Table of Contents
Table of
Contents
Introducing the SunDuino
Overview
DC Outputs
Power Control
Operating Modes
Sleep Mode Operation
SunDuino Software
1
General Description . . . . . . . . . . . . . . . . . . . . .
Primary Power Input . . . . . . . . . . . . . . . . . . . . .
Battery Operation . . . . . . . . . . . . . . . . . . . . . . .
Output Converter. . . . . . . . . . . . . . . . . . . . . . . .
Control Logic . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
7
Operation with Battery and User Application . . 7
Operation without User Application . . . . . . . . . 7
Operation without Battery. . . . . . . . . . . . . . . . . 8
Active vs. Sleep Currents . . . . . . . . . . . . . . . . . 8
Sleep Wake Up Events . . . . . . . . . . . . . . . . . . . 9
11
XC8 Compiler/Linker
Processor Memory Model . . . . . . . . . . . . . . . . 11
C Library Functions . . . . . . . . . . . . . . . . . . . . 12
LED Blink Patterns . . . . . . . . . . . . . . . . . . . . . 13
SunDuino Hardware
15
Overview
Boot Loader
Overview
Sample Wiring
25 Pin D Signals
I2C Voltage Levels
BB25E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BB10B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5V / 3.3V Regulation Selection . . . . . . . . . . . 17
19
Operating Options . . . . . . . . . . . . . . . . . . . . . . 20
Advanced Usage . . . . . . . . . . . . . . . . . . . . . . . 21
23
Connector Signals . . . . . . . . . . . . . . . . . . . . . . 23
Interface Board . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3V and 5V I2C Operation . . . . . . . . . . . . . . 24
Introducing the
SunDuino
1
Overview
General Description
The SunDuino is a complete micro-controller board with an integrated
battery system designed for instrumentation, data collection and portable equipment support. Both solar panels and DC power sources are
used to charge external batteries and supply power to regulated outputs.
User written applications can be loaded into 48-KB of included
FLASH memory for execution in parallel with SunDuino battery
DC Supply
Solar Panel
Battery
Input Filter
&
Battery Charger
DC Converter
&
Output Filter
+5V
+3.3V
+12V
-12V
Microchip PIC1826K20
RTOS Micro Kernel
User Embedded C
Application & Libraries
RS-232 Serial Port, TTL IO Bits and I2C
for Embedded System Application
1-1
Chapter 1 Introducing the SunDuino
charger and control software. A micro kernel provides cooperative
multitasking between user-loaded and native-battery functions.
The software libraries supplied with a SunDuino board provide a
means for user applications to interface with SunDuino power functions. By using the SLEEP mode support supplied in these libraries, a
user application can easily execute operations while using as little as
200 ua. Small rechargeable batteries provide the means for the
SunDuino board to operate at this current for a year or more.
All connections to the SunDuino are made through a single 25 pin D
male connector. Various connector styles such as solder cup and mass
termination connectors can be used to simplify physical interface with
user system components.
A SunDuino can manage batteries of various chemistries and sizes.
Charging and battery control is based on a downloadable EEPROM
configuration table. Configuration tables are provided for numerous
types and sizes of batteries. New battery support is easily downloaded.
SunDuino interfaces can be divided into four sections.
·
Primary Power Input
·
Battery Connection
·
Regulated Power Output
·
Control Logic
Primary Power Input
Unregulated Direct Current power is supplied to the SunDuino through
board’s DC Input. This input provides power for target operation, battery charging, and internal operation. A low-cost wall mount type supply is the most common source for primary power. Solar panels are
supported along with provisions for setting the Maximum Power Point
(MPP) of the connected solar panel. Charging logic will attempt to
maintain the output of each panel at its specified MPP to maximize
power delivered.
A major requirement for the primary power source is the ability to
maintain proper input voltages during both target operation and battery
charging. To charge the battery and run loads properly, the DC input
voltage must be maintained at a level greater than the receiving battery’s peak voltage. For an 12V lead acid battery pack, the corresponding minimum DC input voltage must exceed 16 volts (15.0v charging
voltage and 1.0v ‘overhead’). Note that this 16 volt figure includes leeway for any ripple voltages. If the input voltage is ever less than 16
1-2
Chapter 1 Introducing the SunDuino
volts, battery charging will halt during final charging. If the DC input
voltage continues to drop, the battery will start to discharge as the output converter is switched to battery power.
A major source of failure in microprocessor based systems is the intermittent application of power. Rapid application and removal of power
to a system will at best hang the system. At worst such behavior can
damage both the power supplies and the processing equipment. Hardware circuits and software logic within the SunDuino isolate the target
from severe input variations and supply power to the target in a controlled manner.
Battery Operation
Battery operating characteristics are maintained within a table held in
processor EEPROM. This table of ~43 parameters is configured to control operation of a specific battery type and size. These EEPROM constants can be overwritten by the simple download of an alternate .hex
configuration file. A checksum is included in this table and SunDuino
software will verify this checksum when power is applied.
Optimization of battery life is a primary goal in the SunDuino software
design. Major logic includes functions that limit over-discharge during
battery usage and over-charging during charge cycles. Charge limit is a
particularly difficult task given the desire for 100% charge at a maximum rate. Internal software logic adjusts the charge cutoff point to account for changes in total charge, cell voltages, and temperature.
Additional logic attends to peak charge maintenance and eliminates the
overcharge associated with constant current trickle charging.
While the SunDuino controls all phases of battery charging - design of
a robust system that takes full advantage of the SunDuino requires an
understanding of battery basics. A broader understanding of battery operation will help with the selection of the appropriate battery pack for a
specific load - a selection that will significantly enhance system operation.
Batteries are complex chemical systems which convert energy between
electrical and chemical forms. Power, or the rate of energy transfer, requires a corresponding chemical reaction rate. Batteries do not maintain
a constant ability to react agents as their chemical composition changes.
A fully charged battery contains a large amount of active material, providing delivery of energy at a high rate. Since the fixed voltages on
SunDuino outputs deliver constant power to the load, the DC converter
requires greater battery current as the battery voltage drops. A battery
with a low charge does not contain the same supply of active chemicals. A partially discharged battery cannot provide the high peak cur-
1-3
Chapter 1 Introducing the SunDuino
rents possible with a fully charged battery. Low temperatures will
further reduce the ability of a battery to supply power. Significant battery de-rating is required for low temperature operation with partially
discharged batteries.
When selecting a battery it is important to consider peak load currents
in addition to the total mahr capacity. A good example is a portable instrument using a thermal print head. Print heads draw more than 2
amps during brief printing cycles while the remaining system might
draw only 100mA. Selecting a 1 Amp-Hour battery for 10 hours of operation will result in failure after only a couple hours of operation. Failures take place when the print head energizes, battery voltage drops,
and the system loses power resetting the processor and jamming the
printer. The key to a successful system is knowing the remaining battery capacity and disabling the printing process. The SunDuino solves
these problems by maintaining this information and making it available
to the user applications for the control of system operation.
Software logic within SunDuino and its EEPROM tables prevent operating the battery down to the point of cell reversal. Detection of a minimum battery voltage will abort the discharge process and shut off
regulated power. At this point the battery is considered EMPTY, and
battery usage will not resume. Restoring primary power will not clear
the EMPTY condition. If primary power again fails while the battery is
EMPTY the target is turned off and the battery is not used for power.
Only after the battery is partially recharged will the EMPTY condition
be cleared and the battery made available for target operation.
DC Outputs
Output Converter
A 100 KHz flyback converter accepts energy from the DC input or battery and delivers this energy to 4 output windings. Since one of the
flyback outputs (either the +5 or +3.3 outputs) controls flyback feedback, and given the nature of the coupled secondary flybacks, all 4 outputs remain at constant output voltage while the primary input voltage
changes (Line Regulation). SunDuino line regulation is typically < 2%.
As the target load changes, the remaining 3 none-monitored outputs do
change voltage slightly, typically less than 5%. The single monitored
output is very stable with load variations affecting output voltage measuring at less than 2%. The level of regulation is dependent on the actual load current, while the minimal load current (about 10mA) can
greatly improve flyback coupled regulation.
1-4
Chapter 1 Introducing the SunDuino
Digital systems typically require the greatest regulation on the main
logic supply voltage, with less regulation required for analog processing supplies. The SunDuino provides two digital outputs: +5 and +3.3
volts. Either of these outputs can be directly regulated. Some systems
require both +5 and +3.3 supplies. Strapping options on the SunDuino
connector allow selection of the most variable load, or the most heavily
loaded output for direct regulation. Construction techniques used in
manufacturing the main flyback inductor provide a high degree of regulation between the +5 and +3.3 sections.
Voltage for analog processes consist of two outputs: +15 and -15 volts.
These outputs are not directly regulated but are filtered to reduce noise.
Flyback operation maintains the load regulation of these outputs to
within 10%. All output voltages are adjustable via a potentiometer
mounted on the SunDuino PCB. All voltages are adjusted proportionally. The BB25E unit includes 12V, 100mA linear regulators with
strapping options to allow selection of the 15V raw outputs or 12V regulated outputs. The BB10B is hard wired with 13V flyback regulated
outputs.
BB25E units include additional common mode chokes for EMI control.
Multiple winding common mode chokes provide a high degree of isolation for high frequency signals between the BB25E and the regulated
outputs. This high level of filter isolation make the BB25E an ideal
power source for sensitive analog processing and measurement instruments. High frequency noise on digital power lines is also blocked by
these chokes, simplifying system EMI filtering and regulatory compliance.
The BB10B is a smaller, lower power-lower cost unit. It does not contain the additional common mode chokes. However, both BB10B and
BB25E units incorporate multilayer PCBs which help to minimize system noise.
Control Logic
A single On/Off control signal along with internal SunDuino software
provides the user with a number of possible power control options.
These options include:
·
Push On, Push Off (‘Toggle’) Operation
·
Push On, Release Off Operation
·
Continuous Operation (UPS Mode)
·
Push On - Target Software (Hold and Release)
1-5
Chapter 1 Introducing the SunDuino
Control of the Battery Boss ON/OFF status is through a signal on the
25 pin connector. A 3 volt signal applied to this ON/OFF circuit (>
10K ohm input impedance) will cause the switching regulator to start if
power conditions permit. Software logic will not permit the inverter to
start if the primary voltage is less than permitted or if pervious operation has left the battery in an EMPTY condition. When the converter
starts, hardware circuits limit inrush current and temporarily disable
primary input voltage monitors.
1-6
Power Control
2
Operating Modes
The SunDuino operates in three configurations depending on application requirements. Variations include:
·
Operation with both Battery and User Application
·
Operation without User Application
·
Operation without Battery
Operation with Battery and User Application
The most common application configuration of the SunDuino PCB
uses a battery for backup power while providing DC power conversion
and battery charge control in the background. The ‘On/Off’ input on
the 25 Pin D connects directly to either a momentary switch, a toggle
switch, or an external control signal. Logic in lower level SunDuino
code allows a momentary switch to toggle power ‘On’ then ‘Off’. A
user application executing in the SunDuino can access these signals as
well as exert direct control over power outputs and can cycle of the
user load ‘On’ and ‘Off’. A user application can also lock power into
an ‘On’ state during critical operations such as a data storage write
operation.
User applications are downloaded from a PC using the SunDuino
Boot-Loader program. The boot-loader operates using the Microchip
AN-1310 protocol. Communications between the PC and SunDuino
through this boot-loader are initiated via a push-button interface, after
which a 60-second timeout is provided within the SunDuino firmware
to prevent inadvertent lockout of normal operation. The SunDuino status LED toggles with the button push and then stays on throughout the
duration of boot-load operation. Additional features such as download
of battery configuration files and controlling operation modes are also
supported by the SunDuino Boot-Loader application.
Operation without User Application
Many applications exist where power requirements do not exceed simple Uninterruptible Power Supply (UPS) operation. While the
2-7
Chapter 2 Power Control
SunDuino is operating in this mode, no user application is downloaded
into SunDuino FLASH and only the internal control logic is executed.
Operation of the target power is controlled by the On/Off signal (25 pin
D connector) while UPS and battery charger functions operate normally. If SunDuino EEPROM has been configured to operate with a
solar panel, the firmware will attempt to maintain operation at the Maximum Power Point (MPP) of the panel. The SunDuino Boot-Loader
program is used to customize operating modes and set up solar panel
operation.
Operation without Battery
Operation of the SunDuino does not require that a battery be connected. The SunDuino detects when a system battery is not connected
and will automatically change operating modes to compensate for the
change. When power is applied to the DC input and no battery is connected, the SunDuino will clear the Gas Gauge, start as normal, and
then start execution of the user application. When power is removed,
the SunDuino will shut down as the input voltage fails. During SLEEP
MODE operation, the low level of operating current can result in the
SunDuino running off of internal filter caps for 10s of seconds.
Whenever the SunDuino detects a missing battery, the Gas Gauge is reset to zero. This zero value is also written to the EEPROM locations
where knowledge of the remaining capacity is stored. If a battery is disconnected and remains disconnected for 30 seconds or more during
standard operation, the SunDuino will declare the battery as missing
and the Gas Gauge values will be reset. If a battery is disconnected for
service it must be reconnected quickly. If a new battery is connected
the user should wait 2 minutes to ensure the Gas Gauge has been
cleared.
Sleep Mode Operation
Active vs. Sleep Currents
When operating any system from a battery, it is important to limit execution time as much as possible to minimize power requirements, resulting in an increased battery life and run time. Turning off processor
clocks and the ability to quickly power down the proper circuits is critical, but also critical is the SunDuino’s ability to wake rapidly. A standard PC might take 10s of seconds to wake, whereas an embedded
processor could have the need to wake up in a matter of microseconds.
2-8
Chapter 2 Power Control
The handling of how a system moves into and out of sleep is often a
complex section of embedded design and is prone to various unseen design issues. The SunDuino provides this function within its lower level
RTOS kernel.
Internally, the SunDuino maintains 4 major states: ‘Idle’, ‘Running on
Battery’, ‘Full’, and ‘Charging’. ‘Idle’ is a key state, as it indicates that
the DC power converter is off and NO input voltage is present from a
DC supply or solar panel. It is in the ‘Idle’ state that the SunDuino can
enter sleep to reduce power consumption. During normal operation, the
basic SunDuino processor circuits draw approximately 10mA, in sleep,
the current is reduced to 10s of microamperes. The key parameter associated with average power is the percentage of time the processor is operating. This is about 1% in the SunDuino, including the execution of a
minimal user application. At a minimum the SunDuino exits from sleep
at 8Hz (every 125ms) and executes for about 1ms. The resulting usage
is approximately 150 ìA of average battery load. If the user application
does significant processing (as in floating point operations) during the
wake time, this average draw increases.
Entry into sleep must be coordinated with any user application running
on the SunDuino processor. Since only the user application knows
when it is safe to sleep the, SunDuino library includes a function by
which the processor can invoke sleep mode. The function returns to the
user application when one of several interrupt events are triggered.
Sleep Wake Up Events
There are several events that cause the processor to exit sleep and return to the user application.
·
Real Time Clock tick at 8 Hz.
·
UART Receive character.
·
External ON/OFF signal change.
If the processor is in sleep the above events will bring it out of sleep.
There are also a number of processes that will prevent the processor
from going into sleep.
·
Battery system not in ‘Idle’ state.
·
Critical analog processing running.
·
Various Errors. (Missing battery or power errors.)
2-9
Chapter 2 Power Control
Examples of using SLEEP MODE can be found in the various sample
application provided with SunDuino toolkits. In general a “Main Loop”
in a SunDuino application will look something like:
while (1) {
do
{
SleepRes = bb_func_DoSleep ();
RX_Process ();
//Check for incoming characters
Sec = bb_time_getSeconds();
} while ( Sec == j);
// Drop through means 1 second has passed, do something
do_something();
j = Sec;
//Setup to detect next second.
In the above loop code at “do_something()” will execute once a second. The SleepRes variable can be used to detect if or if not sleep mode
was blocked and why. User application can use SleepRes to control
other software threads if required. In this sample the processor will exit
from sleep and use a change in the Real Time Clock Seconds counter
to trigger execution of the do_something() routine.
2 - 10
SunDuino
Software
3
XC8 Compiler/Linker
SunDuino PCBs use the XC8 Microchip C compiler/linker for the
PIC18F26K20 processor. Various XC8 versions are available, including a free version that requires minimal code optimization. Even when
using the free compiler to compile a user application, floating point libraries and extensive ‘printf’ functions, only about 30% of the available 48KB of program FLASH is occupied. User applications without
‘printf’ statements use significantly less FLASH memory, typically
only a small percentage of available program FLASH. Advanced
optimizing compilers are available for a fee.
Processor Memory Model
SunDuino firmware for low level battery control and charging is stored
in FLASH locations 0x0000-0x3FFF. These locations are protected
from external reading and writing. The remaining memory space
(0x4000-0xFFFF) is free for user applications, typically written in C.
SunDuino low level code also uses 256 bytes of RAM from locations
0x100-0x1FF.
Battery configurations and operating constants are stored in the low
128 bytes of EEPROM. These locations can be programmed with one
of various battery files, allowing users to easily switch between battery
types and sizes. Example source code and .hex files for various battery
types and sizes are provided. A Boot Loader is provided for downloading FLASH and EEPROM from .hex files using a PC with COM
port.
When a project is setup in the MPLAB tool, both a code offset and
RAM exclusions are required by the XC8 Linker:
Memory Model Tab: (In hex.)
RAM ranges
default,-100-1ff
3 - 11
Chapter 3 SunDuino Software
Additional Options Tab:
Code Offset
4000
Both of these settings are required to ensure that users’ compiled C applications do not use SunDuino’s reserved RAM locations and that executable code is pushed into where the write-safe areas of FLASH
memory begins (0x4000).
When the SunDuino powers on, the battery charging and control firmware is initialized. If location 0x4000 is anything but erased (erased
bytes have a value of 0xff), a jump is made to location 0x4000. XC8
will place the run time startup code at 0x4000 (with the code offset defined in the linker), and C code executions takes place. The C application should execute within an indefinite ‘while’ loop and never return.
C Library Functions
The following is a partial list of SunDuino library functions. See
SunDuino_Vxxx.h for details.
Command
Name
bb_battery_getGas()
Cmd
Letter
Returns remaining capacity as mahr.
bb_battery_getPercentage()
Returns remaining capacity as 0 - 100.
bb_battery_getSize()
Returns full capacity of battery.
bb_getTemperature()
Returns battery temperature from -40C to 80C.
bb_volts_getVRun()(
Returns DC input voltage. 0V to 40V
bb_volts_getVBattery()
Returns battery voltage. 0v to 40V
Returns voltage available to charge battery
0V to 40V
bb_amps_getAverageCurrent() Returns current used by output regulator.
0 Amp to 6.5 Amp
Used to place processor in sleep if permitted.
bb_func_DoSleep()
Used to initiate an application WDT.
bb_func_PwrOnOff(Sec)
bb_volts_getVCharger()
bb_func_PowerIsOn
Returns 1 or 0 if output regulator is On or Off.
bb_time_getxxxx()
Functions to read time from Real Time Clock.
bb_date_getxxxx()
Functions to read date from Real Time Clock.
Microchip provides a large library of C functions for numerous types of
IO. The most important of these functions are ‘I2C’ and ‘printf’. I2C
allows the user application to control a vast array of hardware functions, while printf sends characters to external devices using true
RS-232 levels. Various power control states and analog readings are
available from the SunDuino libraries, for a more detailed description
3 - 12
Chapter 3 SunDuino Software
of these, see the SunDuino_Vxxx.h header file. Sample C files are provided.
Once a user application is compiled into a .hex file, the SunDuino Boot
Loader can be used to download this file into SunDuino FLASH or
EEPROM. The Boot Loader runs in a PC and uses a COM port to
download code.
A button on the SunDuino PCB must be pushed to start the Boot Load
process which also aborts all other SunDuino processes. Both the battery charger and output DC regulator are disabled during Boot Loader
operation. When using the Boot Loader, it is impossible to overwrite
low level code in FLASH. Note that (FLASH is write protected, but
EEPROM is writable. Various battery configuration .hex files are provided for programming the lower 128 bytes of EEPROM. It is these locations that control operation for a specific battery type and size.
Writing to any other locations in the lower 128 bytes of EEPROM is
not recommended.
The Boot Loader allows .hex files and .ini files to be passed as command line (or desktop shortcut) options. A complete .ini file is written
to a default file name each time the Boot Loader closes. If this .ini file
is copied to another directory and renamed, it will completely define a
programming session. Passing this renamed .ini file as a command line
operation will completely control a programming session and, causing
the default .ini file to be ignored. When the Boot Loader uses a command line option, it will automatically close, allowing support with
simple batch control files.
The default .ini file location is:
C:\ProgramData\IndexDesigns\SunD_Loader.ini
When a .hex file is passed on a command line, the .hex file will be
downloaded using programming options from the default .ini file.
Again, the Boot Loader will automatically close once the file is downloaded.
LED Blink Patterns
A small LED on the SunDuino PCB is used to provide feedback to the
user about current operation.
·
Fully Charged
Solid On
·
Charging
1 Second On and Off
·
Run On Battery
1/2 Second On 1.5 Off
·
Sleep Mode
Short Blink Every 5 Second
3 - 13
Chapter 3 SunDuino Software
·
Boot Load Mode
Solid On
The Sleep Mode short blink is VERY short, only milliseconds in duration. Users must watch closely as this short blink only happens once
every 5 seconds. This short blink was chosen to minimize battery current drain during SLEEP MODE operation.
3 - 14
SunDuino
Hardware
4
Overview
SunDuino hardware exists in two versions, the BB25E and BB10B.
Both are similar in function, and both run the same firmware. The
BB10 is the smaller, lower power, and less expensive of the two
boards. The BB25E is built using an aluminum backed PCB which supports operation at higher power through improved thermal
management.
Each version provides a general purpose user analog input. A gain set
resistor at location R20 determines the full scale input voltage range. A
default value of 10.2K ohms at R20 provides a full scale reading of
10.0 Volts. Adding an external 15K 1% resistor in series increases this
value to 40V . See schematic for details.
BB25E
The most distinguishing feature of the BB25E is the merging of a thin,
thermally conductive, multi-layer PCB and an aluminum base plate.
Boot Loader
Push Button
Charger
Flyback Transformer
25 Pin D Connector
Voltage 3/5 Volt
Adjust Regulation
Select (R45)
4 - 15
Chapter 4 SunDuino Hardware
The metal base spreads heat away from various power components, allowing operation at higher power. This technique eliminates the need
for heat sinks and simplifies assembly of the final user system. Two
common mode chokes are included, one on the DC input (left side),
and one on the four DC outputs (on the lower right). Two large mounting holes (one on each side), as well as four smaller mounting holes are
provided for mounting simple user hardware. The back side of the PCB
is bare aluminum and is electrically isolated from other circuits. The
top side of the mounting holes are connected to the CHASSIS GND
signal. Inserting a metallic screw into these holes will bond the CHASSIS GND to the aluminum base. Small ceramic bypass caps on both the
input and output circuits form AC connections to SIGNAL GND. Care
must be taken that the CHASSIS GND to input and the output GND
voltage do not exceed the 50V rating of these bypass caps. See the
schematics.
While the EFD20-size flyback transformer will operate at 25 watts, the
true limits are affected by input voltage, available battery current, and
thermal design. Attempting to supply 25 watts from a 6 volt battery
would require 4-5 amps which is greater than what most small batteries
can provide. Output diodes would be stressed both electrically and thermally if that level of power was delivered to the 3.3V or 5V outputs.
OEM implementations with output voltages higher than 5V can easily
reach 25 watts or more with custom magnetic components and synchronous rectifiers.
The BB25E includes an opto-isolator and drive circuit which together
make the 5, 3.3, and +/- 12 volt outputs optically isolated from the input power side. Care must be taken that any common mode voltage differences do not exceed 50V as the circuits contain small AC bypass
capacitors between the various GND signals.
Two linear regulators are included for +/- 12V regulation from the
flyback 15V outputs. Maximum output current from these regulators is
100mA. Flyback windings are designed to provide the +/- 15V which
drives these linear regulators. Jumper pads are included on the lower
and right PCB edges which can short out the regulators and allow delivery of +/- 15V to the SunDuino output. Solder blobs are easily
added.
The BB25E also includes a location where .050 inch-spaced posts can
be mounted for the attachment of a Microchip In-Circuit-Development
(ICD) connector. While small probe points are available for factory
programming, engineering development is simplified with a fixed ICD
connection.
4 - 16
Chapter 4 SunDuino Hardware
System testing and development is best done using a BB25E. If development is accomplished through the ICD connector care must be taken
to NOT ERASE FLASH. Doing so will delete the low level SunDuino
operating code and RTOS. Erasing this flash will require factory
re-flashing as the low level FLASH code is not released as a hex file
for user programming.
BB10B
The BB10B is a simple four layer PCB built using 0.062 thick FR4 material. While internal power planes help conduct heat away from power
components, overall thermal characteristics limit total available power.
A smaller flyback transformer along with lower charger currents are
used as a consequence of this simplified thermal design.
Charger
Flyback Transformer
Boot Loader
Push Button
Voltage
Adjust
3/5 Volt
Regulation
Select (JP1)
25 Pin D Connector
Mounting can be accomplished using thin layers of mounting adhesive
tape or by using the 4 corner mounting holes with #4 hardware. The
bottom side is void of components, which allows simple mounting to
the flat surface. The bottom side of the BB10B does contain circuit
traces, so mounting to conductive surfaces requires insulation.
CHASSIS GND on the PCB is connected to the 4 mounting holes.
Small 50V ceramic bypass caps are included between electrical GND
and CHASSIS GND, so any common mode voltage difference must be
limited to 50V.
5V / 3.3V Regulation Selection
4 - 17
Chapter 4 SunDuino Hardware
Each SunDuino version includes a 0603 sized set of mounting pads
which can be used to control the source for output voltage regulation.
The BB25E part is labeled as R45 while the BB10B part is labeled as
JP1. When these locations are open (default), the 5V output is directly
regulated. Installing a jumper (or solder blob) at this location connects
the 3.3V output into the regulation circuit which causes the 3.3V output
to be directly regulated. In place of a short, a small resistor can be used
to force regulations to a midpoint of both 5 and 3.3 volt outputs.
4 - 18
Chapter 5 Boot Loader
Boot Loader
5
Overview
The SunDuino Boot Loader is a Windows PC application with the main
form shown below. The left hand column shows from top to bottom:
the app version, the green or red connection status, user options, downloaded file, erase options, and memory areas to program. The right
hand side shows Read Device, Clear Flash, and COM Port Select buttons. Also on the right hand side is an area where device content and
programming status is displayed.
SunDuino Boot Loader Main Screen
When the app connects or the Device Read button is clicked, various
key memory areas are read and their content is summarized. The upper
section shows EEPROM content for the first 128 bytes, with the lower
section showing the start of FLASH. Users should never write to the
lower 128 bytes of EEPROM. Only approved battery control files
should be loaded into the lower 128 bytes of EEPROM. Notice that location 0x4000 contains compiled code which indicates that a user application is present. This screen provides a quick reference to battery
type, status, and user application content. The green “Connected” area
is red if the PC cannot detect a connected SunDuino that is in Boot
Load Mode. A user must press the small button on a powered
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Chapter 5 Boot Loader
SunDuino to initiate Boot Load Mode. Assuming the COM Port is connected and working, the pressing of the SunDuino PCB push button
will allow the Boot Loader to connect as shown above. If a connection
is not valid, the Boot Loader application will display ‘Not Connected’
over a red background.
This connection scheme allows the user to verify the quality of the
COM Port connection. Every 500ms the Boot Loader PC application
verifies the SunDuino is still connected by sending a small message to
the SunDuino PCB. If this connection fails an internal ‘FAILED CONNECTION’ counter increments. If this counter ever reaches a value
greater than 0, notice is displayed in the green connection field. By
leaving a SunDuino thus connected for several hours (e.g. overnight),
any connection loss will be captured and counted, however, a correctly
operating COM connection should never fail.
The SunDuino firmware includes a 60 second connection time-out
timer. Should the push button on the PCB ever be pressed WITHOUT
a connection to the Boot Loader application, the SunDuino firmware
will automatically reset after 60 seconds.
Operating Options
SunDuino firmware provides several options for controlling power operations. A number of check boxes are provided along with a WRITE
button which allows the user to configure these options without any file
downloads. When the user writes to EEPROM, a checksum is calculated from the resulting values and written alongside the user’s write in
EEPROM. SunDuino firmware requires that a valid checksum be provided. An invalid checksum will cause the SunDuino PCB LED to rapidly blink while the SunDuino disables all other operations.
Control Option
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Force Pwr On
Description
Forces Output DC Regulator ON
Pwr On after Reset
Force Output DC ON after Reset. (With 2 Second Delay)
Instant On
Force Output DC ON after Reset. (No Delay)
Toggle Mode
Input ON/OFF signal Toggles Output DC On/Off
Enable Pwr Lock
Prevents On/Off switch from turning DC Output Off
Unlock On EMPTY
If Battery hits EMPTY then clear Power Lock.
Keep 3.3V Active
Keep Trickle regulator ON during SLEEP Mode
Use Solar Panel
Enable use of Solar Panel Charging Logic
Solar MPP Voltage
When using Solar Panel this filed defines panel MPP
Write EEPROM
Click this button to WRITE all Options to EEPROM
Refresh
Click the button to refresh controls from EEPROM
Chapter 5 Boot Loader
Advanced Usage
The Boot Loader allows .hex files and .ini files to be passed as command line (or .lnk file) options. A complete .ini file is written to a default file name each time the Boot Loader closes. If this .ini file is
copied to another directory and renamed, it will completely define a
programming session. Passing this renamed .ini file as a command line
option will completely control a programming session. When the Boot
Loader uses a command line option the Boot Loader will automatically
close. This means that the SunDuino integrates well with simple batch
control files.
The default .ini file location is:
C:\ProgramData\IndexDesigns/SunD_Loader.ini
When a .hex file is passed on a command line, the .hex file will be
downloaded using control options from the default .ini file. Again, the
Boot Loader will automatically close once the file is downloaded.
Included in the .ini files is a provision for starting a new application
when the Boot Loader exists. Parameter “ExitFile” defines a file to be
opened by the Windows application associated with the indicated file
type. The following sample line shows an ExitFile with a .ht file extension. This will result in a Hyper Terminal session being started using
the connection profile of the TTY_9600.ht session file.
ExitFile="C:\ProgramData\IndexDesigns\TTY_9600.ht"
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Chapter 6 Sample Wiring
Sample Wiring
6
25 Pin D Signals
Connector Signals
The following table shows the pinout for the SunDuino 25 pin D Connector.
Pin
1
Function
VIN+ DC Input Power
2
VBAT + Battery Positive Terminal. Connect in Parallel with Pin 15
3
VBAT- Battery Negative Terminal. Connect in Parallel with Pin 16.
4
RS-232 Serial Input
5
INTGND Internal Ground.
6
ON/OFF Control Signal. Turns on at 3V and is 20V tolerant.
7
SDA signal for I2C. Port C bit 4 on processor.
8
Clock Out from processor. Port A bit 6.
9
+12V linear regulator output on BB25E. +13V on BB10B.
10
Output GND. Optoisolated on BB25E. INTGND on BB10B.
11
Output GND. Optoisolated on BB25E. INTGND on BB10B.
12
+3.3V Output. Connect in Parallel with Pin 24.
13
+5V Output. Connect in Parallel with Pin 25.
14
VIN- Primary Power Input -
15
VBAT + Battery Positive Terminal. Connect in Parallel with Pin 2
16
VBAT- Battery Negative Terminal. Connect in Parallel with Pin 3.
17
RS-232 Serial Out
18
Battery Thermistor. 10K Ohm 0.5% NTC Battery Thermistor.
19
SCK signal for I2C. Port C bit 3 on processor.
20
Input Select. Connect to Pin 21 to Directly Regulate the 3.3V Output.
21
3.3V linear trickle regulator directly from battery. Max. current 10ma.
22
-12V linear regulator output on BB25E. -13V on BB10B.
23
Output GND. Optoisolated on BB25E. INTGND on BB10B.
24
+3.3V Output. Connect in Parallel with Pin 12
25
+5V Output. Connect in Parallel with Pin 25
6 - 23
Chapter 6 Sample Wiring
Interface Board
To simplify connection of external hardware to the SunDuino and aid
in system integration, a SunDuino “Break Out Board” is available.
Power connections are divided by functions and brought out to terminals with screw-down connections. The RS-232 serial connections are
brought out to a 9 pin D connector with a pinout for direct connection
to a PC (PC is DTE. Breakout Board is DCE). Additional features, such
as a fuse, reverse battery diode, and On/Off switch are included. Note
that the large diode will short any battery connected in reverse, and the
resulting current will clear the board fuse. A push-button switch with
external connections is connected to the SunDuino On/Off signal.
Also notice that the DC Output’s common signals are separate from the
INTGND signal. The BB25E DC outputs are optically isolated, while
the low cost BB10B uses a common GND design. If I2C is to be used
with circuits powered by the DC Outputs, the two GNDs must be connected.
I2C Voltage Levels
3.3V and 5V I2C Operation
The SunDuino process uses a PIC18F26K20 processor running at
3.3V. It is important to note that I2C lines must never be allowed to exceed 3.3V, doing so would back-drive the processor and alter the
6 - 24
Chapter 6 Sample Wiring
power supply’s voltage. The internal 3.3V regulator is a precision device which allows the power rails to be used as a reference voltage for
analog to digital conversion. Back driving the power supply would
cause errors in analog readings or possibly even damage the processor.
I2C operation requires pull-up resistors on both the SCK and SDA
lines. These resistors are typically located on user hardware. If the
hardware uses pull-up resistors to +5 volts (or anything above 3.3V),
some means of limiting SDA and SCK voltages is required. The simple
solution is to add a pull-down resistor on the SDA and SCK lines such
that the pull-up voltage never exceeds 3.3 volts. For example, a 5K
ohm pull-up resistor with a 10K pull-down will only pull up voltages to
reach 3.3 volts.
The 3.3V supply from the SunDuino internal 3.3V trickle regulator can
be used as a pull-up source but that would increase SLEEP MODE current. If user I2C hardware is operated using the SunDuino regulated
3.3V regulated output, then using that regulated 3.3V output as a
pull-up source is suggested. If user software turns off the regulator, the
application software should also change the I2C into outputs driven
with logic zeros. Driving a logic one into unpowered hardware will
draw significant currents.
Examples of using pull-down resistors with I2C operation can be found
in the 4-Digit 7-Segment display board design included with SunDuino
files. When using red LEDs, this board will operate directly from 3.3V.
When using other colors, 5V operation is sometimes required. The
I2CTest.c source file (sample code directory) provides an example of
where the I2C lines are controlled as outputs when power is turned off.
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