-3 below, lets you connect the onboard
control logic interrupt outputs to one of the interrupt channels available on the host
computer XT/AT bus.
Fig. 2-3 Interrupt jumpers from left to right: IRQ 2,5,7,10,11,12,15
Note: The UPS25 hardware does not support interrupt sharing! This feature is
sometimes regarded as a part of the PC/104 special features. After
extensive software and hardware tests we have found that error-free
interrupt performance cannot be guaranteed when sharing interrupts.
Charger control (Factory setting: C/2, top off charge enabled)
The solder blobs shown in Figure 2-4 below let you configure the operation of the
battery charger unit and the charge algorithm. Do not make changes to these
settings without examining the detailed description on the operation of the battery
charger described later in this manual in Chapter 4, hardware description.
Fig. 2-4 Charger control, solder blobs, located near the left side of the PC/104 bus connector

UPS25 16 RTD Embedded Technologies, Inc
Chapter 3 - BOARD INSTALLATION
The UPS25 uninterruptible power supply module is designed to directly mount on
top or under your RTD PC/104 power supply unit. This chapter tells you step-by-
step how to install your UPS25 into your system.
Board installation
Keep your board in its antistatic bag until you are ready to install it to your
system! When removing it from the bag, hold the board at the edges and do not
touch the components or connectors. Please handle the board in an antistatic
environment and use a grounded workbench for testing and handling of your
hardware. Before installing the board in your computer, check the power cabling.
Failure to do so may cause the power supply unit to malfunction or even cause
permanent damage.
General installation guidelines:
• Touch the grounded metal housing of your computer to discharge any
• antistatic buildup and then remove the board from its antistatic bag.
• Hold the board by the edges and install it in an enclosure or place it on the table on an antistatic surface
• Install your board in your system, and wire the power supply correctly.
• Failure to do so may cause the power supply unit to malfunction or even cause permanent damage to the device.
• Check all wiring connections once and then once more again.
• Check the input power to the board is in the range of 10 to 40V DC
• Apply power to your UPS25, this will automatically power your system
Installation integrated with a PC/104 module stack:
• Secure the four PC/104 installation holes with standoffs
• Connect the board to the main power supply using the power interface connectors
• Connect the output of your UPS25 to the input of your RTD power supply

UPS25 17 RTD Embedded Technologies, Inc
Fig. 3-1 UPS25 integrated in a RTD PC/104 cpuModule stack together with a HPWR104 power supply
module
Note: For full output power performance, install your UPS25 toward the top of
your PC/104 system, make sure adequate cooling is provided.

UPS25 18 RTD Embedded Technologies, Inc
External power connections
The illustration 3-2 below shows the input and output power connections of the UPS25
board.
Fig. 3-2 UPS25 power supply connections

UPS25 19 RTD Embedded Technologies, Inc
Connector descriptions:
• VIN:Raw input power to the UPS25. Input voltage ranges 10-40V DC
This input is fed to the power supply through the UPS25 in normal operation mode
(no backup from the battery pack).
Note: The module input power may be 5 Amp peak, this will require a cable wire
diameter of 1,5 sq. mm. Make sure this input wire is kept as short as
possible to reduce voltage drops and interference.
• Batt: Connect your external 8 AA-size 1500mAh Ni-MH or 1000mAh Ni-Cd battery pack here. Batt- is
connected to the system ground.
• NTC: Direct connection to the NTC thermistor of your battery pack.
• VO: Output of the UPS to the power supply module
• VOS: Switched output of the UPS to feed the power supply module. If this connection is used you can under
software control disengage the battery backup when the shutdown procedures are complete. (See later sections for
a more detailed description on the functionality of this output)

UPS25 20 RTD Embedded Technologies, Inc
Chapter 4 - HARDWARE DESCRIPTION
This chapter describes the major hardware building blocks of the UPS25, which are:
• The main 25W +5V step-down converter
• Charger power converter
• Ni-MH/Ni-Cd battery charger
• Power switching circuitry
• Voltage monitors
• UPS control circuitry
• I/O interface connector
Fig. 4-1 Block diagram of the UPS25