Table of Contents - Lafayette College

Maintenance Manual

Senior Design – Spring 2009 Lafayette College

Last Revision(5/15/09)

1

Contents 1 Introduction……………………………………………………………….. 3 2 Principles of Operation…………………………………………………… 4 3 Mechanical Drawings…………………………………………………….. 20 4 Battery Maintenance……………………………………………………... 29 5 Troubleshooting…………………………………………………………... 30 6 Safety Warnings…………………………………………………………... 38 7 Manufacturability………………………………………………………… 39 8 Parts List…………………………………………………………………... 40 9 Interface Control Document……………………………………………... 49 10 Tables for Critical Voltages and Signals………………………………… 50

2

1 Introduction

Purpose of this Manual

The purpose of the Maintenance Manual is to describe the technical details

of the system’s operation. The manual includes information on advanced

maintenance and calibration techniques used for an expert maintainer. The

manual also includes schematics, pinouts, signal assignments, and all

connections used for both hardware and software interfaces.

Procedure

For a specified task, jump to the corresponding section from the Contents. In

the case where there is a problem with the LPRDS-ETS system, follow the

instructions in the Troubleshooting section. This manual contains tables,

documents and instructions on the methods needed to maintain and operate

the entire system.

3

2 Principles of Operation

The system is comprised of multiple subsystems. An overall block diagram

is shown below.

Figure 1 Each subsystem shown in Figure 1 contains schematics shown in the

corresponding subgroup.

RPI

The Raw Power Interface (RPI) subsystem is shown in the box layout in

Figure 2. Also included are the schematics for the Sensor Board (Figures 3

and 4), and the Board Layout is shown in Figure 5.

4

Figure 2

Figure 3

5

Figure 4

Figure 5

6

EDS

The Energy Delivery Subsystem (EDS) includes an H-Bridge (Figure 6),

Differential Amplifier (Figure 7), Voltage Sensor (Figure 8), Filter (Figure 9)

and Microcontroller (Figure 10). The PADS layout is shown in Figure 11.

Figure 6

7

Figure 7

Figure 8

8

Figure 9

9

Figure 10

Figure 11

10

ESS

Schematics for the Energy Storage Subsystem (ESS) are shown in Figures

12-14. The Board Layout is shown in Figure 15.

Figure 12

11

Figure 13

Figure 14

12

Figure 15 SCADA

The Supervisory Control and Data Acquisition (SCADA) board schematics

are shown in Figures 16 and 17. The PCB Layout is shown in Figure 18.

13

Figure 16

14

Figure 17

Figure 18

15

T1

The Filter and Transformer configuration is shown in Figure 19.

Figure 19

Safety

A diagram of the safety interface is shown in Figures 20-26.

Figure 20

16

Figure 21

Figure 22

17

Figure 23

Figure 24

18

Figure 25

Figure 26

19

3 Mechanical Drawings RPI

Figure 27

20

Figure 28

Figure 29

21

EDS

Figure 30

22

Figure 31

Figure 32

23

ESS

Figure 33

24

Figure 34

Figure 35

25

Figure 36

Figure 37

26

SCADA

Figure 38

27

Figure 39

Figure 40

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4 Battery Maintenance

The batteries which were selected are Lithium Iron Phosphate Batteries.

These batteries do not need periodic maintenance. Their chemistry is not

explosive and stable even under under/over charge situations. A typical

service time for LiFePO4 is about 6-7 years or 3000 cycles, depending which

comes first. While the cycles are not counted, we approximate that the

batteries should go through 3000 cycles while in full use approximately

every 3 years. For optimal use, batteries should be replaced every 3 years.

There are a few good rules of thumb when it comes to battery conditioning and

maintenance. A few basic rules are:

• Cycle the battery a few times before using for the first time

• Store in a cool dry place

• If the memory effect is a problem, cycle the battery a few times every few

weeks to undo the effect

• If the batteries need to be stored for a long time unused, then store them in

a cool dry place and charge the batteries before their next use to account

for their self discharge.

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5 Troubleshooting

If point of error is unknown, please proceed through the Acceptance Test

Plan. Failures will give better guidance to the failing subsystem. The ATP is

located at the following address: (http://ww2.lafayette.edu/~ece492-

2009/Documents/FinalDocuments/finalDocs.html). Once the failing

subsystem is discovered, reference the QA tests for more detailed tests.

These can be found at the following location:

(http://ww2.lafayette.edu/~ece492-

2009/Documents/FinalDocuments/ess/essDocs.html).

LPRDS-ETS Information System

For a history of alarms, events, and other data, visit the LPRDS-ETS

Information System located at (http://lprds.aec.lafayette.edu/). Once a failure

is discovered on the Information System website, use the remediation plan as

follows.

There are four errors which can be displayed on the website:

a) Value below minimum permissible threshold

b) Value above maximum permissible threshold

c) Safety fault detected

d) Communication Error

Remediation Steps:

a) Value below minimum permissible threshold

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1) Go to the lprds.aec.lafayette.edu

2) Click on the “Clear Alarms” button

3) The system will then move into the shut down state. However, if the

fault is still present, the system will move back into the fault state.

b) Value above the maximum permissible threshold





c) Safety fault detected





d) Communication Error





PIC Programming

If a Programmable Interface Controller (PIC) has an issue, and it is

determined that it must be reprogrammed, the following instructions will

reprogram the PIC.

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Step 1: Locate a computer already equipped with Xeltek Superpro USB Series

and obtain a device programmer.

Step 2: Connect the USB connector from the device programmer to the PC and

power it on.

Step 3: Open Superpro USB Series from the desktop or program files

Step 4: Under the device options you will see the Manufacturer and the Device

Name categories. You will want to highlight Microchip for the manufacturer and

PIC18F4525 for the device name. See Figure 41.

Figure 41

Step 5: Hit OK

Step 6: Locate the Load File symbol and open

Step 7: Find the file with the appropriate hex file to be downloaded and hit open.

Available Hex Files

SCADAREV1.hex

EDS.hex

ESS.hex

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RPI.hex

Step 8: You will next see an applet pop up. You will want to have the following

configuration shown in Figure 42.

Figure 42

Step 9: Place the 18f4525 into device programmer

Step 10: Select Erase to clear all previous code

Step 11: Select blank check to make sure it processed correctly

Step 12: Select Program

Step 13: Select Verify

Step 14: Remove the PIC and place it in the board.

Creating a Project using MPLAB with integrated MCC18

1. Install MPLAB from the SDK

2. Install MCC18 from SDK. This process will automatically attach itself to

MPLAB

*Note: The MCC18 has a 45 day limit. This can however be worked

around by simply uninstalling the program and re-downloading from

www.Microchip.com

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3. Open up MPLAB

4. Select Project option and you will see an applet

5. Choose a Project name and where you want to save your project to under

Project Directory.

Figure 43 6. Select Project – Build Options – Project. You will see another applet

7. You will be setting up your Include Search Path by selecting Include

Search Path from the Show directories for: drop down box

8. Select New and click on the highlighted blue area with the three dots.

9. You must now find the .h folder located under the MCC18 Directory and

hit OK.

Your screen should like Figure 44 when you have done it correctly.

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Figure 44 10. You will follow the same procedure for adding the Library search path.

Find the lib folder under MCC18. Your screen should now look like this if

you have done it correctly (Figure 45).

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Figure 45 11. Now you are ready to add your linker script. Under the View option you

should select Project.

12. Right click on the Linker Script folder and navigate to the MCC18

directory. Find the lkr folder and chose the 18F4525.lkr.

13. Select open.

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Figure 46 14. It is now time to add your .c files found in the coding files to the Source

Files Folder seen in previous screen shot. If coding the SCADA PIC you

will want to add all the files from the SCADA Code. If coding the ESS,

EDS, or RPI PIC you will want to add the .c files from the sensor board

folder. You can also just start from scratch if you want to.

15. Now you are ready to debug and code, but you must first choose your

debugger. Under the debugger choose Select tool and then MPLAB Sim.

16. You are ready to start programming in C. See the tutorial for using the

simulation environment to count clock cycles, watch port values, and

observe program memory.

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6 Safety Warnings

Before handling any equipment, please review the Electrical Safety Plan

located at the following address: (http://ww2.lafayette.edu/~ece492-

2009/Documents/Official%20Reports/Electrical_Safety_Plan_rev7.pdf). Be

cautious of the high voltage to low voltage divider. The barriers are clearly

labeled on the Interface Control Document, the schematics, the board

layouts, and the devices themselves.

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39

7 Manufacturability

A list of spare parts stocked for replacement is shown below. This list was

generated to reduce the Mean Time to Repair (MTTR).

- Spare fuses for use in RPI, ESS, and EDS cabinets

- Fully populated spares for each PCB in the system

- LEDs for the Display Board

- LiFePO4 battery pack

- Safety relay

- HV Solid-State Relay

To reproduce the circuit boards, all of the documentation is organized by

subsystem at the following location: (http://ww2.lafayette.edu/~ece492-

2009/Documents/FinalDocuments/finalDocs.html). Each folder includes

DxDesigner schematics, PADS Layout board layout, and all necessary board

production files.

All necessary software files can be found at the following location:


2009/Documents/FinalDocuments/scada/scadaDocs.html).

8 Parts List

The parts are separated by subsystem:

RPI BOX Total # of Items Manufacturer Supplier 1 Part # Supplier 1 Cost 1

AE Enclosure $161.12 Stokes Electric Stokes Electric RTL1045500 $161.12AE Window Kit $63.33 1 Electromate Stokes Electric RTL8018444 $63.33

AE Thumb Turn Handle w/ Key Lock $17.42 1 Electromate Stokes Electric RTL2576000 $17.42 solid state relay $153.99 1 Crydom Newark 78H4062 $153.99

heat sink $13.77 1 Crydom Newark 93K7581 $13.77RPI Board

PCB Board $30.00 1 4PCB.com 4PCB.com $30 PIC - IC MCU FLASH 24KX16 40DIP $8.90 1 Microchip Digi-key PIC18F4525-I/P-ND $8.90

TRANSDUCER CURRENT OPEN LOOP 20A $14.00 1 LEM USA Inc Digi-key 398-1025-5-ND $14.00

IC SENSOR THERMAL 3.1V TO-92-3 $0.43 1 Microchip Technology Digi-key MCP9701A-E/TO-ND $0.43

TXRX ISO BUS 1MBS RS485 16SOIC $6.40 1 NVE Corp Digi-key 390-1097-5-ND $6.40

IC SOCKET STRAIGHT 40POS TIN $1.22 1 Assmann Electronics Inc Digi-key AE10008-ND $1.22

IC HS CMOS DUAL OP AMP 8-DIP $3.31 1 Texas Instruments Digi-key OPA2350PA-ND $3.31

CONV DC/DC 10W SNGL 12V 5V PCB $26.00 1 TDK-LAMBDA Digi-key 445-2435-ND $26.00

IC COMPARATOR QD -40-85 C 14-DIP $0.45 1 Fairchild Semi Digi-key LM2901NFS-ND $0.45

IGBT W/DIODE 600V 28A TO247AC $5.34 1 International Rectifier Digi-key IRG4PC30KDPBF-ND $5.34

DIODE ZENER 24V 1W 5% DO-41 $0.41 1 Diodes Inc Digi-key 1N4749ADICT-ND $0.41

Terminal Block - 5.08mm x 4 $0.88 1 Tyco Digi-key A97986-ND $0.88



CAP 4700PF 50V CERAMIC X7R 0805 $0.43 10 Kemet Digi-key 399-1155-1-ND $0.04

CAP 10UF 10V CERAMIC X5R 0805 $2.97 10 Taiyo Yuden Digi-key 587-1300-1-ND $0.30

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CAP 47000PF 50V CERAMIC X7R 0805 $0.61 10 Kemet Digi-key 399-1166-1-ND $0.06

CAP CER 16PF 100V 5% C0G 0603 $0.64 10 Murata Digi-key 490-1332-1-ND $0.06

RES 4.99M OHM METAL FILM .50W 1% $3.99 5 Vishay Digi-key PPCHF4.99MCT-ND $0.80

RES 49.9K OHM 1/4W 1% METAL FILM $0.53 5 Yageo Digi-key 49.9KXBK-ND $0.11


RES 196K OHM 1/4W 1% METAL FILM $0.53 5 Yageo Digi-key 196KXBK-ND $0.11

RES 499 OHM 1/4W 1% METAL FILM $0.53 5 Yageo Digi-key 499XBK-ND $0.11



RES 100K OHM 1/4W 1% METAL FILM $0.53 5 Yageo Digi-key 100KXBK-ND $0.11





LED DOME 583NM YW DFF AXL LO CUR $0.67 1 Avago Digi-key 516-1404-ND $0.67

LED GREEN DIFFUSED ROUND LONG $2.10 10 Panasonic Digi-key P375-ND $0.21

LED AMBER DIFFUSED ROUND $2.50 10 Panasonic Digi-key P372-ND $0.25

EDS BOX Total # of Items Manufacturer Supplier 1 Part # Supplier 1 Cost 1

PCB Board $30.00 1 4PCB.com 4PCB.com $30 solid state relay $153.99 1 Crydom Newark 88K1998 $153.99

Mechanical Package 0 $0.00 6V Pilot Light (Red) $4.00 1 Dialight Digikey.com 612-3132-120F $4.00

6V Pilot Light (Green) $4.00 1 Dialight Digikey.com 612-3232-120F $4.00 6V Pilot Light (Yellow) $4.00 1 Dialight Digikey.com 612-3332-120F $4.00 20A Current Sensor $14.00 1 Digikey.com HXS 20-NP $14.0015A Current Sensor $11.45 1 FW Bell Newark 49H8118 $11.45

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Resistive Divider and Opamp $15.00 3 Digikey.com $5.00 Microchip Thermistor $6.00 6 Digikey.com MCP9701A-E/TO-ND $1.00

EDS Board

HB/ESS High Frequency IGBT $36.00 12 Fairchild Corporation Digikey.com IRGB4B60KD1 $3.00 Filter Electrolytic Cap $12.00 3 Pansonic Digikey.com P6842-ND $4.00

Filter Inductor $120.00 2 Hammond Digikey.com 195C20 $60.00Isolation Tfmer (120Vac @ 15A) $346.00 1 Sola/Heaviduty Freedman Electric HS12F2AS $375.00

IGBT Driver $16.00 4 International Rectifier Digikey.com IR2184PBF-ND $4.00 Thermal Pad $6.00 12 Aavid Thermalloy Digikey.com 189790F00000-ND $0.50

Metal / Heatsink IGBTs $70.00 5 Radian Heatsinks Radian Heatsinks 241209B91200G $14.00

Microcontroller and Board $80.00 2 Atmel Corporation microcontrollershop.co

m AVR-H128 $40.00Opto Isolators $1.11 5 Fairchild Optoelectronics Group Digikey.com 6N135QT-ND $2.00

RS-485 Isolated Drivers (75176) $3.00 3 NVE Digikey.com DS75176BMXTR-ND $1.00 PIC $8.00 1 MicroChip Digi-key PIC18F4525 $8.00

40 Pin Dip Socket $1.22 1 Digikey.com AE10008-ND $1.22 1.65M ohm $0.06 20 Digikey.com

5K ohm $0.06 10 Digikey.com 100K ohm $0.06 10 Digikey.com

10 ohm $0.06 10 Digikey.com 10uf $0.52 10 Digikey.com .1 uF $0.21 20 Digikey.com $0.01

1n4148 $0.20 5 Digikey.com $0.04 DC-DC 12V-5V (un-isolated) $16.20 1 Texas Instruments Digikey.com PT78HT205H $16.20 DC-DC 12V-12V (isolated) $53.80 1 Datel Mouser.com UHE-12/2500-D12-C $53.80

3 pin AWG 10-24 Terminal Block $10.00 5 Tyco Digikey.com A98043-ND $2.00 12 pin AWG 18-26 Terminal Block $6.00 3 Tyco Digikey.com A98274-ND $2.00

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ESS BOX Total # of Items Manufacturer Supplier 1 Part # Supplier 1 Cost 1

Fuse1 (Isolated dc-dc 75W) $0.85 5 LittleFuse Mouser.com 576-312008P $0.17 Fuse Holder $4.80 2 Cooper Bussman Mouser.com 504-HKP $2.40

12V Battery Charger $21.95 1 Powerizer Batteryspace.com CH-UNLA1230 $21.95 mechanical relay $131.78 1 Omron Digikey G9EB-1-B DC12 $131.78

ESS Enclosure

Vented Enclosure Top $35.50 1 Bud Industries Allied Electronics 736-1163 $35.50 Rack Mounted Enclosure $67.05 1 Bud Industries Allied Electronics 736-1176 $67.05 Rack Mounted Enclosure $95.80 1 Bud Industries Allied Electronics 736-1178 $95.80 Solid Enclosure Bottom $67.20 2 Bud Industries Allied Electronics 736-1162 $33.60

Aluminum Chassis $20.00 1 Bud Industries Allied Electronics 736-4242 $20.00 ESS Disconnect Switch

Manual Lockout Switch $151.67 1 Allen Bradley Rumsey Electric 194R-NC030P3 $151.67Manual Lockout Switch Operating Handles $15.50 1 Allen Bradley Rumsey Electric 194R-HS1E $15.50

Manual Lockout Switch Operating Shaft $9.64 1 Allen Bradley Rumsey Electric 194R-R1 $9.64 Manual Lockout Fuse(15A) $6.41 1 Ferraz Shawmut Rumsey Electric AJT15 $6.41

ESS Board

PCB Board $30.00 1 4PCB.com 4PCB.com $30 400 HV cap - 4.7uF-part -unisolated hv-5v $2.37 3 United Chemi-Con digikey 565-1411-ND $0.79

63v cap - 100uf -part- unisolated hv-5v $0.93 3 Panasonic - ECG digikey P5193-ND $0.31 1mh inductor - part- unisolated hv-5v $8.61 3 API Delevan Inc digikey DN7750-ND $2.87

4.3K ohm 1/4W axial resistor $0.06 1 Yageo digikey 4.3KQBK-ND $0.06 510K ohm 1/4W axial resistor $0.06 1 Yageo digikey 510KQBK-ND $0.06 270 ohm 1/4W axial resistor $0.77 12 Yageo digikey 270QBK-ND $0.06 10K ohm 1/4W axial resistor $0.51 8 Yageo digikey 10KQBK-ND $0.06 560 ohm 1/4W axial resistor $0.13 2 Yageo digikey 560QBK-ND $0.06 150 ohm 1/4W axial resistor $0.26 4 Yageo digikey 150QBK-ND $0.06

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120 ohm 1/4W axial resistor $0.06 1 Yageo digikey 120QBK-ND $0.06 910 ohm 1/4W axial resistor $0.19 3 Yageo digikey 910QBK-ND $0.06 750 ohm 1/4W axial resistor $0.06 1 Yageo digikey 750QBK-ND $0.06 1.5K ohm 1/4W axial resistor $0.06 1 Yageo digikey 1.5KQBK-ND $0.06 30K ohm 1/4W axial resistor $0.06 1 Yageo digikey 30KQBK-ND $0.06

IC HS CMOS DUAL OP AMP 8-DIP $6.62 2 Texas Instruments digikey OPA2350PA-ND $3.31 PIC - IC MCU FLASH 24KX16 40DIP $8.90 1 Microchip digikey PIC18F4525-I/P-ND $8.90

IC COMPARATOR HS DUAL 14-DIP $1.20 1 national semicondutor digikey LM2901NNS-ND $1.20 Current Transducer $14.00 1 LEM digikey 398-1025-5-ND $14.00

Thermistor I.C. $3.44 8 Microchip digikey MCP9701A-E/TO-ND $0.43 TXRX ISO BUS 1MBS RS485 16SOIC $6.40 1 NVE digikey 390-1097-5-ND $6.40 CAP 47000PF 50V CERAMIC X7R 0805 $0.37 6 Kemet digikey 399-1166-1-ND $0.06 CAP 4700PF 50V CERAMIC X7R 0805 $0.04 1 Kemet digikey 399-1155-1-ND $0.04

Testing LED for PIC outputs $8.04 12 Avago Technologies US Inc. digikey 516-1404-ND $0.67 2 terminal block $1.30 2 Tyco digikey A97984-ND 0.65 4 terminal block $2.64 3 Tyco digikey A97986-ND 0.88 6 terminal block $1.32 1 Tyco digikey A97988-ND 1.32 12 terminal block $7.32 4 Tyco digikey 1-1546217-2-ND 1.83

4 terminal block HV $1.33 1 Tyco digikey A98115-ND 1.33

0.1UF SMD cap $0.40 4 Panasonic-ECG Digi-Key PCC1828CT-ND $0.10 10UF smd cap $0.55 2 Taiyo Yuden Digi-Key 587-1300-1-ND $0.28 1UF smd cap $0.10 1 Kemet Digi-Key 399-1284-1-ND $0.10

16pF Cap $0.93 3 murata electronics Digi-Key 490-3630-ND $0.31 Fault Indicator LED $0.15 1 Lumex Allied Electronics 670-1192 $0.15

Discharging Indicator LED $1.52 1 Lumex Allied Electronics 670-0169 $1.52 Charging Indicator LED $0.10 1 Lumex Allied Electronics 670-1057 $0.10

30V Indicator LED $0.12 1 Lumex Allied Electronics 670-1059 $0.12

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bs170 mosfet to-92 packaging $0.34 1 Fairchild digikey BS170-ND 0.34 optoisolator - 6n135 $1.11 1 Fairchild opto group digikey 6N135QT-ND 1.11

EDS protection $1.08 1 Tesax Instruments digikey 296-6596-5-ND 1.08 220uF Al Electrolytic Cap $0.37 1 Panasonic - ECG digikey P5183-ND 0.37 47uF Al Electrolytic Cap $0.15 1 Panasonic - ECG digikey P834-ND 0.15 10uF Al Electrolytic Cap $0.14 1 Panasonic - ECG digikey P813-ND 0.14 1uF Al Electrolytic Cap $0.14 1 Panasonic - ECG digikey P824-ND 0.14

3.5A fuse Size:2AG $0.57 1 Littlefuse Inc digikey F2463-ND 0.568 Size:2AG fuse clips $0.46 2 Littlefuse Inc digikey F058-ND 0.228

high voltage to 5V dc-dc $7.81 1 powerex inc. digikey 835-1032-ND 7.81 12V-5V dc-dc 25W $12.10 1 lineage power digikey 555-1058-ND 12.1

SCADA BOX Total # of Items Manufacturer Supplier 1 Part # Supplier 1 Cost 1

Demo Board

Red LED $3.00 20 Allied Electronics Allied Electronics Red (SSL-LX3044ID) $0.15 Green LEDs $3.00 20 Allied Electronics Allied Electronics Green (SSL-LX3044GD) $0.15

Alarm Silence Button $6.88 1 Vamdal Allied Electronics 287-1029 $6.88 Linux Slim-Fit PC $315.00 1 FitPC.com N/A $295.00

USB to RS485 $54.95 1 usconverters.com US485mi $49.95PicoLCD 256x64 Display $67.72 1 Mini-Box.com picoLCD 256x64 $59.95USB to 5 pin cable typeA $2.95 1 Mini-Box.com CAB-USB-5pin-TypeA $2.95

SCADA Board Header, 36-Pin Strip (Ribbon) $2.50 2 3M Allied Electronics 618-5036 $1.25

USB Jack/Header $0.98 1 Amphenol Allied Electronics 625-0039 $0.98 ESD SN75240 $1.08 1 Texas Instr. Digi-Key 296-6596-5-ND $1.08 RS232 Header $1.80 1 Tyco Electronics Allied Electronics 374-0476 $1.80

45

PIC $4.67 1 Microchip Digi-key PIC18F4525-I/P $4.67 40-Pin DIP Socket $1.22 1 Assmann Electronics Inc Digi-key AE10008-ND $1.22

MAX232 $0.90 1 Texas Instr. Digi-key 296-1402-5-ND $0.90 Differential Bus Tranceiver $0.60 1 Texas Instr. Digi-key SN75176 $0.60 RS485 Isolator (IL3285E) $6.40 1 NVE Digi-key 390-1097-5-ND (DK) $6.40

SN75176 $0.80 1 Texas Instruments Digi-key 296-1737-5-ND $0.80 Terminal Block - 5.08mm x 4 $1.76 2 Tyco Digi-key 1776119-4 $0.88 Terminal Block - 5.08mm x 2 $1.95 3 Tyco Digi-Key 1776119-2 $0.65

1K $1.10 22 Ohmite Alied Electronics 296-4741 $0.05 750 $0.20 4 Ohmite Alied Electronics 296-6597 $0.05

698K $0.11 1 Yageo Digi-Key 698KXBK-ND $0.11 499K $0.11 1 Yageo Digi-Key 499KXBK-ND $0.11

560 ohm 1/4W axial resistor $0.13 2 Yageo digikey 560QBK-ND $0.06 120 ohm 1/4W axial resistor $0.06 1 Yageo digikey 120QBK-ND $0.06

931 $0.32 3 Yageo Digi-Key 931XBK-ND $0.11 47UF Cap Throughole $0.64 1 TDK Digi-Key 445-2883-ND $0.64

47UF $0.90 2 Taiyo Yuden Digi-Key 587-1779-2-ND $0.45 47NF $0.06 1 Kemet Digi-Key C0805C473K5RACTU $0.06 .1UF $0.59 6 Panasonic-ECG Digi-Key PCC1828CT-ND $0.10 1UF $0.48 5 Kemet Digi-Key 399-1284-1-ND $0.10 16pF $0.19 3 Murata Digi-Key GRM1885C2A160JA01D $0.06 10UF $0.30 1 Taiyo Yuden Digi-Key LMK212BJ106KG-T $0.30

ESD Cap $0.27 1 On Semiconductor Digi-Key ESD7L5.0DT5GOSTR-ND $0.27 LED for testing $2.01 3 Avago Technologies US Inc Digi-Key 516-1404-ND $0.67

reed relay $3.58 1 Coto Technology Digi-key 306-1115-ND $3.58

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SAFETY Total # of Items Manufacturer Supplier 1 Part # Supplier 1 Cost 1

general purpose relay $5.81 1 Idec Newark 33K1054 $5.81relay socket - DPDT screw terminal $6.18 1 Idec Newark 33K1093 $6.18

solid state relay $153.99 1 Crydom Newark 88K1998 $153.99flush pushbutton $0.00 1 Allen Bradley donated n/a $0.00

contact electrical crtdg, green, N.O. $0.00 1 Allen Bradley donated n/a $0.002 position, push/pull button $0.00 1 Allen Bradley donated n/a $0.00

heat sink $27.54 2 Crydom Newark 93K7581 $13.77thermal pad $3.20 4 Crydom Newark 81H0833 $0.80

varistor $4.84 4 Epcos Allied Electronics 586-0170 $1.2112v pilot light (red) $3.08 1 Dialight Allied Electronics 511-1183 $3.08

Safety Loop Closure (IDEC - RJ2S-CL-D12) $13.00 1 Octopart Newark 33K1060 $13.00

ICD Total # of Items Manufacturer Supplier 1 Part # Supplier 1 Cost 1

Connector Receptacle Housing $4.50 3 Anderson Power Allied Electronics 1470G1 $1.50 Connector Plug Housing $8.46 6 Anderson Power Allied Electronics 1460G1 $1.41

Clamp Kit $4.50 6 Anderson Power Allied Electronics 115G1 $0.75 Connection Pin $0.90 3 Anderson Power Allied Electronics 110G9 $0.30

Red Contact Housing $8.55 9 Anderson Power Allied Electronics 1327FP $0.95 Black Contact Housing $9.60 10 Anderson Power Allied Electronics 1327G6FP $0.96 Green Contact Housing $15.60 10 Anderson Power Newark 1845G1 $1.56

Contact $24.75 25 Anderson Power Allied Electronics 269G1-LPBK $0.99 Ground Contact $8.30 10 Anderson Power Newark 1830G1-LPBK $0.83

Connector Receptacle $13.08 6 Tyco/AMP Digikey 1604210-1 $2.18Connector Receptacle $3.54 6 Tyco/AMP Digikey 350780-1 $0.59

Pins $8.61 70 Tyco/AMP Digikey 350552-1 $0.12

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48

Connector Plugs $4.69 7 Tyco/AMP Digikey 350715-1 $0.67Connector Plugs $3.76 8 Tyco/AMP Digikey 350779-1 $0.47

Sockets $9.73 70 Tyco/AMP Digikey 350551-1 $0.14Connector Receptacle $6.95 1 LCOM Allied Electronics ECF504-BAS $6.95Connector Receptacle $54.05 5 LCOM Allied Electronics ECF504-SC5E $10.81

Cat 5E Cable $10.78 7 Emerson Allied Electronics 73-7775-3 $1.54Cat 5E Cable $1.54 1 Emerson Allied Electronics 73-7770-3 $1.54Cat 5E Cable $4.74 1 Quest Allied Electronics NPC-0315 $4.74

USB to Jtag Converter $54.00 1 Olimex MicroController Pros Corporation AVR-USB-JTAG $54.00USB Cable $4.10 2 Emerson Allied Electronics 30-3007-3 $2.05

125 VAC Midget Receptacle $14.99 1 McMaster-Carr McMaster-Carr 6755K281 $14.99125 VAC Midget Plug $10.03 1 McMaster-Carr McMaster-Carr 6755K15 $10.03

9 Interface Control Document

A detailed connection scheme can be found in the Interface Control

Document (ICD). The ICD is located at the following address:


2009/Documents/FinalDocuments/system/combinedICD%205-13-09.pdf).

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10 Tables for Critical Voltages

Critical voltages, currents and temperatures that are shown in the Acceptance

Test Plan. The test is separated by subsystem and is located at the following

address: (http://ww2.lafayette.edu/~ece492-

2009/Documents/FinalDocuments/ess/essDocs.html).

A list of important voltages is shown below. Voltage points refer to the ICD.

Reference Description System State Expected Voltage

J29 Output Voltage Normal Operation 120V+/- 5V RMS

J10 ESS/EDS Interface with RPI

Normal Operation (Fully Charged) 210 +/- 5V

J10 ESS/EDS Interface with RPI

Normal Operation (Discharged) 190V +/- 5V

J8 Power Source Normal Operation 5V J8 Power Source Normal Operation 12V

LPRDS-ETS Website Batter Sensor Normal Operation (Fully

Charged) (1/4 Voltage) 51.2V


Charged) (1/2 Voltage) 102.4V


Charged) (3/4 Voltage) 153.6


Charged) (Full Voltage) 204.8V

50