ongo01c – project oscar powerseniord.ece.iastate.edu/projects/archive/ongo01/... · ongo-01c...

Ongo01c – Project OSCAR Power

Fall 2003 Status Report -- OSCAR Power Sub-Team Version 2.0

Client: Department of Electrical and

Computer Engineering, Iowa State University

Faculty Advisor: Professor Ralph E. Patterson III

Team Members:

Marquis, Daniel Nguyen, Hong

17 December 2003

Ongo-01c OSCAR power sub-team

Revision History Date Author Description Version17 November 2003

D. J. Marquis Document Inception 1.0

15 December 2003

D. J. Marquis Document Revision 1.5

17 December 2003

D. J. Marquis Addition of Appendices 2.0


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Table of Contents 1. Introduction ............................................................................................................................1

1.1 Executive Summary.................................................................................................................. 1 1.2 Acknowledgement .................................................................................................................... 1 1.3 Problem Statement ................................................................................................................... 1

1.3.1 Primary Problem ................................................................................................................... 2 1.3.2 Secondary Problem.............................................................................................................. 2 1.3.3 Tertiary Problem ................................................................................................................... 2

1.4 Operating Environment ............................................................................................................ 2 1.5 Intended Users and Uses ........................................................................................................ 2 1.6 Assumptions and Limitations .................................................................................................. 3

1.6.1 Assumptions .......................................................................................................................... 3 1.6.2 Limitations.............................................................................................................................. 3

1.7 Expected End Product ............................................................................................................. 3 2. Project Accomplishments and Current Status .......................................................................4

2.1 Previous Accomplishments ..................................................................................................... 4 2.2 Present Accomplishments ....................................................................................................... 4 2.3 Future Accomplishments ......................................................................................................... 4 2.4 Current Project and End-Product Status ............................................................................... 4

2.4.1 DC-DC power supply system for the computer ............................................................... 4 2.4.2 A power budget for OSCAR................................................................................................ 4 2.4.3 A temporary and/or permanent on-board power supply for sensors ............................ 5

2.5 Recommendation for Continued Effort .................................................................................. 5 2.5.1 DC-DC power supply system for the computer ............................................................... 5

3. Documentation of Current Efforts and Results ......................................................................6 3.1 Project Definition Activities ...................................................................................................... 6 3.2 Research activities.................................................................................................................... 6 3.3 Design Activities........................................................................................................................ 6 3.4 Implementation Activities ......................................................................................................... 6 3.5 Testing and Modification Activities ......................................................................................... 6

4. Resources and Schedules.....................................................................................................7 4.1 Resource requirements............................................................................................................ 7

4.1.1 Personnel effort requirements ............................................................................................ 7 4.1.2 Financial requirements ........................................................................................................ 8 4.1.3 Other resource requirements.............................................................................................. 8

5. Closure Materials.................................................................................................................12 5.1 Lessons Learned .................................................................................................................... 12

5.1.1 Went well: ............................................................................................................................ 12 5.1.2 Didn't go well: ...................................................................................................................... 12 5.1.3 Technical Knowledge:........................................................................................................ 12 5.1.4 Non-Technical Knowledge: ............................................................................................... 12 5.1.5 Do differently: ...................................................................................................................... 12

5.2 Risk and Risk Management .................................................................................................. 13 5.2.1 Known risks avoided .......................................................................................................... 13 5.2.2 Unknown risks encountered: ............................................................................................ 13

5.3 Project Team Information ...................................................................................................... 13 5.3.1 Client information................................................................................................................ 13 5.3.2 Faculty advisor information ............................................................................................... 13 5.3.3 Team member information ................................................................................................ 13

5.4 Closing Summary.................................................................................................................... 14


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Table of Figures Figure 4-1 – Power sub-team schedule of tasks.........................................................................10 Figure 4-2 – Power sub-team schedule of deliverables..............................................................11


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Table of Tables Table 4-1: Power sub-team personnel effort expenditures as of December 16, 2003..................7 Table 4-2 – Power sub-team personnel effort budget revision (done November 17, 2003) ........7 Table 4-3 – Power sub-team financial expenditures as of December 16, 2003............................8 Table 4-4 – Power sub-team major tasks schedule.....................................................................9 Table 4-5 – Power sub-team deliverables schedule ....................................................................9


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List of Definitions:

AC/DC inverter = An electronic device that changes Alternating Current (AC) to Direct Current (DC), usually to simulate a regular battery-like power supply.

DC/AC inverter = An electronic device that changes DC current to alternating current, usually to simulate a regular household wall socket power supply.

DC/DC inverter = An electronic device that changes a DC power supply's voltage level to a different voltage level, usually to meet power supply specifications of a load.

OSCAR = Octagonal Speech Controlled Autonomous Robot


1. Introduction

Project OSCAR (Octagonal Speech Controlled Autonomous Robot) is an ongoing senior design project funded by the Department of Electrical and Computer Engineering (ECpE) at Iowa State University (ISU). Its purpose is to maintain and improve robotic ambassadors for the department. Past robots include Zorba and CYBOT. The most recent robot is OSCAR.

None of the robots are completely operational at the moment. Zorba no longer exists. CYBOT is aging and no longer works. OSCAR is in need of some new hardware, some new software, and a new power supply.

The power sub-team is a part of Project OSCAR. The power sub-team has been tasked with solving OSCAR’s power supply problems, which have helped prevent it from giving effective demonstrations and fulfilling its role as a departmental ambassador to the community.

Recent power supply problems resulted from a change in computer hardware. In Spring 2003, a new computer was installed that consumed 300% the power of the old computer. This caused a DC-DC converter that was built that semester to be overloaded and never fully implemented. This semester, however, a more energy efficient computer will be installed and the DC-DC converter should, once again be sufficient.

1.1 Executive Summary The power sub team has run into multiple snags this semester when testing the DC/DC power supply that the previous power sub team made. The power supply wasn't working as stated in previous reports and needed major repair. Also, the power supply has a major design flaw which can cause circulating currents, and subsequent overheating and/or voltage problems.

After testing and repairing and retesting the DC/DC power supply’s circuit boards, the power sub team recommends the purchase of a commercial DC/DC power supply for the computer. Also, the sub team recommends attempting to salvage the DC/DC converters from the current DC/DC power supply for possible use in powering sensors. In the mean time, the power team recommends the continued use of the DC/AC AC/DC voltage conversion scheme.

1.2 Acknowledgement The help of the OSCAR project advisor, Professor Patterson, and the cooperation of other OSCAR sub-teams has proved indispensable to the success of the OSCAR power sub-team’s part of the project.

Also, the help of staff members Jason Boyd and Gary Bridges in finding parts, loaning equipment, and repairing circuit boards is gratefully acknowledged.

1.3 Problem Statement Below are the three problems the power sub-team hoped to solve this past semester. [Caution: The problem statements have been taken, almost word for word, from the project plan; therefore, all references to time (e.g. “currently”) are from that viewpoint.]

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1.3.1

1.3.2

1.3.3

Primary Problem Currently OSCAR is running a PC that uses a standard PC power supply. This supply is fed from a 12/120 DC/AC inverter. The inverter is powered by a twelve-volt, on-board, deep-cycle marine battery. The power sub-team views this inefficient power supply scheme (going from DC to AC to DC) as a wasteful part of OSCAR’s power supply system. Much of the energy wasted going from DC to AC to DC could be saved if a DC/DC power supply was implemented instead. Since the power that OSCAR has on-board is very limited, minimizing the losses in the power system is a high priority.

DC/DC implementation will be accomplished by first doing a power audit on OSCAR to verify that its current/future power needs can be met with the previously built DC/DC converter. If so, the DC/DC converter shall be tested and installed. If not, then an alternative DC/DC shall be considered, and objectives for the semester redefined based on what needs to be done to implement the alternative DC/DC.

Secondary Problem Currently, OSCAR's sensors are not connected to an on-board power supply; instead they are being powered by the wall outlet, which effectively requires OSCAR to be tethered at all times. Since OSCAR is an Autonomous Robot, this is unacceptable, and an on-board power supply must be implemented.

This will be accomplished by a) finding and implementing a quick and easy way to supply sensors with on-board power, b) implementing such a quick fix, and c) starting to research a more permanent solution.

Depending on workload, the sensors sub-team may take the lead in solving this problem.

Tertiary Problem Maintenance and support for the existing power system must be provided so that other teams can test parts of OSCAR and so that OSCAR can do demos.

This will be accomplished by making the DC/AC converter functional, maintaining the fuses, and verifying the battery monitors.

1.4 Operating Environment OSCAR is designed to operate in controlled, indoor environments. Exposure to excessive dust, EM radiation, heat, and physical abuse should be avoided. OSCAR is computer-based and its operating environment constraints are largely set by the operating environment constraints of its electronic components. An occasional 1”-3” drop or fall may occur, but should not be disabling.

1.5 Intended Users and Uses The power system is intended to serve all systems on board OSCAR. This includes the motion control team and their six DC motors, the sensor team and their sensor array, the software team and the on-board computer, and finally the end-effector team and the future arm they will provide.

The power system is intended to supply power to OSCAR for demonstrations. These demonstrations last five minutes, fifteen minutes, half an hour, or even a few hours. The power system is not intended to provide power to non-related devices like home theater systems, full fledged desktop computers, electric lawn mowers, and halogen lamps.

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1.6 Assumptions and Limitations Below are the assumptions and limitations the power sub-team used in creating its plan this semester.

1.6.1

1.6.2

Assumptions • OSCAR’s use will be limited to its currently planned demonstrative capacities. • Sensitive power systems will be isolated. For example, the PC and sensors will not

run off the same battery as the motors (i.e. one battery is reserved for dirty power). • Power requirements will not increase substantially without the power sub-teams first

being notified and consulted so that adjustments can be made.

Limitations • Power supplied can not exceed the amount of power available from the batteries. • The previously built DC-DC converters and sufficient documentation must be found. • The ability of the DC-DC converter to supply power is limited to its rated values. • The amount of time that each member can invest into the project is limited. • There are only two members on the power sub-team this semester. This will require

more time from each sub-team member in order to build the supplies, write reports, attend management meetings, and do presentations and demos.

• The power sub-team budget is currently $0; therefore, spending money should be avoided if at all possible.

1.7 Expected End Product

The expected outcomes of this sub-team's project are:

1) a DC-DC power supply system for the computer

2) a power budget for OSCAR

3) a temporary and/or permanent on-board power supply for sensors

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2. Project Accomplishments and Current Status Below are the details of what was done in previous semesters, what was done this semester, and what remains to be done in future semesters.

More information on many of these items can be found in the appendices.

2.1 Previous Accomplishments Below are some accomplishments from previous semesters.

• DC/DC Converter Designed (Fall ‘02)

• DC/DC Converter Fabricated (Spring ’03)

• Battery Sensors Installed (Spring ’03)

2.2 Present Accomplishments Below are the accomplishments for this semester.

• DC/DC Testing Commenced

• Power Budget Made and posted on web

• Documentation updated & posted on web

2.3 Future Accomplishments Below are some accomplishments. to pursue in future semesters.

• Maintain Power System (ongoing)

• Measure actual peak power usage & refine power budget accordingly (Spring 2003)

• Switch to DC/DC power supply (Spring 2003)

a) Purchase a commercial DC/DC converter (recommended; cost is ~$60)

b) Build a DC/DC power supply(s) (must supply sufficient 5V amperage)

c) Salvage old DC/DC converter (un-paralleling boards may fix problem)

• Improve Fusing (Spring 2003 & ongoing)

2.4 Current Project and End-Product Status Below are the details concerning the current status of the three end products of this project.

2.4.1

2.4.2

DC-DC power supply system for the computer • The 2 boards (which are hooked up in parallel to form 1 supply) have both had their

leads repaired and (as far as one can tell) output the correct voltages. However, there is one chip that gets really hot really fast even with no load. This could either be because the chip is bad or because there are circulating currents. It is usually not a good idea to hook up two voltage regulators in parallel.

A power budget for OSCAR • A preliminary power budget has been made and posted on the website. • Specs for the deep cycle marine batteries OSCAR is using are also posted on the

website.

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2.4.3

2.5.1

A temporary and/or permanent on-board power supply for sensors • Sensors already has a 5V regulator on one of their two power inputs. Therefore, if

need be, one of their power drains could be hooked up directly to the clean power battery.

• Sensors team is currently getting all their power through the computer. While this temporary solution works well at the moment, it increases the power requirements of the computer itself, which would increase the output requirements of any future DC/DC power supply that might be built or bought.

2.5 Recommendation for Continued Effort

DC-DC power supply system for the computer • The 2 boards (which are hooked up in parallel to form 1 supply) have both had their

leads repaired and (as far as one can tell) output the correct voltages. However, there is one chip that gets really hot really fast even with no load. This could either be because the chip is bad or because there are circulating currents. It is usually not a good idea to hook up two voltage regulators in parallel.

• If software team takes up less than one DC/DC converter board's worth of power (~10A @5V), this power team would recommend splitting the boards apart and continuing on as planned.

• If software team takes up more than one DC/DC converter board's worth of power (~10A @5V), this power team would recommend continuing on, but separating the power supply boards so they can be used for sensors/motion control logic and would recommend buying a commercial ATX DC/DC power supply for $60. It would be well worth the investment.

• As far as the project OSCAR itself goes, the power team believes the project should continue on, but with minor modifications: all students would be told up front that they should spend 60 to 120 productive hours on the project, another demo should be scheduled during the semester, and OSCAR would receive enough funding to buy an out-of-the-box motion control solution for the base. The problems experienced by OSCAR are not due to the project itself. The problem is due to a lack of commitment by various team members, lack of (truthful) documentation, and lack of funding.

The project is of great value to the department of electrical and computer engineering. Demonstrations by the projects’ robots have been overwhelmingly successful to the extent that, even two years after Cybot stopped working, requests for demos still come in.

The project is not a failure. This semester, the OSCAR team successfully did a demonstration for a group of 25 seventh and eighth graders. The robot introduced itself, spun, and interacted (speech wise) with the students. (Note: Almost all this was controlled by a laptop computer with wireless access and located in the back of the classroom.) The group of students was impressed and was verbally encouraged to study hard at Math and Science. While it is recommended that further improvements on the robot be made before the next demonstration (particularly in the areas of motion control and voice recognition), significant progress has been made this semester. Project OSCAR delivered a tangible benefit to its client, the department of electrical and computer engineering. A project that is starting to do what it’s supposed to do should probably not be axed.

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3. Documentation of Current Efforts and Results Below are lots of important facts that need to be documented. More information on many of these items can be found in the appendices.

3.1 Project Definition Activities

• Wrote Project Plan

3.2 Research activities

• Found battery specs online

• Found power supply specs online

• Created Power Budget

3.3 Design Activities

• None

3.4 Implementation Activities

• None

3.5 Testing and Modification Activities

• .Tested DC/DC Converters

• Repaired Fried Traces on PC Boards

• Replacing/Evaluating Hot Chips

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4. Resources and Schedules Below is some information about resource allocation and scheduling so far this semester.

4.1 Resource requirements Below is an outline of how the resources were used

4.1.1 Personnel effort requirements

Table 4-1: Power sub-team personnel effort expenditures as of December 16, 2003

ITEM

Daniel Marquis

Hong Nguyen

Est Act Est Act

Meetings 32 18. 16.567 32

Search for / Read documentation (in Town or call people) 8 11.5 5 10

Ordering parts 5 1.5 5 1

Physical installation and testing 10 20.5 15 13.75

Making report 10 80.25 5 47.0

Research 5 2.43 5 0

Total: 70 134.85 67 88.25

Table 4-2 – Power sub-team personnel effort budget revision (done November 17, 2003)

Original Estimate Revised Estimate

ITEM

Daniel Marquis

Hong Nguyen

Daniel Marquis

Hong Nguyen

Meetings (2hr/week/person)* (4 week/month)*(4 month/semester) 32 32 32 32

Search for documentation (in Town or call people) 8 5 8 5

Ordering parts 5 5 5 5

Physical installation and testing 10 15 10 15

Making report 10 5 52 25

Research 5 5 5 5

TOTAL: 68 68 110 87

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4.1.2 Financial requirements Financial expenditures for the power sub-team are listed in Table 3-1 below. Choosing to buy a commercial power supply or buying a separate supply for sensors could increase costs significantly.

Table 4-3 – Power sub-team financial expenditures as of December 16, 2003

Description Estimated Actual Difference

(Estimated - Actual)Project Poster (Cost to Sub-Team)

$50.00 $6.00 $44.00

Fuses $0.00 $3.00 -$3.00 Voltage Regulators $0.00 $0.00 $0.00 Total $50.00 $9.00 $41.00

4.1.3 Other resource requirements • None

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Schedules Below are some tables outlining the power sub-team’s project schedule.

Table 4-4 – Power sub-team major tasks schedule

Task

From

Day Month

To

Day Month

Length of Time

(total day)

Provide Temp Power

Research testing circuit

(DC/DC) Testing DC/DC circuit

Research testing circuit

(Monitor Battery) Testing Monitor Battery

Provide Power

21 9

21 9

30 9

21 9

30 9

26 10

23 11

26 10

30 10

26 10

30 10

25 12

45

25

23

25

23

44

Table 4-5 – Power sub-team deliverables schedule

Deliverable

From

Day Month

To

Day Month

Length of Time

(total day)

Email weekly

Class Presentation

Poster

Start Report

Status report to web Site

21 9

21 10

21 9

27 11

30 11

25 12

21 11

21 10

15 12

15 12

69

30

30

30

27

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A schedule to complete the tasks listed in table 3.4 is shown below, in figure 3.1.

Figure 4-1 –

Power sub-team schedule of tasks

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ub-te

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of ta

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A schedule of deliverables listed in table 3.4 is shown below, in figure 3.2.

Figure 4-2 – Power sub-team schedule of deliverables

Figu

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-2 –

Pow

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ub-te

am s

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of d

eliv

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5. Closure Materials Below are the closure materials for the report.

5.1 Lessons Learned Some lessons learned this semester are outlined below.

5.1.1

5.1.2

5.1.3

5.1.4

5.1.5

Went well: • Found missing information on the DC/DC converter boards and batteries.

Didn't go well:

• Fixing bad equipment: the two converter boards made last year kept breaking and appear impossible to fix due to a major design flaw — two boards are hooked up in parallel.

Technical Knowledge:

• Rechargeable Batteries: Deep cycle batteries can discharge fully, but the life of the battery is inversely proportional to number of times is deeply discharged.

• PC Boards: When making PCB's one can specify a thickness for the traces. Since power supplies have a lot of current they should have thick traces. Otherwise, the traces will burn out (like they did on our current DC/DC converter.)

• Power Supply Hookup: It is not recommended to hook up power supplies in parallel because a slight difference in output voltage will cause circulating currents and a lot of damage. Interestingly, usually only one of the boards is permanently damaged.

Non-Technical Knowledge:

• Documentation: Documentation takes up lots of time, but (if done properly) will save time in the future. Poor documentation is just a plain waste of time for everyone involved.

• Gant Chart Schedules: Gant chart schedules, task lists, and time budgeting are all supposed to be based off of a master list of tasks. That way there is continuity between the three.

Do differently:

• Project Plan: If the power sub team could, it would redo the project plan after the semester's objective had become clearer. Also, the power sub team would rewrite the Gant chart schedules, task lists, and time budgeting sections so there would be continuity between the three. Doing the aforementioned actions, would have helped immensely in project tracking.

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5.2 Risk and Risk Management Below are a couple risks that were avoided or run into unexpectedly.

5.2.1

5.2.2

5.3.1

Known risks avoided • Lack of knowledge and loss of a team member was successfully avoided. All sub

team members are up to speed and still with the team

Unknown risks encountered: • Equipment not performing as stated in status reports was an unknown risk that the

power sub team ran into. The team dealt with this risk by not trusting previous sub team reports without verifying for itself what the reports said.

5.3 Project Team Information Contact information for the various parties involved in the power sub-teams project are as follows:

Client information

Iowa State University Department of Electrical and Computer Engineering 2215 Coover Ames, IA 50011 voice: (515) 294-2663 fax: (515) 294-3637 [email protected]

5.3.2 Faculty advisor information

Ralph Patterson III 326 Town Engineering Ames, IA 50011 voice: 515-294-2428 fax: 515-294-6760 [email protected]

5.3.3 Team member information

Daniel J. Marquis Electrical Engineering, French 4894 Helser Haber Ames, IA 50012 (515) 572-2819 [email protected] mailto:[email protected]

Hong Viet Nguyen Electrical Engineering 1074 16th st Des Moines, IA (515) 243-0397 [email protected]

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mailto:[email protected]



5.4 Closing Summary The power sub team this semester repaired and tested the DC/DC converter that previous semesters built, but found it did not output power of a high enough quality to power the computer. Therefore, the power sub team re-implemented the old DC/AC AC/DC system. The power sub team this semester also found, created, and posted on the web a lot of documentation. Finally, the power sub team this semester would recommend project OSCAR continue. OSCAR has the potential to be as useful to the department of electrical and computer engineering as its predecessor, CYBOT. The power sub team this semester recommends future sub teams seriously consider a commercial DC/DC converter solution for at least the computer’s power supply. Doing so would free the power sub team up to individually fuse all of OSCAR’s components and design a permanent solution for powering the sensors.

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Appendix A: The DC/DC power supplies A1) The Sproggy Mk2.5 DC/DC converter

A1a) Website Printout A1b) Parts List A1c) Circuit Diagram / Schematic A1d) Sproggy Mk2.5 PCB Component Placement / Layout A1e) Sproggy Mk2.5 PCB Trace Layout (For Making The Board)

A2) Sample Commercial mini-ATX DC/DC Power Supplies

A2a) PW-60-MINI-ITX dc to dc converter A2b) PW-70-MINI-ITX dc to dc converter

A3) Power Supply Comparison : Sproggy v2.5 with PW-70-MINI-ITX A4) Sample AC/DC computer power supply Specs A5) Fall 2003 OSCAR Power Sub-Team: DC/DC Pictures

Appendix A: The DC/DC power supplies A1) The Sproggy Mk2.5 DC/DC converter

A1a) Website Printout A1b) Parts List A1c) Circuit Diagram / Schematic A1d) Sproggy Mk2.5 PCB Component Placement / Layout A1e) Sproggy Mk2.5 PCB Trace Layout (For Making The Board)

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uppl N

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AAA333))) PPPooowwweeerrr SSSuuppppllyyy CCCooommmpppaaarrriiisssooonnn ::: SSSppprrroooggggggyyy vvv222...555 wwwiiittthhh PPPWWW---777000---MMMIIINNIII---IIITTTXXX AAA444))) SSSaaammmpppllleee AAACCC///DDDCCC cccooommmpppuuuttteeerrr pppooowwweeerrr sssuuupppppplllyyy SSSpppeeecccsss AAA555))) FFFaaalll lll 222000000333 OOOSSSCCCAAARRR PPPooowwweeerr SSSuuubbb---TTTeeeaaammm::: DDDCC///DDDCCC PPPiiiccctttuuurrreeesss

Power Supply I dislike mains inverters but I have made a page that will hopefully answer some questions about them.

Other mp3 car constructors have made DC-DC power supplies ranging in complexity from very simple to complex. I looked at as many different designs as possible that have been freely published on the internet but saw nothing that I wanted to build or suited my needs. So I set about the construction of my own power supply borrowing some ideas from other peoples designs to suit my own needs.

Mk I

Mk1 Picture (156K) This was a surplus integrated power supply and backup unit being sold for £30 from Bull Electrical. The specification for this unit was very good: 5V at 35A 12V at 9A -5V at 0.5A -12V at 0.5A 21.5Ah 12V Battery pack 240/110V mains operation

But unfortunately the thing was massive and very heavy so it wasn't very suitable for installation in my car

Mk II

After tinkering with the Mk1 power supply I wanted to quickly make something that would be cheap and quick to make, small and reliable. This led to using the popular MAX787 5V switching regulators available as free samples from MAXIM. As my car bettery is healthy at the moment and as I only really listen to music while driving I am using a 12V 1.5A low dropout linear voltage regulator for the 12V supply. This means that the power supply must be above 12.5V to keep the 12V at 12V. Provision is also made for -5V and -12V to ensure correct sound, serial and network functionality. Remote power switching and reverse polarity protection is taken care off by an onboard relay. Specifications: Supply 12.5V - 18V DC 5V at 10A (13A peak) 12V at 1.5A -12V at 100mA

Page 1 of 4Power Supply

10/4/2003http://www.sproggy.freeserve.co.uk/psu.html

-5V at 100mA Circuit Diagram (13k) PCB Layout (jpg 600dpi 260k) PCB Layout (pdf 26k) PCB Layout (Traxmaker 16k) Component Layout (pdf 345k) Bare Printed Circuit Board (650k) Top View (650k) Side View (650k) Underneath View (650k) Installed in my Player (650k) A 10A fuse should be placed in series with the input to the power supply and a heatsink MUST be fitted to the 5 TO220 devices. The two MBR745 diodes MUST be electrically isolated from the heatsink. The 20uH inductors can be made by winding 18 turns of 2 parallel, 0.9mm diameter enamel wires around a 10-20mm diameter toroid ferrite core.

Mk2.5

This is a development of the Mk2 power suppply above offering a wider input voltage range and improved support for 3.3V operation. This design should be more efficient than the Mk2 as a switching regulator is used for 12V.

Specification:

Supply 8-17V DC 5V at 10A* (13A peak) 12V at 1.3A -12V at 100mA -5V at 100mA *3.3V at 5A (6.5A peak) * If the 3.3V option is used then only 5A is available at 5V.

Circuit Diagram (PDF 13k) Parts List (PDF 8k) PCB Layout (PDF 35k) Component Placement (PDF 58k)



Stage1 Stage2

Stage3 Stage4

Stage5 Stage6

Stage7 Stage8



Stage9

MkIII

Under development



Part list for Mk2.5 DC-DC power supply

Component Qty Supplier (order #) Cost (each) Manufacturer Link Notes

MAX787CCK 2* Maxim Free sample Maxim http://www.maxim.com *only 1 required for 3.3V supply*MAX788CCK 1 Maxim Free sample Maxim http://www.maxim.com *only required for 3.3V supplyLM2587-12T 1 National Semiconductor Free sample National Semiconductor http://www.national.com79L05 1 Farnell UK (701-932) £0.31 various http://www.farnell.com47uH Inductor 2 Farnell UK (482-572) £2.78 Newport Power Devices http://www.farnell.com part# 1447385T6 (Q4339-B) 1 Coilcraft Free sample Coilcraft http://www.coilcraft.com part# Q4339-B10uH inductor 2 Coilcraft Free sample Coilcraft http://www.coilcraft.com part# PCV-0-103-05MBR745 2 Farnell UK (878-261) £0.72 Motorola http://www.farnell.comMBR340 1 Farnell UK (638-146) £0.46 Motorola http://www.farnell.comMUR120 1 Farnell UK (930-994) £0.61 Motorola http://www.farnell.comSA28A 1 Farnell UK (167-356) £0.61 Fairchild http://www.farnell.com1N5819 1 Farnell UK (573-115) £0.26 Multicomp http://www.farnell.com

1N4002 2 Farnell UK (365-142) £0.17 Philips http://www.farnell.com Any general >0.5A diode will work3mm Led 1 Use any colour you like12V SPDT Relay 1 Farnell UK (179-325) £2.64 Omron http://www.farnell.com1800uF 35V Electrolytic 2 Farnell UK (303-6443) £1.09 Panasonic FC series http://www.farnell.com Must be low ESR type470uF 25V Electrolytic 4 Farnell UK (303-6273) £0.36 Panasonic FC series http://www.farnell.com Must be low ESR type330uF 35V Electrolytic 3 Farnell UK (303-6406) £0.36 Panasonic FC series http://www.farnell.com Must be low ESR type220uF 25V Electrolytic 1 Farnell UK (303-6250) £0.24 Panasonic FC series http://www.farnell.com0.68uF 35V Tantalium Cap 1 Farnell UK (643-877) £0.16 AVX http://www.farnell.com100nF Polyester cap 1 Farnell UK (301-8660) £0.14 AVX http://www.farnell.com Any 100nF capacitor should work10nF ceramic cap 2 Farnell UK (750-890) £0.12 Multicomp http://www.farnell.com2.7k 1/4W resistor 2 http://www.farnell.com red, violet, red3k 1/4W resistor 1 http://www.farnell.com orange, black, red470R 1/2W resistor 1 http://www.farnell.com yellow, violet, brownPCB 1 Make your own yourselfHeatsink 1 Make your own yourself cut and bend aluminium to fitTO220 heatsink electrical insulators 2 Farnell UK (522-636) £0.13 MBR745 diodes must be electrically isolated10A fuse and holder 1 Connection to battery must be fusedCables and connectors fit as required

*

*

IC2

IC1

IC3

IC4

*

oo

o

For 3.3V operation replace IC2 with MAX788 and leave Pad1 open

For 5V operation join Pad1

Pad1

Remote

1N4002

1N4002

+8-16V

12VCOIL

SPDT

-5V

-12V

+12V

+5V

+5V

+

330uF

IN

COM

OUT

79L05

1N5819

MBR340

+

330uF

+

1800uF

+

1800uF+

0.68uF

0.1uF

SA28A MUR120

LED1

+

470uF

+

470uF

10uH

10uH

MBR745

MBR745

0.01uF

0.01uF

47uH

47uH

+

470uF

+

470uF

+

330uF

+

330uF MAX787

GND

SENSE

VswVin

Vc

MAX787

GND

SENSE

VswVin

Vc

LM2587-12T

GND

Vsw

SENSE

Vin

Comp

T6

3k

470R

2.7k

2.7k

MAX787 MBR745

330uF

MAX787 MBR745

2.7k

47uH

470uF

470uF

330uF

470uF0.01

uF

0.01

uF2.

7k

10uH

10uH 470uF

47uH

LED

470R

LM2587T-12

330uF

220uF

2.7k

1

T6

79L05

0.68

uF

0.1u

F

SPDT Relay

1N5819

MBR340

SA28A

MUR120

1800uF 1800uF

1N4002

+ -

Rem

ote

Appendix A: The DC/DC power supplies AAA111))) TTThhee SSSpprroooggggggyyy MMMkkk222...555 DDDCCC///DDDCCC cccooonnnvvveeerrrttteeerrr he pr

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A2) Sample Commercial mini-ATX DC/DC Power Supplies

A2a) PW-60-MINI-ITX dc to dc converter A2b) PW-70-MINI-ITX dc to dc converter

AAA333))) PPPooowwweeerrr SSSuuppppllyyy CCCooommmpppaaarrriiisssooonnn ::: SSSppprrroooggggggyyy vvv222...555 wwwiiittthhh PPPWWW---777000---MMMIIINNIII---IIITTTXXX AAA444))) SSSaaammmpppllleee AAACCC///DDDCCC cccooommmpppuuuttteeerrr pppooowwweeerrr sssuuupppppplllyyy SSSpppeeecccsss AAA555))) FFFaaalll lll 222000000333 OOOSSSCCCAAARRR PPPooowwweeerr SSSuuubbb---TTTeeeaaammm::: DDDCC///DDDCCC PPPiiiccctttuuurrreeesss

Compact design, less cables. The PW-60 is the only dc-to-dc cableless mini-ATX power supply solution for the VIA platform. Compatible with an entire range of mini-itx motherboards such as VIA EPIA-V, EPIA-5000, EPIA-800, Lucky Star Mini-itx, FIC C3 933 the PW-60 provides a cool, silent power solution for your small mini-itx motherboard. Additionally, PW-60 can power up your EPIA-M series by using a small ATX adaptor cable. PW-60-MINI-ITX dc to dc converter specifications Total output power (combined): 100W

NOMINAL LOAD CURRENT REGULATION VOLTAGE (DC) MIN. MAX. (%)

V(in)=12 Volt 0.1 A 6 A +/- 15

+3.3 Volt 0 A 4.5 A +/- 5

+5 Volt 0 A 5 A +/- 5

-5 Volt 0 A 0.2 A +/- 5

+12 Volt 0 A 6 A -12 Volt 0 A 0.1 A +/- 5

+5 Vsb 0 A 1.5 A +/- 5

Output Voltage Ripple & Noise(p-p)

+3.3 Volts 50 mV +5 Volts 60 mV -5 Volts 60 mV

+12 Volts 120 mV -12 Volts 120 mV

+5sb Volts 100 mV

Cable mess?

Try PW-60

Power Supply Selector

USB devices

CF storage

PCI cards

2.5 drive

SlimCD

3.5" drive

5.25" CD

PW-60 yes yes yes multiple yes * *PW-60a yes yes yes multiple yes multiple yesPW-70 yes yes yes multiple yes * *

PW-70A yes yes yes multiple yes multiple yes*NOTE: See manufacturer. specs, 12V rail should not exeed 1A

PW-60 dc-dc Converter Cables 12V In with 2.5mm standard jack, standard HDD and Floppy connector and a 5V out. Overload protection An over load protection will be effected when either of the loadings:+5V & +3.3V exceeds +120% to 160%. The power supply won’t be automatically recovered after the overload being removed.

Power-good signal After power-on with nominal AC input, there might be a turn-on delay between 100 mS to 500mS before the Power Good Signal is issued, which occurs before +5V output reaches its minimum sense level of +4.75V. When turn-off, the Power Good Signal shall go to a lower level for at least 1 mS before +5V falls under the regulation limit.

Turn-on Delay After turning on, at least 20 mS will be needed for the rise of +5V output voltage (measured from 10% point to 95% point on the waveform) to reach its peak.

Operating environment Temperature 0 to 40 degree Celsius Relative Humidity 10 to 90 percent, non-condensing

Remote ON/OFF control Logic level is LOW: Output voltage is enabled. Logic level is HIGH or floating: Output voltage is disabled.

Shipping and storage Temperature -40 to +70 degree centigrade Relative Humidity 5 to 95 percent, non-condensing

Page 1 of 2Mini-Box.Com

10/22/2003http://www.mini-box.com/PW-60a-specs.htm

Compact design, less cables. The PW-70 is the only dc-to-dc cableless mini-ATX power supply solution for the VIA platform. Compatible with an entire range of mini-itx motherboards the PW-60 and PW-70 provides a cool, silent power solution for your small mini-ITX motherboard. PW-70-MINI-ITX dc to dc converter specifications Total output power (combined): 70W

NOMINAL LOAD CURRENT REGULATION VOLTAGE (DC) MIN. MAX. (%)

V(in)=12 Volt 0.1 A 6 A +/- 15

+3.3 Volt 0 A 5 A +/- 5

+5 Volt 0 A 5 A +/- 5

-5 Volt 0 A 0.2 A +/- 5

+12 Volt 0 A 1.5 A -12 Volt 0 A 0.2 A +/- 5

+5 Vsb 0 A 2 A +/- 5

Output Voltage Ripple & Noise(p-p)

+3.3 Volts 50 mV +5 Volts 60 mV -5 Volts 60 mV

+12 Volts 120 mV -12 Volts 120 mV

+5sb Volts 100 mV

Cable mess?

Try PW-60 or PW-70

Power Supply Selector

USB devices

CF storage

PCI cards

2.5 drive

SlimCD

3.5" drive

5.25"CD

PW-60 yes yes yes multiple yes * *PW-60a yes yes yes multiple yes multiple yesPW-70 yes yes yes multiple yes * *

PW-70A yes yes yes multiple yes multiple yes*NOTE: See manufacturer. specs, 12V rail should not exeed 1A

PW-60 dc-dc Converter Cables 12V In with 2.5mm standard jack, standard HDD and Floppy connector and a 5V out. Overload protection An over load protection will be effected when either of the loadings:+5V & +3.3V exceeds +120% to 160%. The power supply won’t be automatically recovered after the overload being removed.

Power-good signal After power-on with nominal AC input, there might be a turn-on delay between 100 mS to 500mS before the Power Good Signal is issued, which occurs before +5V output reaches its minimum sense level of +4.75V. When turn-off, the Power Good Signal shall go to a lower level for at least 1 mS before +5V falls under the regulation limit.

Turn-on Delay After turning on, at least 20 mS will be needed for the rise of +5V output voltage (measured from 10% point to 95% point on the waveform) to reach its peak.

Operating environment Temperature 0 to 40 degree Celsius Relative Humidity 10 to 90 percent, non-condensing

Remote ON/OFF control Logic level is LOW: Output voltage is enabled. Logic level is HIGH or floating: Output voltage is disabled.

Shipping and storage Temperature -40 to +70 degree centigrade Relative Humidity 5 to 95 percent, non-condensing

Page 1 of 2Mini-Box.Com

10/22/2003http://www.mini-box.com/PW-70-specs.htm


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AAA222))) SSSaaammmpppllleee CCCooommmmmmeeerrrccciiiaaalll mmmiiinnniii---AATTTXXX DDDCCC///DDDCCC PPPooowwweeerrr SSSuuuppppppllliiieeesss


A3) Power Supply Comparison : Sproggy v2.5 with PW-70-MINI-ITX AAA444))) SSSaaammmpppllleee AAACCC///DDDCCC cccooommmpppuuuttteeerrr pppooowwweeerrr sssuuupppppplllyyy SSSpppeeecccsss AAA555))) FFFaaalll lll 222000000333 OOOSSSCCCAAARRR PPPooowwweeerr SSSuuubbb---TTTeeeaaammm::: DDDCC///DDDCCC PPPiiiccctttuuurrreeesss

Daniel J. Marquis Power Supply Comparison : Sproggy v2.5 with PW-70-MINI-ITX page 1 of 1 .

Specification: VoltageCurrent

(x1 board)Current

(x2 boards)Power

(x1 board)Power

(x2 boards)Max Battery Power Drain

Max Battery Current (@ 12V)

(Volts) (Amps) (Amps) (Watts) (Watts) (Watts) (Amps)Sproggy v2.5 (We have 2 built & hooked-up in || )Supply 8-17V DC5V at 10A* (13A peak) 5 5 10 25 50 4.1712V at 1.3A 12 1.3 2.6 15.6 31.2 2.60-12V at 100mA -12 0.1 0.2 1.2 2.4 0.20-5V at 100mA -5 0.1 0.2 0.5 1 0.083.3V at 5A (6.5A peak)* 3.3 5 10 16.5 33 2.75

* If the 3.3V option is used then only 5A is available at 5V.

Total: 58.8 117.6 9.80

The new Board 70-a ($50)

V(in) +/- 15% 12 6 72 6.00 V(in)=12 Volt 0.1 A 6 A 15

3.3 Volt, +/- 5% 3.3 5 16.5 3.3 Volt 0 A 5 A +/- 5

5 Volt, +/- 5% 5 5 25 5 Volt 0 A 5 A +/- 5

-5 Volt, +/- 5% -5 0.2 1 -5 Volt 0 A 0.2 A +/- 5

12 Volt 12 6 72 12 Volt 0 A 6 A

-12V, +/- 5% -12 0.2 2.4 -12 Volt 0 A 0.2 A +/- 5

5 Vsb, +/- 5% 5 2 10 5 Vsb 0 A 2 A +/- 5

Total: 126.9 0

NOMINAL LOAD CURRENT REGULATION

VOLTAGE (DC) MIN. MAX. (%)

9.8A @ 12V = ~3.2hr of operation off of fully charged battery (Till 100% dead; therefore, have 1.6hr of operation till

recharge needed)

NOTE: * Battery Specs say will run 11.6hr@5amp =~60Watt-hr before being 100% dead (though should charge when at 50%) * Calculation of Time DC/DC converter can be connected before battery is 100% drained is as follows: 60Watt-hr / 0.1Watt@off = 600hr = 25 days connected before before battery 100% drained (therefore, assuming no other power drains, would only have 12.5 days between charges (which are needed when battery charge <= 50%))

Comments: Notice how the Max output can't be greater than 70 Watts (Given the Current/Voltage Draw from the Battery & min draw of 0.1A)

PowerSupplyCompairison.xls Printed 10/22/2003


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AAA111aaa)) WWWeeebbbsssiii ttteee PPPrrriinnntttooouuuttt AAA111bbb))) PPPaaarrrtttsss LLLiisssttt AAA111ccc)) CCCiirrrcccuuuiiittt DDDiiiaaagggrrraaammm /// SSSccchhheeemmmaaatttiiiccc AAA111ddd))) SSSppprrroooggggggyyy MMMkkk222...555 PPPCCCBBB CCCooommmppoonneeennnttt PPPlllaaaccceeemmmeeennnttt /// LLLaaayyyooouuuttt AAA111eee)) SSSppprrroooggggggyyy MMMkkk222...555 PPPCCCBBB TTrrraaaccceee LLLaaayyyooouuuttt (((FFFooorrr MMMaaakkkiiinnnggg TTThhheee BBoooaaarrrddd))) AAA111ddd))) OOOuuurrr ssseeetttuuuppp



AAA333))) PPPooowwweeerrr SSSuuppppllyyy CCCooommmpppaaarrriiisssooonnn ::: SSSppprrroooggggggyyy vvv222...555 wwwiiittthhh PPPWWW---777000---MMMIIINNIII---IIITTTXXX A4) Sample AC/DC computer power supply Specs AAA555))) FFFaaalll lll 222000000333 OOOSSSCCCAAARRR PPPooowwweeerr SSSuuubbb---TTTeeeaaammm::: DDDCC///DDDCCC PPPiiiccctttuuurrreeesss

Sample AC/DC computer power supply Specs Downloaded October 20, 2003 Page 1 of 2 http://www.pcpowerandcooling.com/products/power_supplies/economical/145sfx_stndrd230slm/index_econ.htm

Products: Power Supplies: Economical AT STANDARD 230

SLIM Check The Price

Operating Range: Frequency: Current: Efficiency: EMI:

90-135 VAC 180-270 VAC switch 47-63Hz 7.0A @ 115V 3.5A @ 230V 73% FCC-B

Output: Regulation: Ripple: Hold Time: PG Delay:

+5V @ 23A +12V @ 9A -5V @ 0.5A -12V @ 0.5A 5% (+5, +12) 10% (-5,-12) 1% (p-p) 16ms 300ms

OV Protection: OC Protection: Agency Approval:

+5 short circuit UL, ULC, TUV

Temperature: Humidity: Fan Type: Noise:

0º -50º C 10%-90% RH 30 CFM ball 44dB(A)

Form Factor: M/B Connectors: Drive Connectors: MTBF: Dimensions:

Slim 2 6 (2 mini) 50,000 hrs. See diagram

Download this datasheet: Standard 230 Slim (109KB PDF)

5995 Avenida Encinas, Carlsbad, CA 92008 • (760) 931-5700 • (800) 722-6555 • Fax (760) 931-6988 USA E-mail [email protected] • International E-mail [email protected]

http://www.pcpowerandcooling.com/products/power_supplies/economical/145sfx_stndrd230slm/index_econ.htm

http://www.pcpowerandcooling.com/products/index.htm

http://www.pcpowerandcooling.com/products/power_supplies/index.htm

http://www.pcpowerandcooling.com/products/power_supplies/dimensions/dim_slim.htm

http://www.pcpowerandcooling.com/pdf/econ.pdf



Sample AC/DC computer power supply Specs Downloaded October 20, 2003 Page 2 of 2 http://www.pcpowerandcooling.com/products/power_supplies/economical/145sfx_stndrd230slm/index_econ_atx.htm Products: Power Supplies: Economical SFX, ATX STANDARD 180 PS3

Check The Price

STANDARD 250 ATX Check The Price

Operating Range: Frequency: Current: Efficiency: EMI:

95-132 VAC 190-264 VAC switch 47-63Hz 7A @ 115V 4A @ 230V 65% FCC-B, CE

95-132 VAC 180-264 VAC switch 47-63Hz 10A @ 115V 5A @ 230V 65% FCC-B, CE

Output: Regulation: Ripple: Hold Time: PG Delay:

+5V @ 16A +12V @ 10A -5V @ 0.2A -12V @ 0.3A +3.3V @ 16A +5VSB @ 2A +5V & +3.3V<118W 5% (+3.3, +5, +12) 10% (-5, -12) 1% (p-p) 16ms 300ms

+5V @ 25A +12V @ 10A -5V @ 0.3A -12V @ 0.5A +3.3V @ 13A +5VSB @ 2A +5V & +3.3V<150W 5% (+3.3, +5, +12) 10% (-5, -12) 1% (p-p) 16ms 300ms

OV Protection: OC Protection: Agency Approval:

+3.3, +5, +12 short circuit UL, ULC

+3.3, +5, +12 +3.3, +5, +12 UL, ULC

Temperature: Humidity: Fan Type: Noise:



Compatibility: M/B Connectors: Drive Connectors: MTBF: AC Plug Location: Dimensions:

ATX (Rev.2.03) 20-pin 6 (2 mini) 50,000 hrs. N/A See diagram

ATX (Rev.2.03) 20-pin 6 (2 mini) 70,000 hrs. N/A See diagram

Download this datasheet: Economical SFX, ATX Power Supplies (52K PDF)

5995 Avenida Encinas, Carlsbad, CA 92008 • (760) 931-5700 • (800) 722-6555 • Fax (760) 931-6988 USA E-mail [email protected] • International E-mail [email protected]

http://www.pcpowerandcooling.com/products/power_supplies/economical/145sfx_stndrd230slm/index_econ_atx.htm

http://www.pcpowerandcooling.com/products/index.htm

http://www.pcpowerandcooling.com/products/power_supplies/index.htm

http://www.pcpowerandcooling.com/products/power_supplies/dimensions/dim_ps3.htm

http://www.pcpowerandcooling.com/products/power_supplies/dimensions/dim_2atx.htm

http://www.pcpowerandcooling.com/pdf/econ-atx.pdf




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AAA111aaa)) WWWeeebbbsssiii ttteee PPPrrriinnntttooouuuttt AAA111bbb))) PPPaaarrrtttsss LLLiisssttt AAA111ccc)) CCCiirrrcccuuuiiittt DDDiiiaaagggrrraaammm /// SSSccchhheeemmmaaatttiiiccc AAA111ddd))) SSSppprrroooggggggyyy MMMkkk222...555 PPPCCCBBB CCCooommmppoonneeennnttt PPPlllaaaccceeemmmeeennnttt /// LLLaaayyyooouuuttt AAA111eee)) SSSppprrroooggggggyyy MMMkkk222...555 PPPCCCBBB TTrrraaaccceee LLLaaayyyooouuuttt (((FFFooorrr MMMaaakkkiiinnnggg TTThhheee BBoooaaarrrddd)))



AAA333))) PPPooowwweeerrr SSSuuppppllyyy CCCooommmpppaaarrriiisssooonnn ::: SSSppprrroooggggggyyy vvv222...555 wwwiiittthhh PPPWWW---777000---MMMIIINNIII---IIITTTXXX AAA444))) SSSaaammmpppllleee AAACCC///DDDCCC cccooommmpppuuuttteeerrr pppooowwweeerrr sssuuupppppplllyyy SSSpppeeecccsss A5) Fall 2003 OSCAR Power Sub-Team: DC/DC Pictures

Welcome to the Fall 2003 OSCAR Power Sub-Team DC/DC Pictures Page!

DC/DC Converters Outside of Box

Page 1 of 3"Fall 2003 OSCAR Power Sub-Team: DC/DC Pictures"

12/16/2003http://seniord.ee.iastate.edu/ongo01c/OSCAR_Power_Sub_Team_Picts/DC_DC_Pictures_Index....

Two DC/DC Converters Inside Box



The DC/DC Supply Box Return To Homepage Last updated December 16, 2003



Appendix B: Current Setup: The DC/AC AC/DC System

B1) Opinionated commentary on inverters B2) OSCAR’s DC/AC converter B3) One line diagram of current OSCAR power supply system setup B4) Pictures of OSCAR’s current power-deck setup


B1) Opinionated commentary on inverters BBB22)) OOOSSSCCCAAARR’’’sss DDDCCC///AAACCC cccooonnnvvveeerrrttteeerrr 2) R

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Inverters and Get What You Pay For (my views and opinions)

I dislike inverters very much as I think most of the models on the market are very crude ,inefficient and overpriced. There should be no need to convert the 12-14V from the car battery all the way up to 240V (110V in USA)simply for the computer power supply to convert it back down to low voltage again.

Most cheap mains inverters work by applying a 50/60Hz square wave voltage to a step up transformer which provides the mains supply output. The really cheap models will use a self oscillating driving design that can vary with the load and the input voltage resulting in an output than can differ greatly from the 50/60Hz specified.

There is usually no form of voltage regulation on cheap mains inverters so assuming an input voltage range of 12-15V the output voltage could vary between 98-123V(US) and 206-258V(europe)

As the input to the step-up transformer is normally a square wave the output voltage will be something similar. In frequency terms a square wave is composed of a fundamental sinusoid (50/60Hz in this case) and many higher frequency harmonic sinusoid. If these higher frequency harmonics were present on your domestic mains supply you would call them spikes and most likely complain to your electric company and most hi-fi enthusiasts would be horrified ;-)

A switching power supply as used in your PC rectifies and smooths the AC input before switching it to produce the various output voltages. Usually there is a filter circuit before the rectifier to stop voltage transients entering the power supply and to stop noise from power supply entering back into the mains supply. As the inverter output consists of some 30-40% harmonics the filter circuit will be swamped with noise to filter and 30-40% of the inverter power will go into the filter circuit which can cause the filter circuit to break down (regular ticking sound).

Fortunately you can work around this by removing most of the power supplies input filter circuit. The filter will consist mainly of high voltage capacitors connected across the AC input. Simply removing these should remove most of the filter circuit and cure most inverter power problems.

Shown above are the filter capacitors from a typical power supply

Higher quality inverters use a much better method to produce AC approaching what you get from the domestic mains. A high quality inverter will use a switching inverter to produce controlled high voltage DC which will then be shaped into a sinusoid approximation. The higher the quality (higher cost) of the inverter the closer the output will look to a true sinusoid. Such a system would be used in good quality computer backup units.

Page 1 of 1Inverters

10/4/2003http://www.sproggy.freeserve.co.uk/inverters.html


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BBB22)) OOOSSSCCCAAARR’’’sss DDDCCC///AAACCC cccooonnnvvveeerrrttteeerrr B3) One line diagram of current OSCAR power supply system setup BBB44)) PPPiiiccctttuuurrreeesss ooofff OOOSSSCCCAAARRR’’’sss cccuuurrrrrreeennntt pppooowwweeerrr---dddeeeccckk sseeetttuuuppp...



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BBB22)) OOOSSSCCCAAARR’’’sss DDDCCC///AAACCC cccooonnnvvveeerrrttteeerrr BBB33)) OOOnnneee ll iiinnneee ddiiaaagggrrraaamm ooofff cccuuurrrrrreeennnttt OOOSSSCCCAAARRR pppooowwweeerrr sssuuupppppplllyyy sssyyysssttteemmm ssseeetttuuuppp B4) Pictures of OSCAR’s current power-deck setup.

Welcome to the Fall 2003 OSCAR Power Sub-Team PowerDeck Setup Pictures Page!

Views of the Power Deck before the November 2003 Demonstration. Note: DC/AC AC/DC system is in use.

Top view of the Power Deck, showing the batteries (one dirty, one clean), a battery power meter, suspended H-Bridge board (belongs to motion control), and (under H-Bridge) a front-end/top view of the DC/AC power supply with a power bar plugged into it (power bar itself is off screen).

Page 1 of 2"Fall 2003 OSCAR Power Sub-Team: PowerDeck Setup Pictures"

12/16/2003http://seniord.ee.iastate.edu/ongo01c/OSCAR_Power_Sub_Team_Picts/Setup_Pictures_Index.htm

Side view of the Power Deck, showing a rear end view of the DC/AC power supply positioned between the batteries and below the suspended H-Bridge (H-Bridge belongs to motion control). Return To Homepage Last updated December 16, 2003

Page 2 of 2"Fall 2003 OSCAR Power Sub-Team: PowerDeck Setup Pictures"

12/16/2003http://seniord.ee.iastate.edu/ongo01c/OSCAR_Power_Sub_Team_Picts/Setup_Pictures_Index.htm

Appendix C: Batteries

C1) Battery Information, Complete: Interstate 12V Deep Cycle Marine C2) Battery Information, Brochure:

(Interstate, Deep Cycle) Marine/RV Battery Maintenance C3) Picture demonstrating one way to charge the batteries


C1) Battery Information, Complete: Interstate 12V Deep Cycle Marine CCC22)) BBBaatttttteeerrryyy IIInnnfffooorrrmmmaaatttiiiooonnn,,, BBBrrroooccchhuurreee:::

(((IIInnnttteeerrrssstttaaattteee,,, DDDeeeeeepp CCyyycccllleee))) MMMaaarriiinnneee///RRRVV BBBaaattt ttteeerrryyy MMMaaaiinnnttteeennaannnccceee 2) a hur

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3) g CCC33)) PPPiiiccctttuuurrreee dddeeemmmooonnnssstttrrraaattt iiinnnggg ooonnneee wwwaaayyy tttooo ccchhhaaarrrggeee ttthhheee bbbaaattt ttteeerrriiieeesss

Summary page Page 1 of 18 October 2003

SUMMARY OF IMPORTANT INFORMATION ABOUT OSCAR's 12V BATTERIES (Current as of October 2003)

(all information taken or derived from Interstate Battery's website)

Brand: Interstate Model: HD-24DP Type: 12 Volts - Deep Cycle/Cranking BCI#: 24M/10 CCA: 405 MCA: 505 RC: 100 minutes Warranty: 30 months Dimensions (in): 11 x 6.875 x 9.5 Weight: 41 lbs. Terminal: Auto/Stud posts Hours @ Ampere Load: 11.6hr@5Amp; 3.2hr@15Amp; 1.7hr@25Amp [NOTE: must divide time by 2 because can't discharge more than 50%] ------------- (the below definitions were taken from Interstate Battery's website) Definitions: BCI = "Battery Council International... - An association of battery industry companies whose members establish policy and standards for the industry." MCA = "A rating that is used to define the number of amps that a lead- acid marine battery at 32°F (0°C) can deliver for 30 seconds and maintain at least 1.2 volts per cell (7.2 volts for a 12-volt lead-acid battery). This artificially high rating should not be confused with CCA." CCA = "the number of amps a lead-acid battery at 0ºF (-17.8ºC) can deliver for 30 seconds and maintain at least 1.2 volts per cell" (7.2 volts for a 12-volt lead-acid battery)." RC = "Reserve Capacity (RC) - BCI (Battery Council International) defines it as "the number of minutes a new, fully-charged battery at 80ºF (27ºC) can be discharged at 25 amps and maintain a voltage equal to or higher than 1.75 volts per cell" (i.e., 10.5 volts for a 12-volt battery). This rating represents the time the battery will continue to operate essential accessories in the event of a charging system failure. ======================== Open Circuit Voltage VS. State of Charge 12.66V 100% Charged 12.45V 75% Charged 12.24V 50% Charged 12.06V 25% Charged 11.89V 0% Charged NOTES: *Deep Cycle Marine Batteries should not be allowed to go below 50% charged *Voltage @ load will probably be less than Open Circuit Voltage

http://www.ibsa.com/www_2001/content/products/product_marine.asp Page 2 of 18 Accessed October 3, 2003

Dependable Power When You Need It Most!

INTERSTATE'S Deep Cycle and Cranking Marine/RV Batteries are guaranteed FRESH, so you're not left stranded! We regularly check our batteries so you can buy Interstate batteries with confidence. For the rare occasion you need to use the pro-rata warranty, there's help at more than 8,000 Marine/RV dealers across North America. Our new alloy combination brings outstanding features for Marine/RV batteries: • outstanding cycle life • increases overall number of starts • greatly improves recharge acceptance • eliminates hydration shortage to maintain higher state of charge • excellent deep discharge recovery rate Here are some of our more popular Marine/ RV batteries: *CCA: Cold Cranking Amps (30 sec. @ 0° F) **MCA/CA: Cranking Amps (30 sec. @ 32° F) RC: Reserve Capacity

RWarranty: 24 months

Interstate's cranking batteries provide Power Fast...that's Built to Last! For those times you need to get home to fry your day's catch -- you'll want dependable Interstate power! 24M-RD 12 Volts - Cranking BCI#: 24M/10 CCA: 400 MCA: 500 C: 75 minutes

Dimensions (in): 11 x 6.875 x 9.5 Weight: 35 lbs. Terminal: Auto/Stud posts

DW

24M-HD 12 Volts - Cranking BCI#: 24 CCA: 500 MCA: 625 RC: 95 minutes Warranty: 24 months

imensions (in): 11 x 6.875 x 9.5 eight: 38 lbs.

Terminal: Auto/Stud posts

Interstate Batteries is the #1 brand replacement battery in the U.S.A. One out of SEVEN marine batteries sold is an Interstate! HD-24DP 12 Volts - Deep Cycle/ Cranking BCI#: 24M/10 CCA: 405 MCA: 505 RC: 100 minutes Warranty: 30 months Dimensions (in): 11 x 6.875 x 9.5 Weight: 41 lbs. Terminal: Auto/Stud posts Hours @ Ampere Load: 11.6@5; 3.2@15; 1.7@25


Interstate's new 4-post design improves power flow while simplifying installation. It also provides accessibility to support many accessories. SRM-24 12 Volts - Deep Cycle/ Cranking BCI#: 24M/10 CCA: 550 MCA: 690 C: 140 minutes

Dimensions (in): 11 x 6.875 x 9.5


Weight: 46 lbs. Terminal: Auto/Stud posts Hours @ Ampere Load: 16.4@5; 4.6@15; 2.3@25

R

Antimony/Selenium is a unique chemical alloy in Interstate's marine battery connectors. This alloy retards acid penetration, which reduces corrosion and gives you longer battery life!

TM

SRM-27 12 Volts - Deep Cycle/ Cranking BCI#: 27M/10 CCA: 600 MCA: 750 C: 160 minutes

Warranty: 30 months Dimensions (in): 12.75 x 6.75 x 9.5 Weight: 53 lbs. Terminal: Auto/Stud posts Hours @ Ampere Load: 17@5; 5.2@15; 2.6@25


With its advanced design, which provides special vibration resistance, your Interstate Marine battery is insulated from the hard jolts of rough water and bumpy terrain. SRM-29 12 Volts - Deep Cycle/ Cranking BCI#: 29M/10 CCA: 675 MCA: 845 C: 210 minutes

Dimensions (in): 13 x 6.75 x 10 Weight: 61 lbs. Terminal: Auto/Stud posts Hours @ Ampere Load: 21@5; 6.4@15; 3.4@25

Listed below are complete specifications for leading Interstate Marine / RV batteries:Be sure to visit Battery Terms in the FAQ section for definitions of terms like CCA and Reserve Capacity. 12-Volt Deep Cycle/ Cranking

Hrs. at Ampere Load

BCI Grp

# Interstate

Type *CCA **MCA RC (Min.)

Warranty(Mo.)

5 15 25

Dimensions (in.) L | W | H

Weight(lbs) Terminal

24M SRM-24 (Deep Cycle) 550 690 140 30 16.4 4.6 2.3 11 x 6-7/8 x 9-1/2 46 Auto/Stud

posts

24M HD24-DP (Deep Cycle) 405 505 100 30 11.6 3.2 1.7 11 x 6-7/8 x 9-1/2 41 Auto/Stud

posts

24M 24M-XHD 800 1000 135 24 not applicable 11 x 6-7/8 x 9-1/2 48 Auto/Stud posts

24M 24M-HD 500 625 95 24 not applicable 11 x 6-7/8 x 9-1/2 38 Auto/Stud posts

24M 24M-RD 400 500 75 24 not applicable 11 x 6-7/8 x 9-1/2 35 Auto/Stud posts

27M 27M-XHD 800 1000 180 24 not applicable 12-3/4 x 6-3/4 x 9-1/2 54 Auto/Stud

posts

27M SRM-27 (Deep Cycle) 600 750 160 30 17 5.2 2.6 12-3/4 x 6-3/4 x 9-

1/2 53 Auto/Stud posts

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/faq_tech_terms.htm


27M SRM-27B (Deep Cycle) 675 845 180 30 20.4 5.7 3.0 12-3/4 x 6-3/4 x 9-


29M SRM-29 (Deep Cycle) 675 845 210 30 21 6.4 3.4 13 x 6-3/4 x 10 61 Auto/Stud

posts

4DM SRM-4D (Deep Cycle) 1314 1645 390 30 38.0 11.5 6.5 21 x 8-1/4 x 10-


12-Volt Cranking

Hrs. at Ampere

Lo adBCI Grp

# Interstate


Warranty(Mo.)

5 15 25



24M SRM-24 (Deep Cycle) 550 690 140 30 16.4 4.6 2.3 11 x 6-7/8 x 9-1/2 46 Auto/Stud

posts

24M HD24-DP (Deep Cycle) 405 505 100 30 11.6 3.2 1.7 11 x 6-7/8 x 9-1/2 41 Auto/Stud

posts

8-Volt Deep Cycle Industrial

RC (Min.)BCI Grp # Interstate Type *CCA25A 75A

Warranty(Mo.)



- USRM8V19 600 305 92 30 - - - - USRM8V21 715 330 98 30 - - - - USRM8V24 880 430 134 30 - - - - USRM8V26 1050 515 145 30 - - - - USRM8V27 1000 445 122 30 - - -

6-Volt Deep Cycle

Hrs. at A mpere

Load BCI Grp

# In e terstat


W arranty(Mo.)

Free/Prorate 5 amps

15 amps



GC-2 U2200 75 amps @ 80º F 6/ NA 54.5 14.0 10-1/4 x 7 x 11-

1/8 63 US

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/faq_tech_terms.htm Page 5 of 18 Accessed October 3, 2003

Amp-Hour (AH) - The unit of measure for a battery's electrical storage capacity, obtained by multiplying the current in amps by the time in hours of discharge. Example: A battery delivering 10 amps for 20 hours = 10 amps x 20 hours = 200 AH. Deep-Cycle Battery - A battery that is designed to withstand repetitive discharges to a 20% depth of discharge or more and to continue providing its rated capacity after hundreds of cycles. Deep-cycle batteries are often used in marine/RV and industrial applications. Deep Cycling - The process of drawing a high percentage of a battery's capacity (deep discharging) and recharging it to full capacity. Deep Discharge - The discharge of the battery to below the specified cutoff voltage before the battery is replaced or recharged. Depth of Discharge (DOD) - The percent of rated capacity to which a cell or battery is discharged. It is the reciprocal of a battery's state of charge. Example: a battery that has a depth of discharge of 45% has a state of charge of 55%. Duty Cycle - The time duration and use frequency during which a battery is drained. It is affected by such factors as charge and discharge rates, depth of discharge, length of cycle, and length of time in standby mode. Lead-acid Battery - A storage battery with an active material of lead and lead peroxide and with an electrolyte solution of water and sulfuric acid. Maintenance-free, low-maintenance and gel-cell batteries are types of lead-acid batteries. Maintenance-Free Battery - A battery that does not require water addition under normal service conditions. Both positive (+) and negative (-) grids are made of lead/calcium. Memory Effect - A condition that is created when a NiCad or NiMH battery is partially discharged and recharged repeatedly, causing a loss of capacity. Parallel Circuit - A circuit in which the current has more than one path to follow. In this configuration, two batteries of equal rating are wired together positive (+) to positive (+) and negative (-) to negative (-). In parallel, the RC (Reserve Capacity) and CCA (Cold Cranking Amps) double while the voltage remains the same as the weakest individual battery. Self-Discharge - The discharge that occurs in a battery while it is not in use. The higher the temperature, the greater the rate of self-discharge. Self-Discharge Rate - The rate at which a cell or battery loses its capacity when standing idle. Specific Gravity - In a lead-acid battery, the weight of sulfuric acid compared to the weight of an equal volume of pure water. Stratification - A condition in which the concentration of acid is greater at the bottom of the battery than at the top. Normally caused by continued undercharging. Sulfation - The accumulation of lead sulfates on the plates of a lead-acid battery. When enough plate area has sulfated, the battery will not be able to provide enough current and will normally need to be replaced. Unwanted Resistance - Any resistance — e.g., corrosion and inadequate connections — found in a circuit that is not designed into the circuit. Unwanted Resistance - Any resistance — e.g., corrosion and inadequate connections — found in a circuit that is not designed into the circuit.

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_drain.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_discharge_rate.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_dod.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_cycles.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_standby.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_active_material.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_electrolyte.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_maint_free.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_lowmaint.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_gelcell.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_grid.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_nick_cad.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_nick_metal.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_discharged.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_capacity.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_circuit.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_res_capacity.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_cca.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_leadacid.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_resistance.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/terms/term_resistance.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 6 of 18 Charging Batteries = sub title

Charging Batteries

How do I charge my battery?

What's the best way to charge deep cycle batteries?

How long should I charge my battery and at what current?

What will happen if I don't charge my battery properly?

Where can I find a charger for my battery?

What type and size of charger should I buy?

Why won't my battery take or hold a charge?

How can I test my charger to see if it is bad?

Answers:

TOP

How do I charge my battery? All lead-acid batteries contain highly corrosive sulfuric acid, generate explosive gases and have warning labels which should be observed closely. For best results, charge the battery as soon as you know it is discharged. To charge your battery, follow these steps and important safety tips:

Before Charging:

1) Read the charger manufacturer's instructions.

2) Put on protective eyewear, rubber gloves, work clothes and remove all jewelry.

3) Place the battery in a well ventilated area.

4) Don't charge a frozen battery. Allow the battery to warm to about 60ºF before charging.

5) If applicable, remove the vent caps and check the battery's water level and, if low, add distilled water to cover the tops of the plates. Do not overfill.

6) To determine if the battery needs to be charged, test it with a hydrometer to determine its specific gravity and/or with a voltmeter to determine its state of charge.

7) If applicable, reinstall vent caps before charging.

8) While the charger is unplugged, connect the leads to the proper battery terminals. Note: For side-post and studded batteries, we recommend that you use adapters to insure adequate contact. For additional information regarding adapters, contact Interstate Batteries.

9) Set the charger to the proper settings for your battery, e.g. 6 volts vs. 12 volts, low-maintenance vs. sealed, standard automotive vs. deep cycle.

10) Plug in and turn on the charger.

11) Don't wiggle the connections to check contact while the charger is turned on or plugged in.

12) Choose the lowest amperage setting initially. Once the charger is on and the battery is charging, you may want to choose a higher amp setting to reduce charge time.

During Charging:

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/watering.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/testing.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 7 of 18 Charging Batteries = sub title 1) Keep the vent caps on.

2) Don't allow smoking, open flames or sparks near the battery.

3) Don't allow the battery to become hot to the touch.

After Charging:

1) Immediately after the battery is fully charged, turn off and unplug the charger. Continuing to charge a fully charged battery will severely damage the internal plates and shorten battery life.

2) Disconnect the leads from the battery.

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What's the best way to charge deep cycle batteries? The maximum charger rate in amps should be 20% of the amp hour rating of the battery. Normally, deep cycle batteries do not require special charging procedures. However, we recommended that you use a charger designed specifically for deep cycle batteries. It is best to slow charge all batteries, especially deep cycle. The 20% rule should be used when charging a deep cycle battery. That means to choose a charger where the maximum current (in amps) is less than 20% of the Ah rating. For example, an Interstate SRM-27 is rated at approximately 100 Ah, so a 20-amp charger should be the maximum. Also, it is best to use a charger that is adequate to recharge the battery within 10-12 hours (see next question).

TOP

How long should I charge my battery and at what current? Generally, we recommend that you use a low amp charge, i.e. as low as the battery will accept, over a longer period of time. A 10-20 amp charger can charge most automotive batteries. Fully charging a completely discharged automotive battery, for example, with a 10-amp charger may take approximately 6-10 hours at a temperature of 80°F. Lower ambient temperatures require a longer charge time. Some chargers automatically adjust the current and length of charge according to the battery's state of charge and then shut off when the battery is fully charged. If the charger requires manual adjustment for current or shut-off, check the charger's instructions to determine the proper current and length of charge based on your battery's rating.

TOP

What will happen if I don't charge my battery properly? The two extremes of improper battery charging are under charging and over charging. Under charging results from a failure to allow the charger to charge long enough to restore the battery to full state of charge. Continually operating the battery in a partial state of charge or storing the battery in a discharged state will result in a condition known as sulfation. Sulfation reduces the battery's performance and may cause premature battery failure. Over charging causes accelerated corrosion of the positive plates, excessive water consumption, and in some cases, damaging temperatures within a lead acid battery. Deep cycle batteries should be charged after each discharge and/or after storage of 30 days or more. We recommend that a deep cycle battery not be discharged below a 50% state of charge. Recharging a severely discharged battery (below 50% state of charge) can result in the battery becoming overheated or overcharged.

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 8 of 18 Charging Batteries = sub title

TOP

Where can I find a charger for my battery? Interstate chargers are available through our 320 distributors in the U.S., Canada, Jamaica, Puerto Rico, Dominican Republic and Guam.

TOP

What type and size of charger should I buy? Type: The advantage of an automatic charger is its convenience. Once you connect the charger to the battery, the charger does the rest. Manual chargers are less expensive and equally effective at charging batteries, but they require a greater level of supervision. Size: In selecting the proper size of charger, you must consider the battery's capacity and the amount of time that will pass between charges. In applications where cycling is infrequent, such as seasonal RV or boat usage, a charge with an output current rating equal to 20% of the battery's rated capacity will suffice. In applications where battery recharge should be accomplished within 12 hours, a three stage, automatic charger may be required.

TOP

Why won't my battery take or hold a charge? A battery may not accept a charge for several reasons. Your battery may have a bad cell or an internal short and therefore be irreparable. Or it could be so severely discharged that it will require a professional calliber charger to charge it. Many home chargers have minimum voltages that must be present in the battery before the charger will switch on. Normally these low voltages are well below those exhibited by a battery that appears to be "dead." Often however, the battery is not given the adequate amount of time to accept a charge. One of the best tips regarding battery charging is to observe the charger's ammeter swing needle (available on some chargers) during the charging procedure. After the charger is connected to the battery and is on, the needle should deflect to a high amperage level if the battery is partially discharged. If the battery is severely discharged, the needle only deflects slightly away from zero. Continue to observe the needle in either situation. On a normally discharged battery only, the needle will start to taper in amperage back toward zero, usually in less than five minutes. This reduction in amperage typically indicates the battery is accepting a charge. On a severely discharged battery, the needle will start off very low then rise. This rise of the needle is a preliminary indication that the battery is accepting a charge. Always determine the battery's state of charge before and after recharge. The most accurate method (on a removable vent cap battery) is to perform a specific gravity test with a hydrometer. If the battery will not hold a charge adequately, contact the nearest Interstate dealer.

TOP

How can I test my charger to see if it is bad? Check the ammeter gauge (where applicable) or the indicator lamp on the charger. If the charger is working properly, the ammeter gauge should deflect to an amperage level above zero once the charger is connected to the battery and is turned on. If the battery does not respond to charging within a few hours, your charger may not be working correctly.

http://www.ibsa.com/www_2001/content/distributors/us_distributors.htm



http://www.ibsa.com/estore/dealer_locator.asp

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 9 of 18 Maintaining Batteries = sub title

Maintaining Batteries

How do I maintain my battery? Follow these guidelines every three to six months to extend the life of your low-maintenance Interstate battery:

1) Maintain Water Level. If your battery has removable vent caps, you should regularly check the water level and add water when it is low.

2) Keep Terminals Clean. Visually inspect the terminals and cables at least once a year, especially in hot temperatures, for signs of corrosion. If dirty or corroded, clean the connections with a scraper and wire brush. This will ensure a good connection and proper starting.

3) Keep Case Clean. Keep the top of the battery clean of heavy dirt and oil with a cloth dampened by ammonia or a 50/50 solution of baking soda and water. Then rinse with clear water and allow to thoroughly dry.

4) Keep Battery Charged. If your vehicle is not driven weekly, it may be necessary to charge your battery before use. Lack of use is hard on a battery, especially an automotive battery which is designed to be charged regularly by an alternator. Any unused battery, regardless of its chemistry, will self-discharge over time and, if allowed to remain discharged, will undergo severe positive grid corrosion and battery failure. The rate of discharge depends on the type of battery and the storage temperature. So, it's important to keep your battery charged.

If you prefer that your mechanic take care of your battery, be sure to ask him (1) to maintain the water level and (2) to keep the connections and case clean of corrosion and dirt.

As batteries age, do their maintenance requirements change? Yes. Typically the specific gravity gets higher and gassing increases due to some battery deterioration and/or loss of reserve capacity. An older battery normally requires more charging.


http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/charging.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 10 of 18 Replacing Batteries= sub title How do I know when to replace my battery? You might need to replace your battery if:

• your starter motor is experiencing slow or interrupted turnover.

• your instrument panel battery light indicates battery discharge for extended periods after the engine is running.

• your battery seems to lose power quickly in cold or extended starts.

• your headlights dim at idle.

Any of these warning signals may also indicate a problem with the electrical system in your vehicle and not necessarily a battery failure. A battery that is about to fail will often give little or no warning. If you suspect that your battery is failing, test it yourself or have it tested or replaced as soon as possible by your local Interstate Batteries dealer.



http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 11 of 18 Testing Batteries= sub title

Testing Batteries

First, be sure to follow these important safety tips:

• Put on protective eye wear, rubber gloves and work clothes and remove all jewelry.

• Don't allow smoking, open flames or sparks near the battery.

How do I test my battery?

Here are some of the tests available to determine your battery's status: Open Circuit Voltage (OCV) Test

Specific Gravity Test Load Test

TOP

Open Circuit Voltage (OCV) Test An OCV test may be performed with a voltmeter.

1. To determine if the battery is experiencing a problem, turn off all electrical loads and the charging source.

2. For an accurate reading, allow the battery to sit with no electrical loads applied for at least one hour.

3. Connect a voltmeter to the positive and negative terminals and measure the terminal post voltage with no loads or chargers connected to the battery.

4. To determine the battery's state of charge, compare the OCV reading on the voltmeter to the Open Circuit Voltage Chart.

We do not recommend that you substitute the OCV test for a specific gravity test, which is more accurate. The OCV test, however, is the only way to determine the state of charge of a sealed no-maintenance battery.

TOP

Specific Gravity Test This test is performed with a hydrometer, which is the most accurate hand held tool for determining the state of charge of a lead acid battery.

1. Draw electrolyte into the hydrometer a few times so that the float reaches the same temperature as the electrolyte. This will increase the accuracy of your readings.

2. Hold the hydrometer vertically so that the float is free and does not touch the inner walls of the barrel.

3. Hold the hydrometer so that the liquid is level in the barrel and at eye level.

4. When you draw the electrolyte, make sure that the hydrometer is full.

5. Check each individual battery cell. If the specific gravity varies more than .050 or "50 points" among the cells while the battery is at a 75% state of charge or above, then the battery is bad and should be replaced. The cells that have a specific gravity of 50 points less than the highest cell are bad cells. A hydrometer reading of 1.265 or greater at 80°F indicates a full charge for Interstate batteries. To determine the battery's state of charge, compare the hydrometer reading to the Specific Gravity Chart.

6. To get the most accurate hydrometer reading, you should adjust your hydrometer reading according to the temperature. If the electrolyte temperature is ABOVE 80°F ,

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/ocv_chart.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/spec_grav_chart.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/spec_grav_chart.htm

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 12 of 18 Testing Batteries= sub title

ADD .004 (called "four points") to the hydrometer reading for each 10 degrees above 80°F. If the electrolyte temperature is BELOW 80°F, SUBTRACT four points from the hydrometer reading for each 10 degrees below 80°F.

TOP

Load TestThis test is a 15-second discharge of the battery at a 1/2 cold cranking amp level. A more accurate testing method than a voltmeter or a hydrometer, the load test is often required to determine whether a battery is good or bad. It is used by professional technicians.

Open Circuit Voltage VS. State of Charge

12.66V 100%

12.45V 75%

12.24V 50%

12.06V 25%

11.89V 0%

http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 13 of 18 Storing Batteries= sub title

Storing Batteries

What is the proper way to store my battery?

How do I maintain an automotive battery that will be unused for months?

How long can I let my battery sit unused?

Will storing my battery on concrete drain the charge?

Answers:

TOP

What is the proper way to store my battery? Before storing your battery, you should:

1. Clean the battery case and terminals with baking soda and water.

2. Check the water level and add water if needed.

3. Test your battery with a hydrometer and/or a voltmeter to ensure the battery is fully charged.

4. If needed, charge your battery. Batteries stored in a discharged state are susceptible to freezing, sulfation and an increased rate of discharge. A fully charged battery will not freeze unless the temperature reaches approximately 80°F below zero. But if discharged, it can freeze at 32°F.

Store your battery in a dry, cool, well-ventilated area—the cooler the better without going below 32°F—and out of the reach of children and pets. Check the water level and state of charge every 45-60 days. If needed, add distilled water and charge.

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How do I maintain an automotive battery that will be unused for months? Follow the steps above for properly storing a battery. Note: Simply starting your car and letting it idle does NOT sufficiently charge the battery. To fully recharge a battery with your alternator, the vehicle must be driven. Highway driving provides the best charge. However, we recommend that you use a battery charger, instead of relying on your car's alternator, to fully charge a discharged battery.

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How long can I let my battery sit unused? Lack of use is one of the greatest enemies of a battery, especially an automotive battery which is designed to be charged regularly by an alternator. Any unused battery, regardless of its chemistry, will self-discharge over time and, if allowed to remain discharged, will undergo severe positive grid corrosion and premature battery failure. The rate of discharge depends on the type of battery and the storage temperature.

TOP

Will storing my battery on concrete drain the charge? No. Regarding today's batteries, this is a myth. A battery placed on concrete will not discharge any faster, but a battery will discharge over a period of time wherever it is placed. If the battery has a surface layer of acid or grime which is conductive, the battery will self-discharge more rapidly than if it were clean and dry. This myth does have some historical basis. Many years ago, wooden battery cases encased a glass jar with the battery in it. Any moisture on the floor could cause the wood to swell and possibly fracture the glass, causing it to leak. Later came the introduction of the "hard rubber" cases, which were somewhat porous. A current could be conducted through this container, which had a high carbon content, if the moist concrete floor permitted the current to find an electrical ground. The wise advise of the old days to "not store batteries on concrete" has apparently been passed down to us today, but it no longer applies.




http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 14 of 18 Troubleshooting Batteries= sub title

Troubleshooting Batteries

How do I know when my battery is failing?

Why did my battery fail early?

My battery won't take or hold a charge.

My battery light comes on when I'm driving, and the voltage jumps back and forth from high to low.

My second battery failed in less than a month.

My battery keeps failing even though I seldom drive the car.

My battery quickly gets corrosion build-up on the terminals.

My battery starts the car sometimes but not at others times.

Answers:

TOP

How do I know when my battery is failing? Here are some warning signals that may indicate a problem with your battery or your charging system:

1) When starting, your motor turns over slowly or in an interrupted manner.

2) Your battery seems to lose power quickly in cold weather.

3) Your headlights dim when you are idling.

4) The battery/charging system warning light on your instrument panel stays on for extended periods after the engine is running.

To determine if the battery is failing, take it to a qualified mechanic as soon as possible or try testing your battery.

TOP

Why did my battery fail early? According to recent independent laboratory tests, no brand of battery lasts longer than Interstate Batteries. Batteries fail prematurely because of a variety of situations, including poor battery maintenance, hot weather, hot engine temperatures and a failing alternator. Sometimes a defect in the battery may cause it to fail early, and that's why Interstate Batteries offers a warranty.

TOP

My battery won't take or hold a charge. A battery may not accept a charge for several reasons. Your battery may have a bad cell or an internal short and therefore be irreparable. Or it could be so severely discharged that it will require a professional caliber charger to charge it. Many home chargers have minimum voltages that must be present in the battery before the charger will switch on. Normally these low voltages are well below those exhibited by a battery that appears to be "dead." Often however, the battery is not given the adequate amount of time to accept a charge. One of the best tips regarding battery charging is to observe the charger's ammeter swing needle (available on some chargers) during the charging procedure. After the charger is connected to the battery and is on, the needle should deflect to a high amperage level if the battery is partially discharged. If the battery is severely discharged, the needle only deflects slightly away from zero. Continue to observe the needle in either situation. On a normally discharged battery only, the needle will start to taper in amperage back toward zero, usually in less than five minutes. This reduction in amperage typically indicates the battery is accepting a charge. On a severely discharged battery, the needle will start off very low then rise. This rise of the needle is a preliminary indication the battery is accepting a charge. Remember, chargers vary


http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/battery_chart.htm


in capability and always observe safety procedures recommended by the charger manufacturer. Always determine the battery's state of charge before and after recharging. The most accurate method for a battery with removable vent caps is the specific gravity test, using a hydrometer. If the battery will not hold a charge adequately, contact the nearest Interstate dealer.

TOP

My battery light comes on when I'm driving, and the voltage jumps back and forth from high to low. This would typically indicate a charging system or cable connection problem. Take your vehicle to a local Interstate dealer to have the charging system, cables, connections and battery tested. This will help determine what type of problem you are having.

TOP

My second battery failed in less than a month. The possibility of getting two defective batteries in a row is remote. If the battery is undamaged and it recharges and performs well on a load test, then something else is wrong. Make sure that:

• the battery matches the vehicle's make, model and year according to your vehicle owner's manual or your Interstate dealer's application guide.

• the vehicle does not have electrical modifications, such as a non-factory air conditioner, a large stereo system or extra running lights, that may call for an upgraded battery.

• the battery hold-down is secure.

• there is no evidence of shorting or damage to the terminals or cables.

• the battery terminals and cable connections are clean and free of corrosion.

• the vehicle's electrical system is operating correctly.

TOP

My battery keeps failing even though I seldom drive the car. Like people, batteries need regular exercise to remain healthy. Exercise to a battery is getting recharged so it can remain healthy. Batteries will self discharge while sitting unused. Also, every vehicle made since the late 1970s will have some key-off electrical drain, from the computer memories, which may discharge the battery below a no-start condition within a few days to two weeks. Connect a small charger to the battery occasionally. If this problem continues to occur, have the vehicle tested by an Interstate dealer for excessive key-off electrical drain.

TOP

My battery quickly gets corrosion build-up on the terminals. Although all batteries contain highly corrosive sulfuric acid, corrosion should not occur under normal conditions without spillage or one of the following: Overfilling: Add distilled water to the electrolyte of a fully charged battery if it is lower than 1/8" to 1/4" below the vent well at a full charge. If the battery requires charging, only add water if the electrolyte is at or below the plates. Overcharging/overheating: Overcharging by the alternator or normal charging at an extreme battery temperature can result in excessive gassing of the battery, which may produce increased corrosion. Inadequate metal contact: When current passes through poor or loose electrical









connections, a form of corrosion may form. Metallic exposure: When an electrical wire is exposed to salt particles in the air, corrosion will eventually occur. Remember to keep connections clean, tight and sealed by protectorates. Do not overfill the battery or allow it to become overcharged or overheated. If battery corrosion persists, check with your local electrical professional.

TOP

My battery starts the car sometimes but not at others times. This is probably not a battery problem. If the problem occurs only after the vehicle sits overnight or for a day or more before starting, the problem is often a low state of charge. If the battery starts the vehicle once the vehicle has been started recently, test your battery to determine its state of charge. Also, make sure that the alternator is adequately charging and that all the connections are good. If problem continues, see your local Interstate battery dealer.



http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 17 of 18 Watering Batteries= sub title

Watering Batteries

Do I need to add water to my battery?

Do I need to add acid to my battery?

How often should I check my water level?

When should I add water to my battery?

What is the proper water level?

How do I check my water level and add water?

Should I add aspirin or other additives to extend my battery life?

Isn't a sealed no-maintenance battery better?

Answers:

TOP

Do I need to add water to my battery? You may never need to add water to your Interstate battery. But in the event that you should, most Interstate automotive batteries come with removable vent caps. Under normal operating conditions, these "low-maintenance" batteries will require minimal service. In hot climates and in the event of a malfunctioning charging system, it is beneficial to own a battery that can be serviced, and Interstate batteries are designed with this in mind.

TOP

Do I need to add acid to my battery? No! Add distilled water only. When electrolyte is lost under normal use, the water evaporates while the acid remains in the battery. Adding acid will, therefore, alter the chemical composition of the electrolyte and cause the battery to fail more quickly. The only time electrolyte should be added is after accidental spillage.

TOP

How often should I check my water level? If the charging system of your car is not overcharging the battery and your car is not driven in hot places, then you may not need to add water for about 100,000 miles. However, regularly checking the water level of your Interstate battery is a great way to extend its life. We recommend checking it every six months in hot climates and once a year in mild climates. An easy way to stay on top of this is to have your mechanic check it whenever you get your oil changed. Also, if you plan to charge your battery with a charger, we recommend checking the water level before you charge it.

TOP

When should I add water to my battery? If the lead plates of the battery are exposed, you need to add water. To be safe, you can add water any time it falls below the proper level.

TOP

What is the proper water level? Ideally, the water level should be no higher than 1/8 inch below the bottom of the vent well. To avoid irreparable damage, make sure the electrolyte level never drops below the top of the plates. Also, avoid over watering, which may result in electrolyte overflow.

TOP

How do I check my water level and add water? Interstate low-maintenance batteries have removable vent caps, which may be pried off with a flat-head screwdriver. Once removed, you will see individual vent wells. Look down into each individual cell to make sure that the water is covering the lead plates and is at the proper level. Add water to any cells that are low on water. Always use distilled water to fill the battery in order to prevent chemicals from contaminating the battery. Be careful not to overfill the vent wells. The fluid should cover the lead plates in the battery and be no higher than 1/8 inch below the bottom of the vent well.

TOP

Should I add aspirin or other additives to extend my battery life? No. We recommend adding nothing but distilled water. No other additives have been proven to extend battery life and may actually decrease it.


http://www.ibsa.com/www_2001/content/faqs/tech_talk/maintenance/faq_tech_maint.htm Tech Talk: Battery Maintenance Accessed October 3, 2003 Page 18 of 18 Watering Batteries= sub title

TOP

Isn't a sealed no-maintenance battery better? Actually, a low-maintenance battery with removable vent caps has advantages over a sealed no-maintenance battery. Access to the cells allows you or your mechanic to:

• Extend the life of your battery when water evaporation has occurred and delay the purchase of a new one. If a sealed no-maintenance battery has water evaporation or if it is affected by a charging system problem, nothing can be done to extend the life of the battery; it must be replaced.

• Perform a specific gravity test on each cell with a hydrometer, which may reveal important information about the state of the battery, including if one or more of the cells is defective. This test may not be performed on a sealed battery.

Although most Interstate batteries are low-maintenance, we do offer a line of Interstate sealed no-maintenance batteries for cars, trucks and deep-cycle applications.

http://www.ibsa.com/default.asp/products/product_line/extreme_performance.htm


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Welcome to the Fall 2003 OSCAR Power Sub-Team Battery Pictures Page!

Charging the 12V Interstate Deep Cycle Marine Batteries Return To Homepage Last updated December 16, 2003

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