Kontron MARS Smart Battery User Manual
h SBS MARS
h MARS Product Manual
Document Revision: 0.4_preliminary
MARS User´s Guide
Table of Contents
................................................................................................ 3 1. USER INFORMATION
...................................................................................... 3 1.1 About This Manual
......................................................................................... 3 1.2 Copyright Notice
................................................................................................ 3 1.3 Trademarks
................................................................................................. 4 1.4 Standards
................................................................................................... 4 1.5 Warranty
....................................................................................... 4 1.6 Technical Support
...................................................................................................... 5 2. INTRODUCTION
.......................................................................... 5 2.1 Smart Battery System MARS
.................................................................................. 5 2.2 MARS Documentation
................................................................................... 5 2.3 SBS MARS Highlights
................................................................................................... 10 3. SPECIFICATIONS
...................................................................................10 3.1 System components
.............................................................................10 3.2 Mechanical Specification
.........................................................................................................10 3.2.1 Size
...............................................................................10 3.3 Elektrical Specification
............................................................................................10 3.3.1 Input voltage
..............................................................................................10 3.3.2 Input power
.........................................................................................10 3.3.3 Smart Batteries
.........................................................................................11 3.3.4 Output voltages
.......................................................................11 3.4 Environmental Spezifications
.............................................................................................11 3.4.1 Temperature
..................................................................................................11 3.4.2 Humidity
.................................................................................... 12 4. POWER FLOW OF SBS MARS
.......................................................................... 13 5. SMART BATTERY SYSTEM MANAGER
...............................................................................13 5.1 Possible Configurations
..............................................................................................13 5.1.1 LOPWR TRIP
.................................................................................................14 5.1.2 VLIM TRIP
.....................................................15 5.1.3 Activation and Deactivation of the Charger
.........................................................15 5.1.4 Sequentiell Discharging of the Batteries
.............................................................................. 16 6. INPUT BUCK-BOOST CONVERTER
...............................................................................16 6.1 Possible Configurations
.....................................................16 6.1.1 Feed-in with 12V from an ATX power supply
.......................................................16 6.1.2 Feed-in with 5V from an ATX power supply
............................................................................17 6.1.3 Feed-in with 5V up to 28V
...................................................17 6.1.4 Activation and Deactivation of the Converter
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MARS User´s Guide
...................................17 6.2 Cases where no Input Buck-Boost Converter is necessary
........................................................................................17 6.2.1 Basic Conditions
.......................................................................17 6.2.2 How to bypasse the converter
............................................................................ 18 7. OUTPUT BUCK-BOOST CONVERTER
...................................18 7.1 Case where no Output buck-boost converter is necessary
........................................................................................18 7.1.1 Basic Conditions
.......................................................................18 7.1.2 How to bypass the converter?
......................................................................................... 19 8. DUAL BUCK CONVERTER
...............................................................................19 8.1 Possible Configurations
........................................................................19 8.1.1 Adjustment of the frequency
............................................................19 8.2 Dual buck converter without 12V path
........................................................................................19 8.2.1 Basic Conditions
......................................20 8.2.2 How to bypass the 12V path of the dual buck converter
....................................................................... 21 9. USAGE WITHOUT OUTPUT CONVERTER
............................................................................................ 21 10. OTHER ATX VOLTAGES
..................................................... 22 11. ACTIVATING AND DEACTIVATING OF THE SBS MARS
.........................................................................................22 11.1 Standby Mode 1
.........................................................................................22 11.2 Standby Mode 0
.............................................................................................23 11.3 Control LEDs
...................................................................................... 24 12. OUTPUT OF THE SBS MARS
...........................................................................24 12.1 ATX Connector (24 pin) X6
..........................................................25 12.2 HDD Power Connectors (4 pin) X7 + X13
.................................................................................26 12.3 Feature Connector X9
.................................................................................. 28 APPENDIX A: SBS MARS PINOUTS
..............................................................................28 Connector and Testpoint Locations
..............................................................................29 Smart Battery Connector X1 und X2
....................................................................... 32 APPENDIX C: POSSIBLE SMART BATTERIES
................................................................... 34 APPENDIX E: DOCUMENT-REVISION HISTORY
............................................................. 30 APPENDIX B: INTERFACE TO OPERATING SYSTEMS
................................................................. 33 APPENDIX D: COMPATIBLE KONTRON BOARDS
Table of Contents ii
MARS User´s Guide
1. User Information
1.1 About This Manual
This document provides information about products from Kontron Embedded Computers AG and/or
its subsidiaries. No warranty of suitability, purpose, or fitness is implied. While every attempt has
been made to ensure that the information in this document is accurate, the information contained
within is supplied “as-is” and is subject to change without notice.
For the circuits, descriptions and tables indicated, Kontron assumes no responsibility as far as
patents or other rights of third parties are concerned.
1.2 Copyright Notice
Copyright © 2003-2006 Kontron Embedded Modules GmbH
All rights reserved. No part of this document may be reproduced, transmitted, transcribed, stored
in a retrieval system, or translated into any language or computer language, in any form or by any
means (electronic, mechanical, photocopying, recording, or otherwise), without the express
written permission of Kontron Embedded Modules GmbH.
DIMM-PC®, PISA®, ETX®, ETXexpress® , X-board®, DIMM-IO® and DIMM-BUS® are trademarks or
registered trademarks of Kontron Embedded Modules GmbH. Kontron is trademark or registered
trademark of Kontron AG.
1.3 Trademarks
All products and trademarks mentioned in this manual are trademarks of their respective owners.
User Information
3
MARS User´s Guide
1.4 Standards
Kontron Embedded Modules is certified to ISO 9000 standards.
1.5 Warranty
This Kontron Embedded Modules product is warranted against defects in material and workmanship
for the warranty period from the date of shipment. During the warranty period, Kontron Embedded
Modules will at its discretion decide to repair or replace defective products.
Within the warranty period, the repair of products is free of charge as long as warranty conditions
are observed.
The warranty does not apply to defects resulting from improper or inadequate maintenance or
handling by the buyer, unauthorized modification or misuse, operation outside of the product’s
environmental specifications or improper installation or maintenance.
Kontron Embedded Modules will not be responsible for any defects or damages to other products
not supplied by Kontron Embedded Modules that are caused by a faulty Kontron Embedded
Modules product.
1.6 Technical Support
Technicians and engineers from Kontron Embedded Modules and/or its subsidiaries are available
for technical support. We are committed to making our product easy to use and will help you use
our products in your systems.
Before contacting Kontron Embedded Modules technical support, please consult our Web site at
http://www.kontron-emea.com/emd for the latest product documentation, utilities, and
drivers. If the information does not help solve the problem, contact us by telephone or email.
Asia Europe North/South America
Kontron Asia Inc.
4F, No.415, Ti-Ding Blvd.,
NeiHu District,
Taipei 114, Taiwan
Tel: +886 2 2799 2789
Fax: + 886 2 2799 7399
mailto:sales@kontron.com.tw mailto:sales-kem@kontron.com mailto:sales@us-
Kontron Embedded Modules GmbH Kontron America
Brunnwiesenstr. 16 14118 Stowe Drive
94469 Deggendorf – Germany Poway, CA 92064-7147
Tel: +49 (0) 991-37024-0 Tel: +1 (888) 294 4558
Fax: +49 (0) 991-37024-333 Fax: +1 (858) 677 0898
kontron.com
User Information
4
MARS User´s Guide
2. Introduction
2.1 Smart Battery System MARS
MARS is a Smart Battery System, which is able to controle 2 Smart batteries.
The Core of the SBS MARS is a dual Smart Battery System Manager.
Additionally the system contains a buck-boost converter at the input side, a dual buck converter
and a buck-boost converter at the output side.
There is also a CPLD used in MARS to get the functionality of an ATX power supply and for additional
tasks.
MARS = Mobile Application platform for Rechargeable Systems
2.2 MARS Documentation
This Manual is a general guide for a SBS Design. It documents the specification and functions of
the SBS MARS
SBS MARS is based on the SBS Specification of the SBS-forum.org.
2.3 SBS MARS Highlights
Smart Battery Systems have the ability to communicate with the application. Therefore the user
gets information about the current state of each battery. The interface for this communication is
the System Management Bus (abbr: SM-bus). Standard Smart Batteries have a specified 5 pin
header, connecting the power lines and additionally this SM-bus. This standardisation allows using
all available kinds of standard Smart Batteries, which also applies to the SBS MARS. (see also
APPENDIX C:
Possible Smart Batteries)
A typical SBS consists of a Smart Battery System Manager and a charger, which can communicate
with the chipset using the SM-bus.
Fig. 1 shows the typical setup of a SBS, where the SBS hardware can also be part of the PC
hardware.
Introduction
5
MARS User´s Guide
Smart Battery #1
e.g.
Li-Ion
LiPo
NiMH
NiCd
Smart Battery #2
e. g.
Li-Ion
LiPo
NiMH
NiCd
SBS-
Hard-
ware
SBS-
Hard-
ware
Vbatt1+
Vbatt1-
Thermistor1
Vbatt2+
Vbatt2-
Thermistor2
Hardware
Manager +
SM-Bus
SBS-
(System
Charger)
PC-Hardware
Prozessor and
Chipset
SM-Bus
Power
Fig. 1: principle setup of a Smart Battery System
The SBS MARS is a reference design, which enables developers to find an easy and fast solution to
provide an application with mobile energy or to impelement an uninterruptible power supply. Also
the SBS MARS could be used as finished solution, with no further changes.
If there is no possibility to connect the SBS MARS to the SM-bus then the system is able to run in a
stand alone mode with reduced functionality, too.
The SBS MARS was designed for the purpose to cover the widest spectrum of possible applications
of mobile systems. Therefore it has a wide input voltage range of 5V to 28V. The input voltage can
be supplied with an ATX power supply as well as any other power supply. The necessary connectors
are available on the SBS Mars.
Additionally different kinds of Smart Batteries can be used. That means different battery chemistry
and cell configurations up to 10S1P (= 10 cells in series and 1 parallel) at NiMH/NiCd or up to 4S3P
at LiIon/LiPo are possible. But it must be ensured to use standard Smart Batteries, which meet the
SM-Bus standard. Because of the mechanical placement of the Smart Battery connectors it is not
possible to use Smart Batteries with a greater width than 90 mm. The usage of those would be
possible, if either the connectors are placed in another way or a Smart Battery lead is used (e. g.
Introduction
6
MARS User´s Guide
the 5 way Smart Battery connecting lead of Moltech – part number: 629010). In the Appendices
you can find a list of possible Smart Batteries.
The modular setup of SBS MARS is a guideline for the devoloper and the user to configure and set
up the System, as necessary. (fig. 2 and fig. 3)
The buck-boost converter at the input side controls the input voltage to 19V, to get a sufficient
high charging voltage, even when the batteries needs voltages up to 17V. If input voltages of 19V
to 28V are used, this device is not necessary. Then it can be omitted or bypassed.
The buck-boost converter at the output side is used, when there is a Smart Battery which voltage
could drop lower than 12V. If there are only batteries with higher voltages than 12V then the dual
buck converter is enough. In this case the buck-boost converter at the output side can be omitted
or bypassed.
The SBS MARS acts like an ATX power supply. In Standby mode only the 5V SBY are supplied.
Parallel discharging of both Smart Batteries allows, due to reduced temperatures a longer
powersupply than in serial mode. The higher voltages lead to lower currents and that to less heat
which gives the battery longer lifetime. This effect is like an extension of the size of the Smart
Battery System. To use this effect both batteries need to have the same chemistry and the same
cell configuration. Then you could charge both batteries in parallel which leads to a faster charging
procedure.
The SBS MARS is able to choose automatically the best suited powersupply for the system.
A current supervision is implemented at each IC. As the output current of each converter is
controlled, is the charging current, too. Additionally a hardware fuse for each battery to give the
user the highest amount of safety.
The variable voltage input is not protected by hardware against overcurrent. This should be done in
the powersupply.
The connection to the SM-Bus of the baseboard is done by the feature connector which could be
found on most of KONTRON’s backplanes with the same pinning. The SM-bus enables the user to
get information from the Smart Battery Manager and from the Smart Batteries. (Please refer to
Appendix B: Interface to Operating Systems.)
Introduction
7
MARS User´s Guide
,
,
A
(
)
r
alternativ
5 - 28V
SB#1
Li-Ion
(4S3P)
Typ.
14,4 V
11,6V –
8 V
16
TX
Vbatt1+
Vbatt1-
Therm.1
SMBDAT
SMBCLK
SB-Connector
if ≥ 19V
HDD POWER
Buck-Boost
Converter 1
19V
±10%
charge max. 28V
voltage
1
discharge
charge
voltage
12V
Buck-Boost
Converter 2
12V (±5%)
9V 28V
4
+
12V
3
Dual Buck
Converter
5V & 12V
(±5%)
+3,3V
Con-
verte
-5V
Con-
verter
-12V
Con-
verter
3
max.
60W
5V
SBY
(3)
select
battery
20
or
24
ATX_POWER
optional
Prozessor
and
Chipset
SB#2
NiMH
(10S1P)
Typ.
12 V
9V –
4 V
14
Vbatt2+
Vbatt2-
Therm.2
SMBDAT
SMBCLK
SB-Connector
2
discharge
charge
voltage
4
2 3
1
-
Smart Battery
System Manager
SBS
LTC1760
„MARS“
Fig. 2: Block diagram of SBS MARS
SBS
Power
Hardware
SM-Bus
FeatureConnector
Backplane
(ETX or ETXexpress)
Introduction
8
MARS User´s Guide
Fig. 3: Modular setup of SBS MARS
The SBS MARS was the result of the diploma thesis titled „Smart Battery Systeme in mobilen
embedded Applikationen” which was handed in at the University of Applied Sciences in Landshut
in cooperation with Kontron Embedded Modules.
Furthermore we had cooperation with Linear Technologies, whos converter ICs we have used at the
SBS MARS. The experience of LT’s engineers was a great help, especially during layout to develop
such a high efficient system.
Introduction
9
MARS User´s Guide
3. Specifications
3.1 System components
h Smart Battery System Manager and Charger
• LTC 1760: Dual Smart Battery System Manager
h Buck-boost converter (at input and output each)
• LTC 3760
h Dual buck converter at output side
• LTC 3727
h CPLD
• Xilinx XC9536XL
3.2 Mechanical Specification
3.2.1 Size
h 185.0 mm x 160.0 mm (7.28” x 6.3”)
h Hight: 24 mm TBD
3.3 Elektrical Specification
3.3.1 Input voltage
h 5V DC to 28 V DC
3.3.2 Input power
h TBD
3.3.3 Smart Batteries
h NiMH and NiCd up to 10S1P
eg. 9S1P (10.8V), 10S1P (12V)
h LiIon and LiPo up to 4S3P:
eg. 2S2P (7.2V), 3S3P (10.8V), 4S3P (14.4V)
Specifications
10
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