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User Manual: CubeSat 1U Electronic Power System

1. ccccccccssscccesescccseececseececeeesceeeescessuececseeseseessessussessuaeess 24 8 8 SEL Re eyes rsecsces eters earvy cre ceeded sects street neeceh EEE EAEE E EA 26 8 9 ee COMING CE OMe EE 28 Be TUS CS eenegen ghe 29 9 Technical description EE 30 9 1 Charge ISCO EE 30 9 2 BCR Fower Stage ET 31 dE E E WEE 31 GE E en E ER Da N IN EE 32 9 6 Be Ee Cnet ee ner tere rere e er erm ee en er ne ere errr rer rer er eer ere 32 9 7 Cell LOVACCEPTANCE TeStINGiacscsinssseertssnavsasanascasdaxwwravamaciarnaieriaramacimareaaemaanmasmameeeiaeenens 33 10 General PROTECTION DEE 40 PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document User Manual CubeSat 1U Electronic Power System lene and Batteries CS 1UEPS2 NB 10 20 Issue A Date 21 07 2010 Page 5 of 56 Se IOF OvertCurrent Bus Protection eege 40 10 2 Battery Under vollage Protechio get srna a EE E sete tales suse tale S A N EI 40 10 3 Ove r current Polyswitch Protection 41 11 Terre EENEG Reeg 42 ME We OA uea ta ea ac ace ast ee ose aa none vied git AAEE EAE 42 T2 tee leieren ET EE 42 TAS COMMING SUIMMMALY a A A EE E T 44 RE DE VE EE 46 12 RE 48 12 1 Powerup Down Procede vrecdicesecedacecacdetedaantnsseatsesesansassenetastesssaspsenietesen N A a senate 48 LEA ATT Ae e 49 i23 BaL y CUD e ed 49 12 4 Configuration and Testing cccccecccseccceeccceccceceseeeeceeeeseeceseuceseeseseeeseeceseuseseuseseuseseusesausesaess 50 13 RI el eg A
2. Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 23 of 56 8 6 CubeSat Kit Compatible Headers Connections from the EPS to the bus of the satellite are made via the CubeSat Kit compatible headers H1 and H2 as shown in Figure 8 6 DD H2 lele Sp Sp Ho Ho BE HE ENE EE EE Ss ls Ss EE ER Ss EE ENE ENE BIE BE 5V BUS 5V BUS 3 3V BUS 3 3V BUS afe oo Ee m USB 5V 33 34 BATT POS 33 34 BATTPOS PCM IN la PCM IN 37 38 DUMMY LOAD DUMMY LOAD ral S Nc ra DATA BCR OUT BCR OUT SE EE W a5 46 BAT BUS oop BAT BUS afe afa EE EE ale ale Figure 8 5 CubeSat Kit Header Schematic H2 H1 3 3V BUS BCR OUT BAT BUS BATT Gene GND C PCM IN f 6 E H2 EI Tale HE Mon EEDSGEIRSDGREL a fs 33 35 dis USB em CHARGING DUMMY LOAD 12C DATA N2C CLK Figure 8 6 EPS Connector Pin Identification SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 24 of 56 8 7 Cubesat Kit Header Pin Definitions HEADER 1 Name Use Notes Pin Name NC NC NC NC NC NC NC NC 10 10 11 11 12 12 13 13 14 14 HEADER 2 Use Notes Not Connect
3. Issue A Date 21 07 2010 Page 16 of 56 Glasgow G20 OSP UK 7 2 Protection and Redundancy BCRs All the BCR power stages feature full system autonomy They operate solely from the solar array input and do not require any power from the battery systems This feature gives the system inbuilt redundancy as the failure of one BCR does not affect the remaining BCRs Failure of the battery on the CS 1UEPS2 10 will not damage the BCRs but due to the MPPT will result in an intermittent interruption on all power buses approximately every 2 5 seconds Failure of one battery on the CS 1UEPS2 20 will not damage the BCRs and the system can continue to operate with a reduced capacity of 10Wh Batteries All batteries have integrated over current protection This is achieved by using polyswitches which are designed to trip when an over current event occurs To protect the battery and satellite from power faults such as over current or under voltage a system of monitoring and shutdown is required The system must be able to detect and shutdown any power line which has encountered a fault On the CS 1UEPS2 20 the loss of one pair of cells i e one battery in the stack will not affect the performance of the remaining batteries power will continue to be supplied to the system The rest of the power system is a robustly designed single string 7 3 Quiescent Power Consumption All power system efficiencies detailed BCRs and PCMs take into c
4. User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Document No USM 0001 Issue A Date 21 07 2010 Name Date Andrew Author Sirain 21 07 2010 Vicki Approved Wila 21 07 2010 Peter P har Approved ae 21 07 2010 P L wt Space Ltd Building Kelvin Campus West of Scotland Science Park Glasgow G20 OSP UK t i 44 0 141 946 4440 e enquiries clyde space com Ww www clyde space com Registered in Scotland No SC285287 at 123 St Vincent Street Glasgow G2 5EA SOLUTIONS FOR A NEW AGE IN SPACE Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 2 of 56 Document Control Issue Date Section Description of Change Reason for Change A 21 07 10 First Release Revision Control Product Part Number Revisions covered Notes Cubesat 1U Electronic Power System 2G CS 1UEPS2 NB with no battery Cubesat 1U Electronic Power System 2G CS 1UEPS2 10 A with 10Wh battery A Cubesat 1U Electronic Power System 2G CS 1UEPS2 20 with 20Wh battery Acronyms and Abbreviations BCR Battery Charge Regulator PCM Power Conditioning Module PDM Power Distribution Module MPPT Maximum Power Point Tracker USB Universal Serial Bus ESD Electro Static Discharge TLM Telemetry EPS Electrical
5. Figure 12 7 5V USB charge setup This setup should only be used for top up charge on the battery not for mission simulation testing SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 SPACE Mocua User Manual CubeSat 1U Electronic Power System sAd T STE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 54 of 56 Glasgow G20 OSP UK 13 DEVELOPER AIT AIT of the EPS with other CubeSat modules or subsystems is the responsibility of the CubeSat developer Whilst Clyde Space outlines a generic process which could be applicable to your particular system in this section we are not able to offer more specific advice unless integration is between other Clyde Space products or those of compatible products see Table 14 1 AIT is at the risk of the developer and particular care must be taken that all subsystems are cross compatible Throughout the AIT process it is recommended that comprehensive records of all actions be maintained tracking each subsystem specifically Photo or video detailing of any procedure also helps to document this process Comprehensive records are useful to both the developer and Clyde Space in the event of any anomalies complete and rapid resolution will only be possible if good records are kept The record should contain at least e Subsystem and activity e Dates and times of activity start
6. Once the under voltage protection is activated there is a monitoring circuit used to monitor the voltage of the battery This will draw approximately 2mA for the duration of shutdown As the EPS is designed for LEO orbit the maximum expected period in under voltage is estimated to be 40mins When ground testing this should be taken into consideration and the battery should be recharged within 40mins of reaching under voltage otherwise permanent damage may be sustained 10 3 Over current Polyswitch Protection A polyswitch is fitted in line with each string of the battery This is a resettable fuse designed to blow when an over current either charge or discharge is observed by the string The approximate fusing currents are shown in Table 10 1 Temperature Approximate C Trip Current A 0 20 oss jo Jas Table 10 1 Polyswitch Trip Current Variation with Temperature If the cause of the over current subsequently clears the fuse will reset allowing current to flow to and from the battery again Once a polyswitch has been fused and reset once the resistance is unknown as such the efficiency may be degraded following this event Hence if a polyswitch is fused during ground testing it should be replaced SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE an
7. 3 Document Revisions In addition to hardware and software updates we also make regular updates to our documentation and online information Notes of updates to documents can also be found at http www clyde space com SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao A d Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 7 of 56 Glasgow G20 OSP UK 2 OVERVIEW This is the second generation of Clyde Space CubeSat Electronic Power System and Batteries developed by our team of Spacecraft Power Systems and Electronics Engineers Since introducing the first generation in 2006 Clyde Space has shipped over 120 EPS and Batteries to a variety of customers in Europe Asia and North America The second generation EPS builds on the heritage gained with the first generation whilst increasing power delivery capability by approximately 50 Furthermore we have implemented an ideal diode mechanism which ensures that there will be zero draw on the battery in launch configuration The batteries utilise Lithium lon Polymer technology to offer world leading power to mass ratios in a form factor ideally suited to the volume constraints of CubeSats In addition to this testing has been carried out by both ESA and NASA and the batteries have bee
8. Ah Figure 9 11 Discharge traces at C rate at different temperatures Self Discharge Optimum Storage Condition Optimum storage conditions were examined at different temperatures and depths of discharge The results indicated that the best conditions in which to maintain the cell and therefore battery capacity are to store at a depth of discharge around 50 7 4V and at temperatures between 10 C and 10 C It is therefore recommended that when not in use batteries are stored in a refrigerator or similar Vacuum Cycling Vacuum cycling was carried out in a chamber at 19mbar pressure and at ambient temperature A plot of cell voltage vs time for 10 cycles is shown in Figure 9 12 Capacity variation with cycle number is indicated in Table 9 2 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao d Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 37 of 56 Voltage V Time hours Figure 9 12 Cell cycled at C 2 rate in a vacuum of 19mbar Cycle eae Capacity Ah a Jus a Jun a a0 1 198 e Jus e Jus o Jus Table 9 2 Cell capacity variation with vacuum cycle number No change in cell weight was observed following the vacuum cycling weights measured to 2 decima
9. Battery not Battery Bus DO NOT CONNECT Switches gt Input to PCMs and PDMs Unused connection of launch switch closed state gt Switches BCR OUT 2 41 44 Output of BCRs gt Switches Table 8 6 Header pin name descriptions relating CubeSat Kit names to CS names WO WI W2 w3 Switches N C WA W5 8 8 Switch Options The Clyde Space EPS has three connection points for switch attachments as shown in Figure 8 7 There are a number of possible switch configurations for implementation Each configuration must ensure that the buses are isolated from the arrays and battery during launch The batteries should also be isolated from the BCRs during launch in order to conform to Cubesat standard RD 1 CLYDE SPACE 1U EPS User Defined Switch Configuration DUMMY LOAD BATT POS BATTERY DAUGHTER BOARD Figure 8 7 Switch connection points SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao A d Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 27 of 56 Glasgow G20 OSP UK Dummy Load The Dummy Load is available as an additional ground support protection system providing a load for the BCRs when the pull pin is inserted using the normally open NO connection of the Pull Pin By connecting this Dummy Load to t
10. Power System EoC End of Charge AMUX Analogue Multiplexer ADC Analogue to Digital Converter AIT Assembly Integration and Testing 1U 1 Unit Cubesat standard size 3U 3 Unit Cubesat standard size FleXU Flexible Unit suitable for various satellite configurations rh Relative Humidity Wh Watt Hour Ah Ampere Hour DoD Depth of Discharge Kbits Kilobits per second Voc Open Circuit Voltage Isc Short Circuit Current 2s1p Battery configuration 2 cells in series 1 battery in parallel single string SOLUTIONSFORANEWAGEINSPACE e www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document User Manual CubeSat 1U Electronic Power System SSES and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 3 of 56 Glasgow G20 OSP UK 2s2p Battery configuration 2 cells in series 2 batteries in parallel 2s3p Battery configuration 2 cells in series 3 batteries in parallel Related Documents No Document Name Doc Ref RD 1 CubeSat Design Specification Rev 12 RD 2 GSFC STD 7000 April 2005 Power System Design and Performance on the World s RD 5 Most Advanced In Orbit Nanosatellite As named Warning Risk Ensure headers H1 and H2 are correctly aligned If misaligned battery positive can short to before mating boards ground causing failure of the battery and EPS If power is applied with incorrect switch Ensure switching configuration is implement
11. cable one end connects to the EPS with two halves of the harness connecting to opposing solar panels Clyde Space solar arrays use Hirose DF13 6P 1 25H as the interface connector to the harness 8 4 Temperature Sensing Interface Temperature sensing telemetry is provided for each solar array connected to the EPS A compatible temperature sensor LM335M is fitted as standard on Clyde Space solar arrays for non Clyde Space panels refer to section 8 5 The output from the LM335M sensor is then passed to the telemetry system via on board signal conditioning Due to the nature of the signal conditioning the system is only compatible with zener based temperature sensors i e LM335M or equivalent Thermistor or thermocouple type sensors are incompatible with the conditioning circuit CLYDE SPACE EPS Micro Controller ae E Solar Array Figure 8 6 Temperature sensor block diagram 8 5 Non Clyde Space Solar Arrays When connecting non Clyde Space solar arrays care must be taken with the polarity Pins 1 2 and 3 are for array and pins 4 5 and 6 relate to the opposite array Cells used should be of triple junction type If other cells are to be interfaced please contact Clyde Space SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 gt gt D Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20
12. tested with a battery in the system If a Clyde Space battery is not available this can be done using a power supply and load to simulate the behavior of a battery This setup is shown in Figure 12 3 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 50 of 56 Glasgow G20 OSP UK CLYDE SPACE EPS Electronic Power Load Supply Set to 0 5A 7 74V draw 1 2A BATTERY Figure 12 3 Simulated Battery Setup 12 4 Configuration and Testing The following section outlines the procedure for performing basic functional testing PCM Testing In order to test the PCMs power must be applied to the PCM_IN connection In order to do this the Pull Pin should be removed connection the battery as shown in Figure 12 4 CLYDE SPACE EPS 5 BT SEPARATION 5 SWITCH A 0 d BCRx 2c c 0 0 DUMMY LOAD ELECTRONIC LOAD Aardvark PC H1 43 HI Battery Daughter Figure 12 4 Test set up with Pull Pin Removed In this configuration all buses will be activated and can be measured with a multimeter By increasing the load on each of the buses you will be able to see the current trip points activation as discussed in Section 10 1 SOLUT
13. the BCRs Under these conditions if power is applied to the input of the arrays or by connecting the USB there is a possibility of damaging the system In order to mitigate this risk a Dummy Load fitted on the EPS SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 28 of 56 Glasgow G20 OSP UK Option 2 m da E a LI EEASS SEPARATION El a E DUMMY LOAD SEPARATIO SWITCH 2 mi 7 89 Ze E BATTERY DAUGHTER BOARD Figure 8 9 Switch Configuration Option 2 Option 2 is compatible with structures incorporating two separation switches providing complete isolation in the launch configuration The dummy load is not activated in this configuration Care should be taken to ensure that the switches used are rated to the appropriate current levels Please contact Clyde Space for information on implementing alternative switch or dummy load configurations 8 9 Battery Connection Connection of the battery systems on the 1U EPS is via the fixing screws for power transfer and an additional telemetry connector for all signals Once mounted on the EPS the pins on the mother board are live When integrating the mother board ensure that the pins are aligned a
14. 001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 12 of 56 Glasgow G20 OSP UK 6 MATERIALS AND PROCESSES 6 1 Materials Used Material Manufacturer TML CVCM WVR SE 1B31 Acrylic Humiseal 3 89 0 11 Conformal Coating Adhesive fixing on modifications Thermally Conductive RTV a 4952 Emerson iS CEET Solder Resist CARAPACE 0 95 0 02 EMP110 or or 0 995 Or 0 001 XV501T 4 7 Solder Sn62 or Sn63 Tin Lead Flux Alpha Rosin Note ESA Flux RF800 ROL Recommended 0 Table 6 1 Materials List Note worst case on NASA out gassing list Part Used Manufacturer Contact Insulator Type DF13 6P 1 25DSA 50 Hirose Gold Plated Polyamide Solar Array Connectors ESQ 126 39 G D Samtec Gold Plated Black Glass Filled CubeSat Kit Polyester Compatible Headers DF13 6S 1 25C Hirose N A Polyamide Crimp Housing Harness for Solar SC Gs Se separately DF13 2630SCFA 04 Hirose Gold Plated N A Crimp Harness for Solar al eal aes en separately Table 6 2 Connector Headers 6 2 Processes and Procedures All assembly is carried out and inspected to ESA Workmanship Standards ECSS Q ST 70 O8C and ECSS Q ST 70 38C SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System
15. 2C Write Collision No 12C Write Collision Collision Occurred 1 2 DC Overflow No DC Overflow Ge Overtlow Occurred Received Messages Last Message Correct Length incorrect Length ar nouse JL Rats as Table 11 2 Status Bytes 3 Received Message too Long SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 46 of 56 11 4 ADC Channels Each of the analogue channels when read returns a number between 0 1023 To retrieve the value of the analogue signal this number ADC is to be entered into an equation When the equation is used the value calculated is the value of the input analogue signal Table 11 4 contains example equations of the conversions of each of the channels To get more accurate equations full calibration test should be carried out ADC Channel Signal Approx Conversion Equations Units Notes d 0 5 x ADC count 515 7 Sei 5 Array 0 163 x ADC Count 110 338 Temperature 3 Array pair 0 0086 x ADC Count 8 81 Voltage A 0 5 x ADC count 515 Y Y 5 Array X 0 163 x ADC Count 110 338 Temperature e Array pair X 0 0086 x ADC Count 8 81 Voltage X l Z Z Y Array Y Current Array X Current Arra
16. E www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 52 of 56 Glasgow G20 OSP UK Noise Filter Off 400rns CC EEE Figure 12 6 Waveform of Solar Array Input EoC Operation Using the test setup detailed in Figure 12 5 the EoC operation can be demonstrated By raising the voltage of the simulated battery above 8 26V the EoC mode will be activated This can be observed using an ammeter coming from the Array input which will decrease towards OA it will never actually reach OA closer to 10mA as the BCR low level electronics will still draw form the array 5V USB Charging Figure 12 7 shows the test setup for the 5V USB charging SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 53 of 56 N CLYDE SPACE EPS SEPARATION SWITCH 5V USB BCR_OUT Charging E e e A BCRx Power W Supply SV 4 SA DUMMY LOAD BATT POS ELECTRONIC LOAD 9 O Aardvark H1 43 H1 41 Battery Daughter Board
17. ETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 33 of 56 Glasgow G20 OSP UK 9 7 Cell Lot Acceptance Testing In order to determine the cell s suitability for space applications Clyde Space undertakes an extensive Lot Acceptance Testing regime The process is detailed in this section Destructive Parts Analysis Destructive Physical Analysis DPA of the cell reveals a stacked cell architecture as shown in Figure 9 2 The cell is hermetically sealed in a plastic coated foil casing The cell stack pictured on the left hand side of the photograph in Figure 9 2 consists of 12 layers The top layer is shown separated as far as possible in the figure The individual components are well adhered confirming the presence of a polymer electrolyte but can be separated into current collectors separators and active materials The active material can be removed with a scalpel to reveal the copper electrode Figure 9 2 DPA showing separated cell components Capacity Variation with Discharge Rate and Temperature Discharge plots are shown in Figures 9 3 to 9 6 for rates of C 15 C 10 C 5 C 2 and C at 40 C Figure 9 3 20 C Figure 9 4 0 C Figure 9 5 and 20 C Figure 9 6 In Figures 9 7 to 9 11 capacities for each discharg
18. Helix Building WSSP Issue A Date 21 07 2010 Page 21 of 56 Glasgow G20 OSP UK Name Notes Use GND Ground n Power RTN and GND connection for Temp Sensor ER Y TEMP_TELEM Y Array Telemetry Telemetry YARRA P RTN ND ti GND round Une ower and GND connection for Temp Sensor d Y TEMP_TELEM Y Array Telemetry Telemetry Table 8 2 Pin out for Header SA1 Pin Use Notes Ground Line Power RTN and GND connection ym GND for Temp Sensor ER X_TEMP_TELEM X Array Telemetry Telemetry D Ground Line Power RTN and GND connection oe GN for Temp Sensor ag X TEMP_TELEM X Array Telemetry Telemetry Table 8 3 Pin out for Header SA2 Name Use Notes GN Ground Line Power RTN and GND connection for Temp Sensor Ground Line Power RTN and GND connection GN for Temp Sensor Z_TEMP_TELEM Z Array Telemetry Telemetry Table 8 4 Pin out for Header SA3 D Z_TEMP_TELEM Z Array Telemetry Telemetry D SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 22 of 56 Glasgow G20 OSP UK 8 3 Solar Array Harness Clyde Space supply harnesses sold separately to connect the solar panels to the EPS comprising of two Hirose DF13 6S 1 25C connected at each end of the
19. IONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 SPACE EA User Manual CubeSat 1U Electronic Power System sAd T and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 51 of 56 Glasgow G20 OSP UK Undervoltage Protection When using a simulated battery it is possible to trigger the undervoltage protection Using the same test setup as detailed above with a simulated battery if the voltage is dropped to below 6 2V the undervoltage will be activated This can be observed by the power buses shutting down Note This test takes the battery to 100 DoD and should always be followed by a charge cycle BCR Testing In order to test the operation of the BCRs the separation switches should be moved to flight configuration as shown in Figure 12 5 with the pull pin still removed Once this is done the array input can be connected CLYDE SPACE EPS BCR OUT Array G a Input O Tel DUMMY _ LOAD EI SEPARATION SWITCH ELECTRONIC LOAD H1 43 H1 41 Aardvark haem node Battery Daughter a TTT WM PS Es Figure 12 5 Test set up in Flight Configuration To check the operation of the BCR MPPT an oscilloscope probe should be placed at pin 1 of the active solar array connector not at the power supply The wave form should resemble Figure 12 6 SOLUTIONS FOR A NEW AGE IN SPAC
20. OR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 SPACE each User Manual CubeSat 1U Electronic Power System 14 421 Ce SE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 40 of 56 Glasgow G20 OSP UK 10 GENERAL PROTECTION The EPS and batteries have a number of inbuilt protections and safety features designed to maintain safe operation of the EPS battery and all subsystems supplied by the EPS buses 10 1 Over Current Bus Protection The EPS features bus protection systems to safeguard the battery EPS and attached satellite sub systems This is achieved using current monitors and a shut down network within the PDMs Over current shutdowns are present on all buses for sub system protection These are solid state switches that monitor the current and shutdown at predetermined load levels see Table 10 1 The bus protection will then monitor the fault periodically and reset when the fault clears The fault detection and clear is illustrated in the waveform in Figure 10 1 SYSTEM EVENT TEST SYSTEM VER CURRENT S Ee SHUTDOWN TEST PERIOD CLEARS PERIOD RESUME BUS VOLTAGE A CURRENT Law NORMAL LEVEL I Ir r NORMAL r T f OPERATION EE Shutdown period Shutdown period Shutdown period NORMAL OPERATION Figure 10 1 Current protection system diagram Period Approximate Duration ms Bus Shut
21. RE 54 14 OU CHO Et KE 56 SOLUTIONSFORANEWAGEINSPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 6 of 56 Glasgow G20 OSP UK 1 INTRODUCTION This document provides information on the features operation handling and storage of the Clyde Space second generation 1U EPS with integrated 10Wh or 20Wh batteries The 1U EPS is designed to integrate with a suitable battery and solar arrays to form a complete power system for use on a 1U CubeSat 5V USB a gt q t QG HVU Mrr ECR OUT nud ve Diode x x pill l PCM N I q Switch Z f s O Configuration D o As Defined By t User 3 S 88 BATT POS O lt LL i2c node Battery Daughter Board CLYDE SPACE EPS Figure 1 1 System Diagram 1 1 Additional Information Available Online Additional Information on CubeSats and Clyde Space Systems can be found here http www clyde space com You will need to login to our website to access certain documents 1 2 Continuous Improvement At Clyde Space we are continuously improving our processes and products We aim to provide full visibility of the changes and updates that we make and information of these changes can be found by logging in to our website http www clyde space com 1
22. SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 13 of 56 Glasgow G20 OSP UK 7 SYSTEM DESCRIPTION The Clyde Space 1U EPS is optimised for Low Earth Orbit LEO missions with a maximum altitude of 850km The EPS is designed for integration with spacecraft that have six or less body mounted solar panels i e one on each spacecraft facet The EPS can accommodate various solar panel configurations and has been designed to be versatile please consult our support team if you have specific requirements for connecting the EPS to your spacecraft The Clyde Space EPS connects to the solar panels via three independent Battery Charge Regulators BCRs These are connected as shown in Figure 7 1 and Figure 7 2 with panels on opposing faces of the satellite connected to the same BCR i e X array and X array are connected to BCR1 Y and Y to BCR2 and Z and Z to BCR3 In this configuration only one panel per pair can be directly illuminated at any given time with the second panel providing a limited amount of energy due to albedo illumination Each of the BCRs has an inbuilt Maximum Power Point Tracker MPPT This MPPT will track the dominant panel of the connected pair the directly illuminated panel The output of the three BCRs are then connected together and via the switch network described in Section 7 2 supply charge to the battery Power Conditioning Modules PCMs and Power Di
23. Si so Sei NB 10 20 Figure 7 3 Board dimensions mm SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 eves User Manual CubeSat 1U Electronic Power System 14 421 T and Batteries CS 1UEPS2 NB 10 20 SPACE Issue A Date 21 07 2010 Page 18 of 56 Helix Building WSSP Glasgow G20 OSP UK 8 INTERFACING The interfacing of the EPS is outlined in Figure 8 1 including the solar array inputs connection to the switch configuration output of the power buses and communication to the I C node In the following section it is assumed that the EPS will be integrated with a Clyde Space Battery 5V USB g gt d q E QG DV mera ECR OUT g 0 lt Diode a x eal PCM_IN Switch S gt o Configuration D m As Defined By x gt Z User q a 88 BATT POS D D ILI ic node mateo io da ee Reim SEIT gt WW Figure 8 1 Clyde Space EPS and Battery Simplified Connection Diagram SOLUTIONSFORANEWAGEINSPACE e www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 ferns User Manual CubeSat 1U Electronic Power System mada T and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 19 of 56 8 1 Connector Layout The connector positions are shown in Figure 7 3 and described in Table 8 1 Connector Function Solar Array connector
24. UEPS2 10 and CS SE a iia 1UEPS2 20 only C mA Array Z 0 163 x ADC Count 110 338 Temperature Array Z Current 0 5 x ADC count 515 7 P Table 11 3 ADC Channels SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 48 of 56 Glasgow G20 OSP UK 12 TEST All EPS are fully tested prior to shipping and test reports are supplied In order to verify the operation of the EPS please use the following outlined instructions Step by step intro of how to connect and verify operation In order to test the functionality of the EPS you will require e EPS e Battery or simulated battery e Breakout Connector with connections as per Figure 12 1 e Array Input test panel solar array simulator or power supply and limiting resistor e Oscilloscope e Multimeter e Electronic Load e Aardvark I2C connector or other means of communicating on the i2c bus CLYDE SPACE EPS BCR OUT SEPARATION SWITCH HS ap d M a A DUMMY Loan A 2 27 gt ELECTRONIC LOAD 3 H1 43 H1 41 U O Aardvark Battery Daughter Figure 12 1 Suggested Test Setup The breakout connector should be wired with the switch confi
25. ad command returns the result All commands start with the 7 bit slave address and are followed by two data bytes The first data byte should be the command The second byte represents the data that is used as part of the command An example of the data is the analogue to digital channel to read An example of a read command would be e The master transmits the slave address with write flag command type 0x00 and data ADC channel e The slave acts on the commands sets the correct channel and reads the analogue to digital converter e The master transmits the slave address with read flag e The slave responds with a two byte value If a read message does not have a preceding write message the value OxFOOO is returned All bit level communication to and from the board is done by sending the MSB first If both bytes are not read then the system may become unstable ADC The I C node acts as a multi channel Analogue to digital convertor which allows the board to supply sensor data to the user When the command is received a delay approximately 1 2ms is inserted to allow the analogue reading to settle After this delay the result can be retrieved The result is a 10 bit value with the first byte received containing the two most significant bits and the second byte received the remaining 8 bits MSB LSB First byte k e Second byte Used bits Figure 11 2 ADC 10bit data packet To retrieve a sensor reading the following procedure sh
26. chdog N A Causes a soft reset of the micro Table 11 1 Command Summary Status The status bytes are designed to supply operational data about the 1 C Node To retrieve the two bytes that represent the status the command 0x01 should be sent The meaning of each bit of the status byte is shown in Table 11 2 PDM Off There may be a time when the user wishes to turn of the PDM s for a short period They may wish to do this to create a hard reset of a circuit To carry this out the command Ox0002 is sent followed by the data byte The data byte has a range of O to 7 Bit O corresponds to the battery bus bit 1 the 5V bus and bit 2 the 3 3V bus Any combination of busses can be turned off however is should be noted that if the user switches the 3 3V PDM off the UC node will be reset Version The firmware version number can be accessed by the user using this command Please contact Clyde Space to learn the version number on your board WatchDog The Watchdog command allows the user to force a reset of the TC node If the user detects or suspects an error in the operation of the UC node then this command should be issued When issued the VC node will reset and return to an initial state Heater Pin 10 of the PIC microcontroller RB7 is configured as an override control for the battery heater The heater can only be turned off it cannot be forced on This is controlled by the board temperature SOLUTIONS FOR A NEW AGE IN SPACE www cl
27. d Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 42 of 56 Glasgow G20 OSP UK 11 TELEMETRY AND TELECOMMAND The telemetry system monitors certain stages of the power system and battery while also allowing a small degree of control over the PDM stages and battery heater The telemetry system transfers data via an UC bus The telemetry system operates in slave mode and requires an IC master to supply commands and the clock signal Control systems within the EPS offer the user the ability to temporarily isolate the EPS buses from the on board computer systems CUIARRAY Sense E Current PDM voltage Ir current BCR3 Sense Sensing AMUX c 5V PDM temperture g urrent 8 Sensing 3 3V Batter e voltage kd Battery current charge discharge kd Sensing EN Heater 2 PC databus GC NODE Seen ignal line temperture Control line ARRAY Sense voltage ARRAY Sense voltage Figure 111 1 Telemetry functional diagram 11 1 IFC Node The IC Node is based on the Microchip PIC16F690 The device node is configured to act as a single channel analogue to digital converter The microcontroller controls the analogue multiplexer that routes the signals from the sensors The PIC16F690 program is designed to operate as a slave sensor node on the UC bus The program will select and then convert the desired signal data from the telemetry network on demand There is also a control fea
28. down period Battery Bus Test period 5V Bus Ieren im shutdown period 1 me 3 3V Bus Testpeod OOO ooo o w Table 10 1 Bus protection data 10 2 Battery Under voltage Protection In order to prevent the over discharge of the battery the EPS has inbuilt under voltage shutdown This is controlled by a comparator circuit with hysteresis In the event of the battery discharging to 6 2V slightly above the 6 1V that results in significant battery degradation the EPS will shutdown the supply buses This will also result in the I C node shutting down When a power source is applied to the EPS e g an illuminated solar panel the battery will begin charging immediately The buses however will not reactivate until the battery voltage has risen to 7V This allows the battery to charge to a level capable of sustaining the power lines once a load is applied SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 l Helix Building WSSP Issue A Date 21 07 2010 Page 41 of 56 Glasgow G20 OSP UK It is recommended that the battery state of charge is monitored and loading adjusted appropriately turning off of non critical systems when the battery capacity is approaching the lower limit This will prevent the hard shutdown provided by the EPS
29. e rate are compared for all temperatures Note that these measurements were carried out per cell A summary of the results is shown in Table 9 1 T C Discharge Rate and measured capacity Ah C 15 1 437 C 10 1 435 C 5 1 283 C 2 1 208 C 1 171 C 15 1 501 C 10 1 430 C 5 1 276 C 2 1 226 e C 15 1 358 C 10 1 294 C 5 1 161 C 2 0 716 cs 1 055 c 02s Table 9 1 Measured capacities at different discharge rates and temperatures SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 i Helix Building WSSP Issue A Date 21 07 2010 Page 34 of 56 Glasgow G20 OSP UK 4 1 SSS 8 c is E 3 5 c 10 c s 3 3 C72 Time hours Figure 9 3 Discharge traces at 40 C at C 15 C 10 C 5 C 2 and C rates 3 7 715 S 3 5 c 10 C S 3 3 Cc 2 3 1 Time gemet Figure 9 4 Discharge traces at 20 C at C 15 C 10 C 5 C 2 and C rates ep G S 4 8 S e C D 3 3 CA O 2 a 6 R gas cease 12 14 16 LS 20 Figure 9 5 Discharge traces at 0 C at C 15 C 10 C 5 C 2 and C rates SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Docume
30. ear of these headers Gloves should be worn when handling all flight hardware Flight hardware should only be removed from packaging in a class 100000 or better clean room environment The exterior surface of the cells is covered with space grade Kapton adhesive tape this provides insulation for the cells and is not to be removed 5 3 Shipping and Storage The devices are shipped in anti static vacuum sealed packaging enclosed in a hard protective case This case should be used for storage All hardware should be stored in anti static packaging Rate of capacity degradation of lithium polymer cells in storage is dependent on the storage environment particularly temperature and cell state of charge It is recommended that the batteries are stored with voltages approximately 7 4V 50 DoD at a temperature between 5 C and 15 C and in a humidity controlled environment of 40 60 rh The most serious degradation occurs when cells are stored in a fully charged state If batteries are stored for long periods of time they may over discharge To prevent this batteries should be charged periodically to maintain 7 4V It is also recommended that the Pull Pin is left in place replaced during periods of storage The shelf life of this product is estimated at 5 years when stored appropriately SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0
31. ed configuration the output of the BCR can be correctly before applying power to EPS blown causing failure of the EPS and subsequent damage to the battery The battery is a static sensitive system Failure Observe ESD precautions at all times to observe ESD precautions can result in failure of the battery S Exceeding any of the stated maximum limits can Ensure not to exceed the maximum stated limits ER result in failure of the battery If not fully isolated by switch configuration or Ensure batteries are fully isolated during storage separation the battery may over discharge resulting in failure of the battery These pins are used to connect the battery to No connection should be made to H2 35 36 the EPS Any connections to the unregulated battery bus should be made to pins H2 43 44 These headers have exposed live pins which H1 and H2 pins should not be shorted at any should not be shorted at any time Particular care should be taken regarding the surfaces these are placed on The EPS includes a number of protection circuits for the battery Operation without these protections may lead to damage of the batteries Battery should only be operated when integrated with an EPS If the battery is discharged to a voltage below 6V Do not discharge batteries below 6V the cells have been compromised and will no longer hold capacity If the battery is over discharged below 6V it should not be recharged as this may lead to cell r
32. ed Not Connected m m Oo ON DU BW N Oo ON DU BPW N NC NC NC NC NC NC NC NC NC NC NC NC NC 21 23 15 Not Connected Not Connected 15 Not Connected Not Connected 16 17 18 19 20 Not Connected Not Connected Not Connected Not Connected ALT PC Oohm resistor CLK Alt C clock connection R265 must fit to NC Not Connected Not Connected operate 22 2 Oohm resistor ALTIC 2 DATA Alt C data connection R264 must fit to NC Not Connected Not Connected operate 24 Not Connected Not Connected 24 Not Connected Not Connected 25 Not Connected Not Connected 25 5V BUS 5V Power bus Regulated 5V bus 26 Not Connected 26 5V BUS 5V Power bus Regulated 5V bus 3 27 NC Not Connected Not Connected 27 daii geed Regulated 3V3 bus BUS bus 28 NC Not Connected Not Connected 28 ed aver out Regulated 3V3 bus BUS bus d Syst ge connection return Ground System power 30 NC Not Connected Not Connected GND connection return 31 Not Connected Not Connected 32 USB _5 USB 54v Use to charge GND Ground System power battery via USB connection return BATT Pull pi II 33 NC Not Connected Not Connected Power line PARN ae y POS connected pin BATT Pull pi II 34 NC Not Connected Not Connected Power line SC dees y POS connected pin Sep SW normally 35 NC Not Connected Not Connected PCM IN Power line f connected pin W II 36 NC Not Connected Not Connected PCM IN Power line SE Gehier S connected pin D k Pull pi II Protection open
33. finish key milestones e Operator s and QAs e Calibration of any equipment e Other subsystems involved e Method followed e Success condition or results e Any anomalous behaviour Before integration each module or element should undergo an acceptance or pre integration review to ensure that the developer is satisfied that the subsystem meets its specification through analysis inspection review testing or otherwise Activities might include e Satisfactory inspection and functional test of the subsystem e Review of all supporting documentation e Review of all AIT procedural plans identifying equipment and personnel needs and outlining clear pass fail criteria e Dry runs of the procedures in the plan Obviously testing and analysis is not possible for all aspects of a subsystem specification and Clyde Space is able to provide data on operations which have been performed on the system as detailed in Table 13 1 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 55 of 56 Glasgow G20 OSP UK Performed on Availability Functional Module supped Providedwitnmodue Calibration Module supped Providedwitnmodue Vacum Pertormedon module prototype inmanual Thermal Pertormed
34. for 3W Y arrays Solar array connector for 3W X arrays Solar array connector for 3W Z arrays Cubesat Kit bus compatible Header 1 Cubesat Kit bus compatible Header 2 Table 8 1 Connector functions SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 eves User Manual CubeSat 1U Electronic Power System madz T and Batteries CS 1UEPS2 NB 10 20 Issue A Date 21 07 2010 Page 20 of 56 Helix Building WSSP Glasgow G20 OSP UK 8 2 Solar Array Connection The EPS has three connectors for the attachment of solar arrays Each interface accommodates inputs from two arrays with temperature telemetry for each CLYDE SPACE 1U EPS Solar Arra Solar Arra Figure 8 2 Solar Array Configuration HIROSE DP12 6P 1 25 DSA connector sockets are used on the EPS These are labelled SA1 SA2 and SA3 routed to BCR1 BCR2 and BCR3 respectively Each of the BCRs are capable of interfacing to 3W panels and should be harnessed to arrays on opposing faces of the satellite The string length should be 2 triple junction cells 11000000 ech M Ww A OO Figure 8 3 Solar Array Pin Numbering SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document eo 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20
35. guration to be used under mission conditions 12 1 Power up Down Procedure The order of assembly should follow the order detailed below e Breakout connector assembled with switches set to launch vehicle configuration as shown in Figure 12 1 e Fit Breakout connector to EPS e Connect battery to stack e Connect electronic load no load to buses SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 49 of 56 Glasgow G20 OSP UK e Remove Pull Pin e Activate Separation Switch e Connect array input When powering down this process should be followed in reverse 12 2 Solar Array Input There are 3 options for the array input section e A solar array e A solar array simulator e A benchtop power supply with current limiting resistor When using a solar array or solar array simulator the limits should not exceed those outlined in Table 12 1 dd Isc mA acra pat BCR SA2 BCR Aa Table 12 1 solar array limits When using a power supply and resistor setup to simulate a solar panel the required setup is shown in Figure 12 2 Array Input Power t J Supply e Set limits Figure 12 2 Solar Panel using power supply 12 3 Battery Setup The system should be
36. he NO pin BCR damage can be circumvented The wiring arrangement for the dummy load is indicated in Figure 8 8 The load protects the battery charge regulator from damage when the USB or array power is attached and the batteries are not connected This system is not operational during flight and is only included as a ground support protection The Clyde Space Dummy Load system has been a standard feature from revision D of the EPS onwards If the Dummy Load is required for an earlier revision please contact Clyde Space for fitting instructions Options 1 and 2 below are two suggested methods of switch configuration but are by no means exhaustive If you wish to discuss other possible configurations please contact Clyde Space Option 1 CLYDE SPACE 1U EPS SEPARATION SWITCH BCR OUT DUMMY eege PULL PIN a BATT POS BATTERY DAUGHTER BOARD Figure 8 8 Switch Configuration Option 1 Option 1 accommodates the CubeSat Kit bus available switches offering two stage isolation The separation switch provides isolation of the power buses during the launch The pull pin may be used for ground based isolation of the batteries though it does not provide any isolation during launch NOTE The second generation Clyde Space EPS has zero current draw when the pull pin is removed i e there will be no current drawn from the battery while on the launch vehicle When pull pin is inserted the battery is isolated from the output of
37. he subsystem interfaces to ensure cross compatibility Verification should work upwards towards confirming top level requirements as the system integration continues This could be achieved by selecting a base subsystem such as the EPS OBC or payload and progressively integrating modules into a stack before structural integration Dependent upon the specific systems and qualification requirements further system level tests can be undertaken When a subsystem or system is not being operated upon it should be stowed in a suitable container as per Section 5 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 56 of 56 Glasgow G20 OSP UK 14 COMPATIBLE SYSTEMS Compatibility Notes CubeSat Kit Bus CubeSat Kit definition pin compatible See Non standard Wire Connector User defined Connector Other Connectors Please contact Clyde Space Lithium Polymer 8 2v 2s1p to 2s2p More strings can be connected in parallel to increase capacity if required Batteries Lithium lon 8 2v 2s1p to 2s2p e More strings can be connected in parallel to increase capacity if required Other Batteries Please contact Clyde Space 3W triple junction cell arrays 2 in series connection Other array technologies An
38. il in RD 5 In this document there is on orbit data showing the operation and how the current fluctuates with changing illumination conditions and orientation of the spacecraft with respect to the Sun 9 2 BCR Power Stage Overview As discussed in Section 8 the EPS has three separate independent BCRs each designed to interface to two parallel solar arrays on opposing faces of the satellite The design offers a highly reliable system that can deliver up to 80 of the power delivered from the solar array network at full load 3W BCR Power Stage Design Each 3W BCR uses a high efficiency SEPIC converter interfacing to solar arrays of two triple junction cells in series This will deliver up to 80 output at full load The BCR will operate with an input of between 3V and 6V and a maximum output of 8 26V 7 4V nominal 9 3 MPPT Each of the BCRs can have two solar arrays connected at any given time only one array can be illuminated by sunlight although the other may receive illumination by albedo reflection from earth The dominant array is in sunlight and this will operate the MPPT for that BCR string The MPPT monitors the power supplied from the solar array The data from this is then used to calculate the maximum power point of the array The system tracks this point by periodically adjusting the BCRs to maintain the maximum power derived from the arrays This technique ensures that the solar arrays can deliver much greater usable power i
39. l places and there was no evidence of any cell leakage or any unusual behaviour in the cycling profile The cell capacity varied slightly with subsequent cycles with a decrease of 0 5 in the measured capacity between cycle 1 and cycle 10 Standard capacity measurements were carried out following the vacuum cycling Very little difference was seen in the capacity measured before and after vacuum cycling 1 257Ah before 1 243Ah after Vacuum cycling therefore did not have any significant detrimental effect on the cell capacity Although the cells bulge in a vacuum the stack arrangement of the cell and use of polymer electrolyte means that there is no separation of cell components in a vacuum and therefore little effect on the cell cyclability EMF vs SoC Cells were cycled at a slow rate C 50 in order to minimise the cell internal resistance and therefore measure the cell capacity This test was carried out at room temperature SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 38 of 56 Glasgow G20 OSP UK A plot of voltage vs capacity is shown in Figure 9 13 3 9 Voltage V 2 7 o DS a re WL 2 2 5 Capacity Ah Figure 9 13 Discha
40. me The EoC voltage is held constant and a tapering current from the panels is supplied to top up the battery until at full capacity In EoC mode the MPPT circuitry moves the solar array operation point away from the maximum power point of the array drawing only the required power from the panels The excess power is left on the arrays as heat which is transferred to the structure via the array s thermal dissipation methods incorporated in the panels The operation of these two modes can be seen in Figure 9 1 9 r 1 2 end of charge voltage i constant battery i 8 5 J i j voltage at 8 2V 8 0 8 75 3 0 6 Fi lt LN E b 6 5 4 taper charge end of r 04 del e ken C discharge gt voltage O 6 0 2 constant current 5 5 4 charge again constant current dicharge Lo charge made on orbit charge current is proportional to solar panel illumination 0 2 4 5 5 conditions 4 04 0 5000 10000 15000 20000 25000 30000 Time s Figure 9 1 Tapered charging method SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 SPACE Mocua User Manual CubeSat 1U Electronic Power System sAd T STE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 31 of 56 Glasgow G20 OSP UK The application of constant current constant voltage charge method on a spacecraft is described in more deta
41. mponent 95 15 4 CS 1UEPS2 20 H is bottom of EPS board to top of tallest component Weight eneen ED ewa EE Tr Table 4 1 Performance Characteristics of the 1U EPS and Batteries 3 z SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 11 of 56 Glasgow G20 OSP UK 5 HANDLING AND STORAGE The EPS and batteries require specific guidelines to be observed for handling transportation and storage These are stated below Failure to follow these guidelines may result in damage to the units or degradation in performance 5 1 Electro Static Discharge ESD Protection This system incorporates static sensitive devices and care should be taken during handling Do not touch the EPS and batteries without proper electrostatic protection in place All work carried out on the system should be done in a static dissipative environment 5 2 General Handling The EPS and batteries are designed to be robust and withstand flight conditions However care must be taken when handling the device Care should be taken not to drop the devices There are live connections between the battery systems and the EPS on the CubeSat Kit headers All metal objects including probes should be kept cl
42. n cleared for launch on NASA manned flights Clyde Space is the World leading supplier of power system components for CubeSats We have been designing manufacturing testing and supplying batteries power system electronics and solar panels for space programmes since 2006 Our customers range from universities running student led missions to major space companies and government organisations SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 8 of 56 3 Maximum Ratincs OVER OPERATING TEMPERATURE RANGE UNLESS OTHERWISE STATED BCR SA1 pin 1 or pin 4 10 Input Voltage SA2 pin 1 or pin 4 10 SA3 pin 1 or pin 4 10 Battery 3 3V Bus A u lt olw v on E D i CH Uo oo e Je le Je le le SA1 750 mA Input Current SA2 750 mA Value Charge Limits d i A Current Rate max C Capacity Discharge Limits oe DE Fraction of Current Rate max C Capacity Value Unit feauevos esz Je Ja Output Current EN p3aveus Jew Ja Ja O ee Se Value Unit Operating Temperature C Storage Temperature S Vacuum 10 torr Radiation Tolerance kRad Vibration Table 3 1 Max Ratings of the 1U EPS and Batteries 1 S
43. ncreasing the overall system performance Increasing Temperature Odd Maximum Power Point Array Current Increasing Temperature Vmpp Voie Array Voltage Figure 9 2 Solar Array Maximum Power Point The monitoring of the MPP is done approximately every 2 5 seconds During this tracking the output voltage from the array will step to o c voltage as shown in Figure 9 3 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 32 of 56 Glasgow G20 OSP UK Noise Filter Off 400rns IZ EE eo oe Figure 9 3 Input waveform with Maximum Power Point Tracking 9 4 Discharge The central section in Figure 9 1 shows the profile of a full discharge of the battery at a C 5 rate 0 25A for a 2s1p battery A full discharge cycle is carried out on all Clyde Space batteries prior to shipment to verify their capacity In order to maximise the cycle life of the battery it is recommended to discharge the battery to a maximum of 20 DoD 9 5 5V and 3 3V PCM The 5V and 3 3V regulators both use buck switching topology regulators as their main converter stage The regulator incorporates intelligent feedback systems to ensure the voltage regulation is maintained to 1 devia
44. nd located in the correct position as any offset can cause the battery to be shorted to ground leading to catastrophic failure of the battery and damage to the EPS Failure to observe these precautions will result in the voiding of any warranty When integrating to the bus ensure that the pins are aligned and located in the correct position as any offset can cause the battery to be shorted to ground leading to catastrophic failure of the battery and damage to the EPS Failure to observe these precautions will result in the voiding of any warranty When the battery is connected to the EPS the battery will be fully isolated until implementing and connecting a switch configuration as discussed in Section 8 8 Ensure that the battery is fully isolated during periods of extended storage When a battery board is connected to the CubeSat Kit header there are live unprotected battery pins accessible H2 33 34 These pins should not be routed to any connections other than the switches and Clyde Space EPS otherwise all protections will be bypassed and significant battery damage can be sustained SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 eves User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Issue A Date 21 07 2010 Page 29 of 56 Helix Building WSSP Glasgow G20 OSP UK 8 10 Buses All power buses are accessible via
45. nt User Manual CubeSat 1U Electronic Power System SE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 35 of 56 Glasgow G20 OSP UK 8 g e O 2 a G 3 gien 12 14 16 18 20 Figure 9 6 Discharge traces at 20 C at C 15 C 10 C 5 C 2 and C rates e ZS i O 0 2 0 a 0 6 0 5 1 1 4 1 6 Capacity Ah Figure 9 7 Discharge traces at C 15 rate at different temperatures otage DI 0 2 oa oO om 1 1 2 1 4 1 0 Capacity Ah Figure 9 8 Discharge traces at C 10 rate at different temperatures a s ei o oe oa 0 6 o s a a 2 KS 1 6 Capacity Ah Figure 9 9 Discharge traces at C 5 rate at different temperatures SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 CL c 1a c s Era bes 20 C Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 36 of 56 Glasgow G20 OSP UK Voltage V w w 0 2 oa LA on 1 1 2 1a 1 6 Capacity Ah Figure 9 10 Discharge traces at C 2 rate at different temperatures 40 C 20 C Voltage V Orc 2 C O 0 2 0 4 0 6 0 8 1 Bi 1 4 L G Capacity
46. on module prototype inmanual Simulation amp modeling not performed notavatae Table 13 1 Acceptance test data Following this review it is recommended the system undergoes further testing for verification against the developer s own requirements Commonly requirement compliance is presented in a compliance matrix as shown in Table 13 2 pass fail SYS 0030 The system mass TEST 01 0 957 kg X lt 1kg PASS shall be no more than 1 kg SYS 0040 The error LED TEST 02 LED LED off FAIL ID Requirement Procedure Result X Success criteria Compliance remains off at flashing initialisation sooo 1 LI LL Table 13 2 Compliance matrix example All procedural plans carried out on the EPS should conform to the test setups and procedures covered in Section 12 During testing it is recommended that a buddy system is employed where one individual acts as the quality assurance manager and one or more perform the actions working from a documented and reviewed test procedure The operator s should clearly announce each action and wait for confirmation from their QA This simple practice provides a useful first check and helps to eliminate common errors or mistakes which could catastrophically damage the subsystem Verification is project dependant but should typically start with lower level subsystem specific requirements which can be verified before subsystems are integrated in particular attention should be paid to t
47. onsideration the low level control electronics associated with them As such these numbers are not included in the quiescent power consumption figures The TC node is the only circuitry not covered in the efficiency figures and has a quiescent power consumption of 0 1W which is the figure for the complete EPS When the heater is active the power drawn from the 3 3V Bus will rise to 0 22W on the CS 1UEPS2 10 and 0 44W on the CS 1UEPS2 20 7 4 Mass and Mechanical Configuration The mass of the EPS is approximately 83g and is contained on a single PC 104 size card compatible with the Cubesat Kit bus The 10 and 20 versions require one and two battery daughter boards respectively to be fitted The mass of these systems including the cover protection board are approximately 163g and 229g Other versions of the EPS are available without the Cubesat Kit bus header The dimensions of the EPS including all connector positions are shown in Figure 7 3 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 17 of 56 4 PLATED MOUNTING HOLES 3 2 THRU melled t CO nls ID rere z nt Ih hi S e R e a E AR iP d d Die Us H s 8 29 08 SA2 1 3 80 01
48. ould be used Send 0x00 followed by OxOX where X represents the channel number in Hex format This instructs the IC node that the user wishes to retrieve a sensor value and which sensor to take the reading from After a small delay approximately 1 2ms the user can issue a read command and the result will be transmitted The most significant byte is sent first followed by the least significant byte The result received should then be entered into the conversion equations covered in a further section which calculates the requested parameter If the reading is not yet ready OxFOOO is returned This process should be followed for all ADC channels SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 44 of 56 Glasgow G20 OSP UK 11 8 Command Summary Table 11 1 below provides a list of the commands for the EPS The data that should accompany the commands is included in the table Descriptions of the commands follow the table Command e Command Type Value Range Description DXF Name DXF ADC Read ADC Channel N A Request Status Bytes PDM Off Turns off the selected PDM for a short time N A Request Firmware Version Heater Force off 0 1 Forces Battery Heater off Wat
49. pin 38 Not Connected Not Connected 39 40 Data for TC communications es Clock for TC communications Se 47 Not Connected 47 Not Connected Not Connected 48 Not Connected 48 Not Connected Not Connected Protection open pin BCR OUT Power line E SS pins BCR OUT Power line A AEP SS pins BCR OUT Power line samman a AN SS pins SS pins Bus bus SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 25 of 56 Glasgow G20 OSP UK HEADER 1 HEADER 2 Pin Name Use Notes Pin Name Use Notes 49 Not Connected SK 50 50 51 Not Connected 51 Not Connected Not Connected 52 Not Connected Not Connected 52 Not Connected Not Connected Table 8 5 Pin Descriptions for Header H1 and H2 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 26 of 56 Glasgow G20 OSP UK NODE HEADER CUBESAT KIT NAME NOTES 5V BUS 2 25 26 5V Regulated Bus Output 3 3V BUS 2 27 28 VCC SYS 3 3V Regulated Bus Output BATT POS 2 33 34 PCM IN KE Positive Terminal of
50. rge trace at C 50 rate at 20 C The capacity of the cell discharged at C 50 was 2 495Ah which is almost double the cell nameplate capacity and indicates the effect of internal resistance on the cell capacity Internal resistances have been estimated from previous figures at the cross over point from discharge to charge Cells cycled at C 2 have an estimated internal resistance of 0 5250hms and at C 5 an estimated internal resistance of 0 4120hms These figures show that the cell internal resistance increases as the charge discharge rate also increases In Table 9 3 the cell voltage at different depth of discharge is shown for discharge rates of C 5 compared with C 50 It is clear from the table that the voltage remains higher as the discharge progresses at C 50 rate compared to C 5 Voltage of cell Voltage of cell DoD discharged at discharged at C 5 V C 50 V 4 200 4 200 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ey 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 39 of 56 Glasgow G20 OSP UK Voltage of cell Voltage of cell DoD discharged at discharged at C 5 V C 50 V 75 3 692 3 769 om 2 3 754 0 sa sno 100 Table 9 3 Voltage variation with DoD at C 5 and at C 50 SOLUTIONS F
51. rray X Array Y Array Not shown CS 1UEPS2 NB CS 1UEPS2 10 CS 1UEPS2 20 Figure 7 1 Configurations SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 15 of 56 7 1 System Overview UNDER VOLTAGE tS H2 27 28 ae H2 25 26 5V BUS 12C BUFFER H2 45 46 a oO BATTERY BUS 5 2 8 O oO N 2 5 Fs S O D gt mM m H2 35 36 PCM_IN H2 33 34 BAT_POS H2 41 44 dias BCR_OUT fe ae OOO LN wi l Ww H2 29 31 32 LL oun LH EE RE Ken Of N 1 z D s ae ee a LA bo ae N SN Ge I amp 7 e EDRI 3 g H1 32 J l D gt a oO E sv ue FI fa a E eh P a Ae 3 Z Wa em d z l I 2 J z offe l l GE z SE ts io ce ba NI q O 4 Se C h L Cae i l _ SE I Figure 7 2 Function Diagram SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao A d Vi USM 0001 User Manual CubeSat 1U Electronic Power System SPACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP
52. stribution Modules PDMs via the switch network Clyde Space batteries offer high capacity with low weight and volume The battery systems all have integrated heater systems to enhance operation at low temperatures There is over current protection incorporated to protect the cells in the event of a power line fault The battery heater is an independent analogue circuit which maintains the battery temperature above 0 C The heater is thermostatically controlled to automatically turn on when the battery temperature falls below 0 C and switch off again when the temperature rises above 5 C The heater can also be switched off by UC command for power conservation through the EPS The PCM PDM network has an unregulated Battery Voltage Bus a regulated 5V supply and a regulated 3 3V supply available on the satellite bus The EPS also has multiple inbuilt protection methods to ensure safe operation during the mission and a full range of EPS telemetries power bus resets and a heater off command via the I C network These are discussed in detail in Sections 10 and Error Reference source not found respectively SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document User Manual CubeSat 1U Electronic Power System lee and Batteries CS 1UEPS2 NB 10 20 i Helix Building WSSP Issue A Date 21 07 2010 Page 14 of 56 Glasgow G20 OSP UK Z Array Y Array X A
53. the CubeSat Kit headers and are listed and described in Table 8 5 These are the only power connections that should be used by the platform as they follow all battery and bus over current protections All I C communications can are accessible via the CubeSat Kit header See Section 11 SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 30 of 56 Glasgow G20 OSP UK 9 TECHNICAL DESCRIPTION This section gives a complete overview of the operational modes of the EPS and battery and the testing undertaken to ensure their suitability for space It is assumed that a complete Clyde Space system is in operation for the following sections 9 1 Charge Method The BCR charging system has two modes of operation Maximum Power Point Tracking MPPT mode and End of Charge EoC mode These modes are governed by the state of charge of the battery MPPT Mode If the battery voltage is below the preset EoC voltage the system is in MPPT mode This is based on constant current charge method operating at the maximum power point of the solar panel for maximum power transfer EoC Mode Once the EoC voltage has been reached the BCR changes to EoC mode which is a constant voltage charging regi
54. tion The efficiency of each unit at full load is approximately 96 for the 5V CPM and 95 for the 3 3V PCM Full load on each of the regulator have a nominal output current of 2 5A which is upgradable to 4 5A Each regulator operates at a frequency of 480 kHz 9 6 Battery Heater Each battery board has its own autonomous heater designed to maintain the temperature of the batteries above 0 C to maximise the capacity of the battery The heater is controlled by a thermostat circuit with hysteresis This monitoring circuit is normally active drawing 2 5mW from the 5V Bus When the temperature of the board drops below 0 C the heater on each board will switch on drawing approximately 0 22W from the 3 3V Bus This can be observed via the current telemetry on the 3 3V Bus Once the temperature rises above 5 C the heater will switch off again The heater can be forced and held off with a telecommand as described in Section 11 allowing a reduction in power consumption if required 2 5mW from the 5V Bus If this command is sent the battery temperature may drop below zero reducing the achievable capacity of the batteries as discussed in Section 9 7 Once this command has been sent all heaters will remain off By resetting this command the heater can be re enabled at which point the thermostat circuit will become operational again It is not possible to force the heater to switch on SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRI
55. tresses Beyond those listed under maximum ratings may cause permanent damage to the EPS and Batteries These are the stress ratings only Operation of the EPS and Batteries at conditions beyond those indicated is not recommended Exposure to absolute maximum ratings for extended periods may affect EPS and Batteries reliability 2 De rating of power critical components is in accordance to ECSS guidelines SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 9 of 56 4 ELECTRICAL CHARACTERISTICS Description Conditions Min Typical Max D gt 3W BCR Input Voltage ese V Output Voltage V CHE Output Current 160 170 180 KHz 71 79 80 Operating Frequency Efficiency 6V input Full Load Battery Charge Conditions EoC Voltage DO N N 2 N oO 8 30 V Recommended maximum GE 0 625 gt Charge Current Battery Discharge Conditions 6 16 eu N EEEE 7 eu N D Full Discharge Voltage CS EPS2 NB N A CS EPS2 10 Recommended max C 2 CS EPS2 20 Recommended max C 2 Disch C t ischarge Curren 0 625 A kA 2 LI A Capacity Recommended 20 Depth of Discharge Batter
56. ture that can briefly shutdown PDMs within the EPS The following sections briefly describe the hardware that is used Analogue Multiplexer A 32 channel analogue multiplexer is used for selecting the correct sensor signal The multiplexer is controlled from the microcontroller Additional Hardware Further required hardware includes an oscillator and an UC bus extender The oscillator provides a robust clock signal for the microcontroller The bus extender provides greater robustness to signal noise on the I C bus during integration and operations 11 2 BC Command Interface All communications to the Telemetry and Telecommand TTC Node are via an I C interface The TTC Node is configured as a slave and only responds to direct commands from a master IC node No unsolicited telemetry is transmitted A maximum 400Kbit bus speed is supported with typical bus speeds of 100Kbit The address of the TTC Node is factory set The address is Ox2D SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document ao 4 Vi USM 0001 User Manual CubeSat 1U Electronic Power System SDPDACE and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 43 of 56 Glasgow G20 OSP UK Message Formats Two message structures are available to the master a write command and a read command The write command is used to initiate an event and the re
57. upture If batteries are over discharged DO NOT attempt to recharge SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document User Manual CubeSat 1U Electronic Power System lene and Batteries CS 1UEPS2 NB 10 20 Issue A Date 21 07 2010 Page 4 of 56 Se 1 WN Fa ot DEE 6 1 1 Additional Information Available Online ccccccscccccsseeceeeeeeeseeceeseeeeeeseecessueeeeseeeeeseeseeeseseensuess 6 1 2 Continuous MINOW EE 6 1 3 DOCUIMENE REVISIONS E 6 2 I ee 7 3 Maximum Ratings NN NE ENE NAA NE ANE E I E N E A A T EA 8 4 Electrical Ee E 9 5 R Ne Tue SO TEE 11 5 1 Electro Static Discharge ESD Protection 11 SE e EI Eet ele 11 2 AMIS SIR Ke 11 6 Materials and Ree 12 6 1 Materials Used WE 12 SC Processes and PROC SCN SS at cecetsereercdee ste ac enteaetuectatunateeacess tate teeyaeencete E a tetas 12 7 SEENEN 13 7 1 GEERT 15 7 2 Protection ANd Redundancy 16 73 Quiescent POWEMC OMS Di re E 16 7 4 Mass and Mechanical Confieuraton 16 8 WGI GGT CUI EE 18 8 1 Son earel E a eebe 19 8 2 solar Array CONNECTION rerien E re Terre tr err 20 8 3 e ge e Ee 22 8 4 Temperature Sensing IEN rsisi nieni unsa AEAN TANAAN SENE 22 8 5 Non Clyde Space Solar Arrays 22 8 6 CubeSat Kit Compatible Headers cccccccseccssseccseeecececseceseeceseeceseeseseuceseesessesesseseseusesesesseeeses 23 8 7 Cubesat Kit Header Pin Definitions
58. y X Current 0 5 x ADC count 515 7 Array 0 163 x ADC Count 110 338 C Temperature Array pair 0 0086 x ADC Count 8 81 V Voltage Array Z Current 0 5 x ADC count 515 7 11 Array 0 163 x ADC Count 110 338 Temperature 13 Array Y Current 0 5 x ADC count 515 7 1A Array 0 163 x ADC Count 110 338 Temperature 17 Battery Bus 3 153 x ADC Count 3250 815 Current 18 BAT1 Temperature 0 163 x ADC Count 110 835 CS 1UEPS2 20 only 19 BAT1 Full Voltage 0 0939x ADC Count 9 791 CS 1UEPS2 20 only CO BAT1 Current High Bat charge Chg Dis CS 1UEPS2 20 only 12 GND G Z J 16 21 Direction Low Bat discharge Chg BAT1 Current 3 20 x ADC Count 2926 22 CS 1UEPS2 20 only SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 47 of 56 Glasgow G20 OSP UK BATO Temperature 0 163 x ADC Count 110 835 CS 1UEPS2 10 and CS P 1UEPS2 20 only 0 0939x ADC Count 9 791 CS 1UEPS2 10 and CS GE ee iy 1UEPS2 20 only E 5V Bus Current 3 500 x ADC Count 3611 509 Oo BATO Current High Bat charge Chg Dis CS ood and CS i i 1UEPS2 20 on Direction Low Bat discharge Chg y C V V mA 3 3V Bus Current 4 039 x ADC Count 4155 271 3 20 x ADC Count 2926 22 CS 1
59. y Capacity CS EPS2 NB CS EPS2 10 CS EPS2 20 Unregulated Battery Bus N A discharge rate C 5 20 C discharge rate C 5 20 C 1 276 2 5952 eu N Ko Ui CO N oO oe gi KA N lo nn Output Voltage Output Current Operating Frequency Efficiency 98 5 99 99 5 5V Bus Output Voltage 8 26V input Full Load Output Current fc O 7 4 CO 0 kHz Operating Frequency Efficiency 5V input Full Load 95 96 98 3 3V Bus Output Voltage 3 276 3 3 3 333 V Output Current 470 480 kHz 94 95 Operating Frequency Efficiency 3 3V input Full Load 97 Communications Protocol 100 3 3V Ox2D 7bit 8MHz Transmission speed KBps Bus voltage 3 26V 3 33V Node address Hex Address scheme H Node operating frequency Quiescent Operation SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Glasgow G20 OSP UK Issue A Date 21 07 2010 Page 10 of 56 Flight Configuration of Power Draw Switches lt 0 2 Power Drawn for heater CS 1UEPS2 10 from 3 3V Bus SR Ca ae when active CS 1UEPS2 20 from 3 3V Bus i Physical H CS 1UEPS2 NB H is bottom of EPS board to top of tallest component 95 12 65 mm CS 1UEPS2 10 H is bottom of Dimensions EPS board to top of tallest co
60. y that conform to the input ratings for Voltage and Current Structure Clyde Space 3W solar array Connects to BCR 1 3 via SA1 3 Solar Arrays ISIS CubeSat 1U compatible Please contact Clyde Space Table 14 1 Compatibilities 1 Refers to series and parallel connections of the battery cells within the battery system e g 2s1p indicates a single string of two cells in series 2 Will require some alteration to MPPT Please contact Clyde Space SOLUTIONS FOR A NEW AGE IN SPACE www clyde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010
61. yde space com PROPRIETARY amp CONFIDENTIAL INFORMATION Clyde Space Limited 2010 Document USM 0001 User Manual CubeSat 1U Electronic Power System and Batteries CS 1UEPS2 NB 10 20 Helix Building WSSP Issue A Date 21 07 2010 Page 45 of 56 Glasgow G20 OSP UK If a value of 0x01 is written as the command value the output is driven high turning the heater off The heater will remain off until a value of Ox00 is written as the command value allowing the thermostat circuit to take control of the heater If any other command values written the command is ignored and UnknownCommandValue is set bit1 byte O of TTC status Byte Bit Description him Low IO If High 1 Note L Bi Unknown Command Type BS TEE ast Command it cleared Unknown when read Last Command 1 Unknown Command Value Last Command Value OK Value Out of Range ADC Result Not Bit cleared 2 ADC Result Not Ready ADC Result Ready C Result Not Bit cleare Ready when read s C dl Not Used emia External Oscillator External running Oscillator failure Watchdog Reset Bit cleared 5 Watchdog Reset Occurred No Watchdog Reset SE Occurred when read Bit cleared when read Sawer On eee enred Power On Reset No Power On Bit cleared Occurred Reset Occurred when read j D Pesce cued Brown Out Reset No Brown Out Bit cleared Occurred Reset Occurred when read 12C Error No I2C Errors Es Error Bit cleared Occurred when read L t Write 1 1

User Manual: CubeSat 1U Electronic Power System

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