BAO Kit ICD 2 - Power Manager.pdf

System Specification (SS)

Figure: Spiral II Power Manager

General Description

The Power Manager enables soldiers in the field to make use of any energy source over the complete mission duration. It harvests and manages energy from several different sources.

Possible power sources include batteries of various chemistries, fuel cell, solar panels, automotive battery buses or laptop AC chargers. It creates different voltages to power various kinds of military or commercial equipment. An intelligent SMBus structure combined with an internal data logger provides and stores critical mission data.

In- and Out-Ports

30V I/O

The Power Manager offers three 30 VDC in- / outputs for Fuel Cell, Zinc-Air batteries type

Electric Fuel BA-8180 or BA-8150, hybrid system battery type Microsun, Harris Radio PRC-117 as well as other military and commercial 30V devices.

Ports provide 30 +0.5VDC when used as an output. In case no hybrid system battery is used or communication to system battery fails the output voltage will be reduced to 28.8VDC to avoid overcharging and enable secure operation with 24VDC lead-acid batteries. When ports are being used as inputs the acceptable input voltage range is from 22 to 34VDC.

The maximum current carrying capability is 16 Amps.

The connector type is Glenair 804-005-07ZNU8-13S. 3 pins on each port are reserved for SMBus communication with batteries and fuel cells. For detailed pinning see table below.

Table 1: Pin out of 30 V Port

Signal Pin-Number

Power 3,4,5,10,11

Ground 2,6,9,12,13

SMBus 8=G,7=C,1=D

12V In

One 12VDC input can be used for military batteries type BB-2590 or Li-145, 12V lead-acid batteries, portable solar panels, HUMVEE Power, commercial AC/DC adapters as well as for other commercial and military power sources.

The 12VDC port will accept input voltages in the range from 10 to 32V, the recommended operating range for optimum efficiency is 10 to 24VDC.

The maximum input current is limited actively to 9.5 Amps (120 Watts).The input provides

Maximum Power Point (MPP) Tracking for ideal operation with solar panels. A circuit breaking device protects the input from damage in case of overload or short circuit on the 30V bus.

The connector type is Glenair 804-005-07ZNU6-7S. 3 pins on each port are reserved for SMBus communication with batteries. For detailed pinning see table below.

Table 2: Pin out of 12 V In-Port

Signal Pins

Power 1,2

Ground 6,7

SMBus 5=C, 4=D, 3=G

15V Out (10 – 24V adjustment range)

Two identical and totally parallel 10 to 24VDC outputs are provided for use with Toughbook CF-

18, MBITR Radio, TACTER laptop computer, X-590 devices and other military or commercial

12 or 24VDC devices.

The output voltage is self-adjusting (supports cable identification). As soon as a valid cable is plugged in, the device will start up the internal power conversion and adjust the output voltage automatically to the required value. Manual adjustment is also possible if no cable is identified.

In case two cables with different cable ID get plugged in, the device will automatically adjust to the lower of the two required voltages to prevent devices from damage through over voltage.

The maximum output current is 6.5 Amps in total for both outputs. The output is self-protecting against overload and short-circuit.

The connector type is Glenair 804-005-07ZNU7-10S. Two pins are reserved for cable identification, 4 pins are reserved for USB. For detailed pinning see table below.

Table 3: Pin out of 15 V Out-Port

Signal Pins

Power 3,7

Ground 2,6

USB

1=V,4=D+, 8=D-,5=G

Resistor 9,10

Operation with Fuel Cell

The Power Manager can be used to control and operate with up to two fuel cells. The fuel cells will be remote controlled by the Power Manager. An intelligent algorithm assures highly efficient use of the fuel cells.

Coulomb Counter

One of the 30V I/O ports is specially prepared for operation with Zinc-Air batteries. If activated by the user, the used energy from the Battery will be measured by a coulomb counter and calculated into a State of Charge [%] which will be indicated on the display. The coulomb counter will work for different combinations of Zinc-Air batteries. Allowed combinations are one

BA-8180, two BA-8180, one BA-8150’s two BA-8150’s. If no Zinc-Air is used, the Coulomb

Counter can be disabled. The SOC can be reset via user-interface or via USB after the mission.

Data Logger

A data logger stores a number of relevant mission parameters as SOC, voltage, current and power of connected batteries and devices in an internal memory. The memory can be read out to a computer via USB. The data logger stores a record every two minutes for duration of approximately 80 hours. After 80 hours the internal memory is full and will stop, until it gets reset via USB.

USB Interface A USB-Interface provides access to the logged mission data. In addition parameters like time and date can be set via USB, also a Power Manager firmware-update can be run via USB. This enables future firmware updates of the Power Manager for additional devices and cable in needed in the future.

The USB-interface is realized as virtual COM-port with a baud-rate of 38400.

Physical and Electrical System Specification

Criteria SFC Proposal

Physical Specification

Size 5.55 x 3.48 x 1.21 Inch

141 x 87 x 31 mm

Weight 0.92 lbs

Color Grey (RAL 9007)

Operating Temperature -20 to 55°C

Storage Temperature -30 to +80°C

Water Resistance submergible at 1 meter for 1 hour

Electrical Specification

Inputs 30V I/O: 22 to 34V

16 Amps max.

12V IN: 10 to 32V

9.5 Amps max., active limitation

Outputs 30V I/O: 30 / 28.8V (depending on operating mode)

Output voltage accuracy +/-0.5V

16 Amps max.

15V OUT: 10 to 24VDC (set by cable ID or manually)

Output voltage accuracy +/-0.5V

6.5 Amps in total

Converter Efficiency up to 96%

Display Indicates relevant system and battery parameters such as system voltages and currents, SOC, remaining runtime, etc.

Electronic Fuses Self-resetting overload and short circuit protection, protection against overheating and over temperature, sensing and protecting from use of invalid combination of devices

Detailed System Specification

Criteria Requirement SFC Proposal

Size weight and volume

Weight Power Manager < 2 lbs (T) 0.9 lbs (T+)

< 0.30 lbs (O)

BAO HMI Endurance -mission cycle without re-supply

72 h (T) The proposed PM used with a hybrid battery with high energy density and a mission extending source such as a Zinc Air battery or a fuel cell enables mission cycles of 84+h (O+)

84 h (O)

Energy Discharge (Peak)

Peak Average Power 80 W for 60 min. (T) 80 W for 240 min.

(O) 80 W for 240 min. (O)

Peak Instantaneous Power 380 W for 1 min. (T) 480 W for 5 min on

30 V Bus (O+) 380 W for 5 min. (O)

State of charge indicator SOC in numerical manner

(T) proposed PM displays SOC of connected SMBus compliant batteries and Zinc-Air

Batteries in a numerical manner

(T+)

SOC user selectable (O)

Mission Reliability 15 x 72h-mission in 120 days (T) proposed PM does not limit the mission reliability (O+) continuous operation for

120 days (O)

Emissions no emissions which may harm the operator

No harmful emissions by proposed PM (T)

System Environment Requirements

Operating Temperature MIL-STD-810F, Table

502.4-II and Table 501.4-II for basic hot and cold environments

-10 to +55°C (T) -20 to 55°C (O)

-20 to +55°C (O)

Storage Temperature -20 to +55°C (T) -30 to +80°C (T+)

-40 to +55°C (O)

Thermal Shock MIL-STD-810F, Method

503.4

PM complies with

MIL-STD-810F,

Method 503.4 (T)

Storage Duration 3 months (T) > 12 months (O+)

12 months (O)

Operational Altitude 10,000 ft MSL (T) 35,000 ft MSL (O)

35,000 ft MSL (O)

Transport Altitude 35,000 ft MSL unpressurized

35,000 ft MSL unpressurized (O)

Shock MIL-STD-810F, Method

516.5, Procedure I and IV

PM complies with

MIL-STD-810F,

Method 516.5, Procedure I and IV

(T)

Vibration MIL-STD-810F, Method

514.5, test for categories

2,4,5,8,9,10,23 (per table

514.5-I)

1) PM complies with

MIL-STD-810F,

Method 514.5, test for categories 5,9 and 23 (per table

514.5-I) (T)

Sand and Dust MIL-STD-810-F, Method

510.4, Procedures 1,2,3

2) Connectors are fully compliant with

MIL-STD-810-F,

Method 510.4 (T)

Water Resistance MIL-STD-810F, Method

506.4, Procedures I and II

3) PM complies with MIL-STD-

810F, Method 512

(1 meter for 1h) during operation and storage (T)

Water Immersion MIL-STD-810F, Method

512.4

(1 meter for 30 min.)

PM complies with

MIL-STD-810F,

Method 512

(1 meter for 1h) during operation and storage (T+)

Weather Resistance system shall be able to be worn in all types of weather, with no risk of electrocution, or other harm to the user from the device regardless of environmental condition

PM provides weather resistance according to requirement (T)

Exterieur System Surface

Temperature system shall emit heat at a level that does not injure or cause harm to the operator or his equipment (T)

PM heat dissipation is at a level that does not injure or cause harm to the operator or his equipment (T) system shall emit no heat that can be felt or sensed by the operator or sensors. (O)

Orientation +/- 90 degrees orientation independent from vertical

(T)

PM is fully orientation independent (O) able to function in any orientation (O)

Color light in color (T) PM is available in any color (O+) Gray, Green, Tin or Brown

(O)

Operator Safety MIL-STD-1472F - "Human

Engineering" for design criteria proposed PM can be worn >20h continuously according to MIL-

STD-1472F (O+)

wear system safely for 12 hours continuously (T) wear system safely for 20 hours continuously (O)

Cable Management reduce the amount of cables used from current configuration (T)

Proposed PM cable set enables the user to choose and carry cables as needed for mission purposes to reduce the total amount of cables (T) operate cable free (O)

System Safety integrated safety circuitry shall be incorporated in the

Rechargeable Battery and

Power Manager as needed to prevent short-circuiting:

proposed PM has auto safety fuse and temperature devices with an automatic-safety reset with manual override (O) with safety fuse, temperature device, and manual safety reset with manual override (T) with auto safety fuse and temperature devices with an automatic-safety reset and manual override (O)

Transportation

DOT approval transport via commercial or military air and military transportation systems (T)

Proposed PM contains no transportation critical or hazardous material that interfere with DOT

(O) transport via commercial air, passenger air, or submarine (O)

Transport Electromagnetic

Effects (EME)

Requirements

MIL-STD-461E test methods RE102 and CE102

PM complies with

MIL-STD-461E test methods RE102 and

CE102 (T)

Susceptibility

Requirement

MIL-STD-461E RS103

(AF internal levels), CS114

(curve #3), CS115, and

CS116

PM complies with

MIL-STD-461E

RS103 (AF internal levels), CS114

(curve #3), CS115, and CS116 (T)

External Power Source system shall be able to convert power from worldwide AC-DC power sources (T) proposed power manager is able to harvest power and convert from a variety of power sources with greater than 90 % efficiency including worldwide

AC-DC power-sources (T+) system shall be able to harvest power and convert from all power sources with greater than 90% efficiency

(O)

Mean Time between

Failure (Power Manager)

MTBF >5000 hours (T)

MTBF >100,000 hours (O)

> 5000 hours (T)

(tested by 4) accelerated aging lifetime testing)

1)

MIL-STD-810F, Method 514.5, test for categories 5,9 will be conducted presentable for vibration testing for transportation.

2)

Used connectors are fully compliant with MIL-STD-810-F, Method 510.4. As the used housing is submersible according to MIL-STD-810F, Method 512 (1 meter for 1h) it is not considered being critical for sand and dust requirements.

3)

As device complies with PM MIL-STD-810F, Method 512 (1 meter for 1h) during storage and operation, water resistance is considered being critical.

4)

Device will be tested at nominal load and 55°C for 19 days to simulate a lifetime of

>5000h at 20°C. Industry standard for accelerated aging calculates 5016h @ 20°C = 209d

/ (2^3.5) @ 55°C = 18.47d @ 55°C.

Content of proposed Package (offered in CLIN 0002 & 0005)

Power Manager V3.1

Transport box

Operating Manual and USB-Driver on CD-ROM

Standard set of cables, containing:

30V Power Manager (PM) to Battery Box (BB) “Battery Box I/O” (24”)

30V PM to Zinc Air “Zinc-Air IN” (18”)

15V PM to BA-5590 adaptor “15 V 5590 OUT” (8”)

15V PM to Toughbook CF-18 “CF-18 OUT” (24”)

12V PM to Battery Terminal 12/24V “Terminal IN” (36”)

12V PM to Car Adapter “12/24V Auto IN” (36”)

12V PM to BA-5590/BB-2590 “12 V Battery IN” (8”)

12V Power Manager to Solar Panel “Solar IN” (24”)

12V Power Manager to AC/DC Adapter “AC Charger IN” (8”)

Additional Cables (not included in CLIN 0002 & 0005)

30V PM to Fuel Cell “JENNY IN” (24”)

30V PM to SOFLAM “SOFLAM OUT” (60”)

15V PM to Toughbook CF-18 “CF-18 OUT 48”” (48”)

15V PM to BA-5590 adaptor “15 V 5590 OUT 24””(24”)

15V PM to TACTER “TACTER OUT” (48”)

12V PM to Li-145 “Li-145 IN” (24”)

Please note: costs for the additional cables are provided in the Cost Proposal (see Section 3)