mobile data power model: mdp-25.0 installation/operation · operate entirely from the mdp reserve...

P.O. Box 1306Newport BeachCalifornia 92663

Phone: 714-751-0488 Fax: 714-957-1621

E-Mail: [email protected]

Topic PageQuick Reference Guide............................................. 2Operational Features Summary............................... 3Materials Provided.................................................... 3Installation................................................................ 3

MechanicalPower WiringSignal WiringMotorola Output Settings: Default and Optional

Operation................................................................ 4Status LEDsDisconnect Timer (TMR) OperationAdvanced Settings: Backup Timer, Trigger Threshold, and Hysteresis

Battery Replacement.............................................. 8Test/Troubleshooting.............................................. 9Specifications.......................................................... 9Dimensional Drawing............................................. 10

Mobile Data PowerModel: MDP-25.0

Installation/Operation

M-MDP25.0As of 041714


Phone: 714-751-0488 Fax: 714-957-1621


Quick Reference Guide

Status LEDs Page 5

Status LEDLegend Page 5

D-Sub 9 Pin Motorola Interface Page 4

Input/Output Wiring Page 3

Fuses Page 3

Time Out Programming (Side of Unit)

Page 5

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Phone: 714-751-0488 Fax: 714-957-1621


Features:

•Protectsmobilecomputersagainstsystemcrashpreventinglengthyrebootsequencesandlossofdatadueto:•Voltagedipduringenginecranking.•Voltagedropanddecayduetoloadinghighpoweraccessoriesandagingbatteries.

•Providessupplementalvoltageinmili-secondstomobilecomputerswhenlowvehiclebatteryissensed,ensuringno interruption in power.

•Back-UpBatterymaintainsDCoutputvoltageduringdipsandblack-outs—preventingmemorylossandsystemcrashesinmissioncriticalmobileelectronics.Internalback-upbatteryautomaticallyswitchesonlinewhenthevehicle’sbatteryvoltagereaches10.0VDC.Vehiclebatteryauto-reconnectswhenvehiclevoltagereaches11.5VDC or higher.

•InternalBatteryCharger•Built-in,3-Stagetemperaturecompensatedbatterychargermaintainsinternalbatteryatfullcharge,ready to provide back up power for an extended period.•Noisefiltereliminateselectronicnoiseandinterference,providingcleanpowerrequiredbymobileelectronics for proper operation.

•Overvoltagetransientprotectionpreventsdamagetosensitivecircuitryduetovoltagelinespikes.

•Whenactivated,loaddisconnecttimer(TMR)eliminatesdeadvehiclebatteriescausedbypowerdrainfromradiosand mobile data terminals that must operate while the engine is off. Allows use of accessory loads per programmed timelimit(useradjustable)whilepreservingbatteryforemergencystarting.Factorydefaultisnotactive,seepage5.

•Built-inLVD(LowVoltageDisconnect)activateswhentheinternalback-upbatteryreaches9.6VDC;protectingthe internal battery from complete discharge.

•Powerconservingcircuitryplacesinternalchargerinsleepmodeafterapproximately30minutesoncechargerswitches tofloatmode.Sleepmodedurationadjustable(factorydefaultis6hours),thenchargercomesbackonlinetocharge and float battery for a minimum of 30 minutes before sleep mode is restarted. Note:Sleepmodeisdelayedifback-up mode is detected before the 30 minutes has elapsed. Once again, when charger reaches float mode the 30 minute delay starts.

•Alertswhensystemisoperatingonbatteryback-up.

•PowerStatusindictorsprovidevisualsystemoperationalstatus/disconnecttimeractivation/troubleshooting.

•Conformalcoatedprintedcircuitboardresistscorrosion.

•Rugged,rustandcorrosionresistantpowdercoatedaluminumcaseprovidesprotectionforcomponents.

•All components selected for dependable performance in hostile environments.

•Twoyearlimitedwarranty.

Motorola Work Station Features

•Providesoutputwarningsignalstomobilecomputers(suchasMotorola®MW800seriesworkstationsandvideo recording system cameras).

•Initiateslowvoltageshutdownsequenceinmobilecomputersprotectingdataandharddrive.

2

D.C.Input Problems Here

VOLTAGE SPIKES

NOISE

LOSS OF POWER

VOLTAGE DIPS CAUSED BY ENGNE STARTING

No Power Problems Here RADIO

MOBILE COMPUTER TERMINAL


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MATERIALS PROVIDED

TheMDP-25.0issuppliedwiththefollowingmaterials:(4) # 8 ring lugs for 8 gauge wire (1) Terminal block cover (attached)(1) Installation/Operation Manual Checktoseethatthesehavebeenincludedwiththepackaging.Foranymissingitems,pleasecontactFactory.

INSTALLATION

Mechanical:Locate a flat surface close to the power line that feeds the electronics. For best results, the MDP should be within 24” of the critical electronics. The case need not be grounded, so it is acceptable to mount the unit on wood or metal. Securely mount the unit in any orientation, however horizontal is best. Note: In order to ease future battery replacement, it is recommendedthatthefrontoftheMDPremainun-obstructed.

Power:

Input wiring:

1)RemovebothInputandOutputfusesonMDP(ATC-30x2)beforeinstallation.Removeterminalblockcover.

2)Turnoffthepowerontheinputwiresbydisconnectingthebatteryorshuttingofftheappropriatecircuit.Note,theMDP functions as an uninterruptable power source. If electronics are wired directly to the MDP output and the primary feed voltage to the MDP is via an ignition switch, when the switch is turned off the MDP will continue to power the load until its internal battery reaches a low voltage disconnect point.

3)Identifythepositiveandnegativeleadinthepowerlineandcutatanappropriatelocation.Usethelugs supplied, wire the input to the MDP – note it is recommended that the input be fused at the source, see illustration below.

Output wiring:

Usingthetablebelow,selecttheproperwiresizeforyourinstallationandattachtoterminalblock.Fourringslugsfor8AWGwiresizeareincludedwiththeMDP-25.0.Replaceterminalblockcovertopreventaccidentalshortingoftheterminals.

3

(+)

(-)

DCInput(Connecttofused,unswitchedDCsourceor one which always stays on)

ToCritical+12Vloads

ToCritical-12Vloads

CircuitBreakers/Fuses(Optional)

Ground POSITIVE

GROUND

AMPS* CABLE LENGTH (feet) 10’ 15’

0-10AMPS 12 AWG 10 AWG

10-25AMPS 8 AWG 8 AWG

* Current draw of Electronics being powered.

>

Fig. 1: Input and Output Wiring


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1

4

3

2

5

6

9

8

7

Ignition OUT

Ignition IN

Charge/Discharge

Not Used

Not Used

Not Used

Not Used

Not Used - INPUT

4

Motorola Output Signals:

The MDP is programmed to provide early warning signals to mobile data computers designed for this input (such as Motorola®MW800Seriesworkstationsandvideorecordingsystemcameras.)InterfacesignalsforthisoutputislocatedontheD-sub9pinconnectorperthefollowingpinout(pleasecontactfactoryformatingconnectorwithpigtails,partnumber425-5233-0):

Signal Key:

1)IgnitionOUT:tobeconnectedtoMDTinterfacewithsignalwhichinitiatesstartupandshutdownsequenceofcomputer. 2) Ignition In3)Charge/DischargeSignal:usedtosignalcomputerthatpoweriscomingfromback-upbattery.ActiveLOW(<2V) 4)-Input:Ground

OPERATION

Undernormaloperatingconditions,theelectronicsoperatefromprimarybatteryvoltageofthevehicleorvessel.Thissame voltage powers the internal battery charger that maintains the MDP internal battery in a fully charged state. The chargercircuitoperatesonaninputrangeof10.2-15.5volts,soeveniftheprimarybatteryvoltagedecaystheMDPinternal battery will receive proper voltage and be maintained at full charge. The internal charger has a rapid recovery, three step output and temperature compensation sensor that varies the charge voltage based on ambient temperature to prolong battery life.

A fast acting sense circuit connects the internal battery online to the electronics any time when the input voltage drops below10.5voltsortotalinterruptionofvoltageoccursaugmentingvoltagetotheelectronicsfor3seconds.Ifproperprimary voltage is not restored within the 3 second time frame, input from the vehicle battery disconnects and electronics operate entirely from the MDP reserve battery (see settings sections for variations on this function).

The internal MDP battery will continue to supply power until primary vehicle or vessel battery voltage is restored (> 12.0 volts)ortothepointwheretheMDPinternalbatterydischargesbelow9.6volts,atwhichtimealowvoltagedisconnectenergizes, shutting off all power to the MDP output. When primary vehicle or vessel voltage is restored, the internal battery willbegintorechargeandbeavailableforreservepoweraftervoltageisrestoredto>13.5volts(approx120minutesfromfully discharged state)

Important Note: The MDP function is that of an uninterruptable power source, so if electronics are wired directly to the MDP output and the primary feed voltage to the MDP is via an ignition switch, when the switch is turned off the MDP will continue to power the load until its internal battery reaches a low voltage disconnect point. Ideally the power to the MDP should be left on. If the vehicle is left for an extended period, the powered electronics should be shut off to conserve the primary battery. The MDP has a power conservation “sleep mode” that initiates and turns off the 3 stage charger when the unit senses float charge for more than 20 minutes. For long term storage, remove loads from MDP output and remove input and battery fuses.

CAUTION:DONOTLEAVETHEBATTERYDISCHARGEDFOREXTENDEDPERIODSOFTIME.ITMAYBEPERMANENTLYDAMAGEDANDMAYNOTTAKEARECHARGE.

CAUTION: IFRE-INSTALLINGFUSESAFTERVEHICLEBEING‘OUTOFSERVICE’,ALLOWFOR2HOURSTOCHARGETHEINTERNALBATTERYBEFOREMDPISPUTINTOSERVICE.

Fig. 2: Input/Output Signals (D-Sub 9 Pin) - Motorola Apps.


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Status LEDs

Refer to the illustration below for location of the front panel status indicator lights:

1.‘CHARGING’GreenLEDactivateswhencharge-modebeginsor,INPUTpowerisappliedforthefirsttimeandindicatesBack-upbatteryisbeingcharged.

ChargingColor Status

AMBER Bulk/Hi Rate

GREEN Float

OFF ChargerOff

Flashing RED ChargerOver-Temp

2.Amber‘ONBACK-UPPOWER’LEDindicatesBack-upbattery providingpowertoOUTPUT

On Back-Up PowerColor Status

AMBER Input below 10.5VDC

3.‘INPUTCONNECTED’GreenLEDactivateswhenINPUT>10volts andindicatesINPUTisprovidingpowertoOUTPUT.

StatusLED Operation StatusSteadyGREEN Input voltage range normal/

OK

FlashingGREEN Disconnect Timer (TMR) Activated

Flashing RED Input voltage range abnormal

Steady RED Outputdisconnected-TMRtimed out

Internal Battery Charger Operation

Theinternallead-acidbatteryischargedbya3stagechargerwithautomatictemperaturecompensation(30mV/°Cfrom25°C).Whentheinternalbatterygoesthroughadischargecyclethechargerisautomaticallybroughtonlineandcharges the battery. Initially the charging voltage increases to produce a constant current of approximately 1.8 amps tothebattery(stage1-bulkrate).Oncethebatteryvoltagereachesapproximately14.2volts,thechargingcurrentwillstarttoreduce.Thevoltagewillremainat14.2volts(stage2-highrate/absorptioncharge)untilthecurrenttothebatterydecreasestoapproximately0.5amps.Theoutputvoltageisthenreducedtoapproximately13.6volts(stage3-floatcharge) and remains there for a fixed time of approximately 1 hour after which the charger is turned off. The charger will periodicallyre-starttotopoffthebattery.(Thechargerre-starttimeintervalisadjustable,seeAdvancedSettingspage7).Completechargingcycleoffullydischargedbatteryisapproximately3-4hrs.Chargerover-temperatureprotection:ThebatterychargercircuitwillautomaticallyswitchtoreducedfloatvoltageiftheMDPinternaltemperaturereaches55°C.Theover-temperatureprotectcircuitwillautomaticallyresetonceinternaltemperaturereducestoapproximately50°C

Disconnect Timer (TMR) Operation

TheMDP-25.0incorporatesanoptionaltimedloaddisconnectfeature(TMR).Whenactivatedthetimerwillbegintimingwhenthevehiclebatterydropsto12.0VDCorless.Iftheignitionoverridefeatureiswiredtotheignitionswitch(J1pin2,‘IgnitionIN’),itwilldisabletheTMRtimeddisconnectassoonasitsenses2voltsorgreater.ToenabletheTMRfeatureandselect a disconnect time period via the DIP switches, you must do following:

Settings: Modifications can be made to disconnect pointsandtimercircuits,seepage6forTimeDelaySettings.

5

Fig. 3: Status LEDsStatus LED Legend refers to


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1.IftheMDP-25.0isalreadyinstalled,turnoffall12voltloadsconnectedtotheoutputanddisconnectthe12voltinput.If unable to remove power first, make the DIP switch changes and then capture the changes by pressing the RESET button once.

2. Access the DIP switches by removing two Phillips head srews securing the access plate located on the side of the unit (left side if looking at the front of MDP).

Fig. 4: DIP Switches-Access Plate Removed

3.ToactivateTMRfeature:MoveS3groupnumber6switchtothe“ON”position(downwards).

4.Settingtimedelay:S3groupnumbers1-4setsthedelaytimeperTable1belowwhentheMDPsensesthevehiclebatteryhasfallento12voltsorless.Thetimerwillresetorstoptimingwhenthevoltagesensedis13.5voltsorgreater,example: engine alternator charging. See Table 1 below for time delay choices.

5.NotethattheTMRfeatureisdisabledifthe‘Ignition-IN’pin(Pin2oftheD-sub9pinconnectoronfrontpanel,see Figure2)isconnectedtoavoltagegreaterthan2volts(i.e.+battery).Back-upfunctionwillstilloperateevenwhenthetimerisactivated,however;theloadwillstillberemovedaftertheTMRtimerhastimedout,eveniftheback-upbatteryisable to support the output load.

Table 1: Time Delay Settings

S3 Pos 1 Pos 2 Pos 3 Pos 4 Pos 5 Pos 6Timer Disabled X X X X X OFF

10 Minutes OFF OFF OFF OFF X ON

15Minutes ON OFF OFF OFF X ON

18 Minutes OFF ON OFF OFF X ON

24 Minutes ON ON OFF OFF X ON

30 Minutes OFF OFF ON OFF X ON

45Minutes ON OFF ON OFF X ON

1 Hr OFF ON ON OFF X ON

1.5Hr ON ON ON OFF X ON

2 Hrs OFF OFF OFF ON X ON

3 Hrs ON OFF OFF ON X ON

4 Hrs OFF ON OFF ON X ON

8 Hrs ON ON OFF ON X ON

10 Hrs OFF OFF ON ON X ON

11 Hrs ON OFF ON ON X ON

12 Hrs OFF ON ON ON X ON

13 Hrs ON ON ON ON X ON

X = Either On or Off - it makes no difference

On = Down

Off = Up

USB (Factory Use Only)

Reset Button Boot (Factory Use Only)

S5 Back-Up Trigger Voltage Threshold &

Back-Up Timer Interval

S4Back-Up Hysteresis &

Charger Re-Start Interval

S3Timer Activation & Delay Time Setting


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Advanced settings (Technician Recommended): Back-Up Timer, Trigger Threshold and HysteresisFactory Defaults

Setting Factory DefaultTMR Disconnect Time Notactivated

Back-UpTimer(battery) 15min.

Back-UpTriggerVoltage 10.5V

Back-UpHysteresis 1V

ChargerRe-StartInterval 6hrs.

1.DIPswitchgroupS5,switchnumbers1-3areforchangingtheBack-Up Timer Interval (See Table 2). This adjustment setstheamountoftimetheMDP’sinternalback-upbatteryremainsconnectedtotheoutput/loadwhenalowvoltageevent is detected.

2.DIPswitchgroupS5,switchnumbers4-6areforchangingtheBack-Up Trigger Voltage Threshold (See Table 3). This adjustment sets the voltage at where the internal battery is applied to the output/load and the input source (vehicle battery) is disconnected.

3.DIPswitchgroupS4,switchnumbers4-6areforchangingtheBack-Up Hysteresis (See Table 4). Hysteresis sets a voltagelevelabovetheback-uptriggerlevelforthereconnectionofinputsourceanddisconnectionofinternalbattery(seetable4).HysteresisshouldbesetafterdeterminedtheamountofvoltagedropfromtheDCsource(vehiclebattery)to input terminals of the MDP, when the intended output load current is at its maximum level. Note: Remember to take into account at least 2 amps for internal charger. The internal charger can draw approximately 2 amps from the input source to charge the internal back-up battery if it is deeply discharged.

4.DIPswitchgroupS4,switchnumbers1-3areforchangingtheCharger Re-start Interval(SeeTable5).Thechargingtimeoftheinternalbatteryisnotsettable;itisdictatedbythebatterystateofcharge,batteryconditionandtemperature.In order to reduce the current drain on the vehicle battery the internal battery charger turns OFF once it completes a charging cycle. However the time at which the charger will turn back on to refresh the charge on the internal battery is adjustable.

Table 2 Table 3

S5 - Back-Up Timer

Pos 1 Pos 2 Pos 3

15Minutes OFF OFF OFF

30 Minutes ON OFF OFF

1 Hr OFF ON OFF

2 Hrs ON ON OFF

3 Hrs OFF OFF ON

4 Hrs ON OFF ON

5Hrs OFF ON ON

6Hrs ON ON ON

S5 - Back-UpTrigger

Pos 4 Pos 5 Pos 6

10.5Volts OFF OFF OFF

11.0Volts ON OFF OFF

11.2Volts OFF ON OFF

11.4Volts ON ON OFF

11.6Volts OFF OFF ON

11.8Volts ON OFF ON

12.0Volts OFF ON ON

12.2Volts ON ON ON

7


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Table 4 Table 5

S4 - Back-Up Hysteresis

Pos 4 Pos 5 Pos 6

1Volts OFF OFF OFF

1.2Volts ON OFF OFF

1.4Volts OFF ON OFF

1.6Volts ON ON OFF

1.8Volts OFF OFF ON

2.0Volts ON OFF ON

2.2Volts OFF ON ON

2.4Volts ON ON ON

INTERNAL BATTERY CHARGING & REPLACEMENT:TheMDPinternalbatteryisasealedleadacidandrequiresnomaintenance.Batterylifeistypicallyuptofiveyears,butwillvarydependingonuseandoperatingenvironment.Thebatteryshouldbereplacednolessfrequentlythaneveryfive(5)yearstoguaranteeproperoperationoftheMDP.(Requestpart#591-0712-0)

To determine the age of the battery, check the date code located on top of the battery. The four digits refer to the year and monthofmanufacture.Forinstance,aunitwithadatecodeof“1035”wasmanufacturedthe35thweekof2010.ToreplacethebatteryfirstremovepowertotheMDPinputwiringandturnoffall12VoltloadsconnectedtoMDP.Removethefusefromtheholderlabeled“BATTERY”.Toaccessthebattery,loosenandbackoutthefourfrontBatteryAccessPlatesecuring screws and remove Battery Access Plate.

Once the plate is removed, you will see the battery is secured in position by a Locking Plate. Loosen and back out the two Locking Plate locking screws. Lift Locking Plate up from bottom and remove battery. When the terminals are exposed, disconnect the push on connectors and remove the battery. Reinstall the new battery by lifting up on the Locking Plate andslidingthebatterypartiallybackintothecompartment,re-attachtheterminals(confirmproperpolarityordamagecan result) and push the battery all the way back in until the Locking Plate can shut properly. Dispose of the old battery properly.Re-tightenthetwobatteryretainingbracketsecuringscrews.Re-installthebatteryaccessplateandre-installandtightenthefourbatteryaccessscrews.Althoughthebatteryissealed,itisaLead-Acidtype,sotherearerestrictionson its disposal.

S4 – Charger Re-Start Interval Pos 1 Pos 2 Pos 36Hrs OFF OFF OFF

7Hrs ON OFF OFF

8 Hrs OFF ON OFF

9 Hrs ON ON OFF

10 Hrs OFF OFF ON

12 Hrs ON OFF ON

24 Hrs OFF ON ON

48 Hrs ON ON ON

Battery Access Plate

Front Screws

Lock Screws

Locking Plate

Battery

Terminals

+

-

CAUTION: Observe correct battery polarity!

8

Fig. 5: Internal Battery Charging & Replacement


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9

TEST / TROUBLESHOOTINGRefertothestatusLEDindicatorlegendonpage5,whichprovidesdiagnosticsofwhatstagetheMDPiscurrentlyoperating.

1) Testing Battery Back-up Function: With a load connected to MDP output remove input fuse and confirm load is powered without interruption from MDP internalbattery:ThetwoGREENLED’s(“CHARGING”&“INPUTCONNECTED”)shouldextinguishandtheAMBER“Back- up Power” LED will illuminate.

2) Start-up:WhenconnectingorreconnectinginputpowertotheMDPitisnormalforthe“INPUTCONNECTED”LED&“BACK-UP POWER”LEDtobothillimunatefor2-3seconds.

3) Charging LED: a)ItisnormalfortheCHARGINGLEDtoextinguishwhenthethreestagechargergoesintosleepmode.(Sleepmode reduces MDP input current draw when the internal battery is full charged.)

b) Iffusesblowrepeatedly,thisusuallyindicatesashortedcomponent.ContactNEWMARforfurthertroubleshootingadvice.Alwaysverifythatthereplacedfusesareofthecorrectrating.UsestandardATCfuses.Donouse slow-blowfuses.

c)FlashingRedLED-internalchargingtemperatureexceeds50°C.

FACTORY CONTACT INFORMATIONIfaproblempersistsafteryouhaveappliedtheabove-outlinedsolutions,orifyouhaveanyquestionsabouttheinstallationandproperoperationoftheMDP-25.0,pleasecontactNEWMAR’sTechnicalServicesManager:

Phone: 714-751-0488-Fromthehoursof7:00A.M.to4:30P.M.weekdays,P.S.T.Fax:714-957-1621Email: [email protected]

Wearehappytoconsultwithyoutoresolveanyproblemsorquestionsyoumayhave.Ifduringconsultation,itappearstheMDP-25.0mustbereturnedtothefactoryforrepairwewillissueaReturnMaterialsAuthorizationatthattime.

SPECIFICATIONS:

INPUT:Stand-by:12VDC,12.2->15.5VDC,11.5minimuminputrequiredforstartup,MaximumInputCurrent:28.5Amps(25Ampsmax.Load+3.5AmpsCharger)Stand-byCurrent:<40mA(noloadonoutput,internalbatterycharged,3Stagechargerinsleepmode) OUTPUT:12VDCFiltered,VoltageSpikeProtectedwithBack-UpBattery25ampsMax. BACK-UP POWER: 12.0VDCNominal,from7AHinternalbattery: 5ampsfor60Minutes 10 amps for twenty Minutes 25ampsforsixMinutes(Alltheaboveassumingfullychargedbattery@25°C) BATTERY:SealedLeadAcid,Rechargeable7.0AH,5YearsTypicalLife-UserReplaceable

INTERNAL CHARGER: 2Amps,3Stage,TemperatureCompensated

FILTERING: Audio through 200 MHz

VOLTAGE SPIKE PROTECTION: TransientEnergyCapability;100Joules,4,000ampsMax

OPERATING TEMPERATURE: 0-50°C

SIZE/WEIGHT:5.75”Hx6.0”Wx8.5”D(14.6x15.24x51.59cm)/9.4lbs.(4.3kg)


Phone: 714-751-0488 Fax: 714-957-1621


DIMENSIONAL DRAWINGS:

6.980

8.460

5.400

4.750.300

6.000

∅.281 x 4

5.790

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mobile data power model: mdp-25.0 installation/operation · operate entirely from the mdp reserve...

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