Electrical Engineering 595 Capstone Design Team #4 Universal Power Box

Project Abstract With the immense selection of electrical devices used in everyday lives, there can be much need to convert between one type of power source into another. The Universal Power Box (UPB) will combine many types of conversions into one product. Cost, reliability, accuracy and safety are key aspects in the scope of this project.

Product Description The user will attach a power source to the UPB, then enter a desired output power type and level. The UPB will sense the type of power the user is inputting. The UPB utilizes a Flyback DC to DC converter and an H-bridge inverter which doubles as a full-wave rectifier for power conversion. The power converters are run by a microprocessor, which takes input from a variety of feedback sensors. All converters are pulse-width modulated. An internal power supply, which draws from the power input by the user, powers the UPB.

Product Feature Set Desired Features of the UPB: The UPB will be able to convert AC to DC, DC to AC, and DC to DC. The user will interact with the UPB through an LCD and numeric keypad. The UPB will draw its internal power supply from the input power. The UPB will have a Total Harmonic Distortion sufficiently low for consumer electronics applications. The UPB will have a weight, size, and durability that allows it to be portable.

Target Market This product is being developed for use with consumer electronics in the North American environment. Common applications will include: Creating 120 VAC from a car outlet (for both 14Vdc and 42Vdc systems). Replacing consumer electronic AC to DC adapters.

Staff Gerry Callison, BSEE Maria Schlicht, BSEE Ethan Spafford, BSEE Expertise: Power Systems, Digital Design, Presentation Experience: 3 years experience at Johnsons Controls Maria Schlicht, BSEE Expertise: Micro controllers, PLCs, Project Management, Technical Writing, Language Skills Experience: 8 years experience at Rockwell Automation Ethan Spafford, BSEE Expertise: RF, Circuit Design, Optical Communication, PSpice Software

Staff Matt Risic, BSEE/BSCS Vanessa White, BSEE Expertise: High Level Programming, Assembly, Computer Networks, Computer Organization Experience: Two summers interning at Philips Advance Transformer Vanessa White, BSEE Expertise: Digital Design, Micro controllers, PLC Logic Experience: One year experience at Harley Davidson

Team Logistics Meetings: Held on a need basis, usually in the evenings of weeknights. Tasks were primarily delegated to individuals, to maximize productivity. On average, each team member spent about 10 hours per week on the project. Decision making: Conesus/Majority vote. Project duties: Webmaster: Matt Risic Archiver: Vanessa White Presentation Manager: Gerry Callison Report Manager: Ethan Spafford Graphics Manager: Maria Schlicht

Product Performance Requirements Input voltage ranges: 14-50Vdc 108-132VAC Maximum input current: 7 amps Output power: 75 watts Output voltage ranges: Maximum output current: 5 amps Total Harmonic Distortion < 5%

Product Standard Requirements Operating Requirements 0-50 degrees Celsius 0-70% RH Maximum product size 2000 cm^3 Maximum product mass 2kg Maximum parts count 200 3 Years Component Life

Productization Aspects & Requirements Legal/Ethical Aspects & Requirements Includes UL labels Includes safety labels (liability protection) All labels and user manual in English and Spanish Safety/Health Aspects & Requirements Includes proper shielding Safety directions in product manual

Productization Aspects & Requirements Sustaining Aspects & Requirements This product does not require field service Design team will monitor field defects for future versions Reliability Aspects & Requirements 1 year warranty standard Products which fail under warranty should be returned for analysis.

Productization Aspects & Requirements Environmental Aspects & Requirements Proper disposal: Recycled, NOT thrown in general refuse The following power and EMF tests should be used: IEC61000-3-2 IEC61000-3-3 IEC61000-4-6 IEC61000-4-11 EN61000-6-2

Block Diagram Gerry Matt Maria Ethan Vanessa

Functional Block Description Agenda Microprocessor - Matt User Interface - Maria Power Conversion - Gerry Internal power & Cooling - Ethan Sensor & I/O - Vanessa

Product Definition: User Requirements Product: Universal Power Box Industry Family: Consumer Electronics Useful to eliminate the multitude of power adapters needed for many electronic devices so that they may be powered by any battery or standard wall plug regardless of the type of power required by the device Intended for use in home electronics devices The UPB will deliver power with simplicity! Many different power adapters available, but none known that combine AC-DC, DC-AC, and DC-DC in one product

Project Selection Best fit for scope of project and component availability Fullest use of skills and experience of team Major risks Electrical Safety Electronic Overload Physical Durability Other projects rejected for lack of variety in tasks and their limited scope Decision unanimously supported by team Selection Process Majority vote after input from faculty advisors

3 MODES OF OPERATION AC to DC. DC to DC. DC to AC.

AC to DC operation overview AC voltage applied to I/O AC. Uncontrolled Inverter/Rectifier converts AC to DC. Buck-Boost converter adjusts output DC voltage to user-defined level.

DC to DC operation overview User inputs DC to I/O DC. Buck-boost converter adjusts DC to user defined level of DC. Inverter/Rectifier switches configure to pass through output DC without altering it.

DC to AC operation overview User inputs DC through I/O DC. Buck-boost converter adjusts level of DC necessary for proper AC output. Inverter/Rectifier runs PWM switching to output AC.

TOP-LEVEL FUNCTIONALITY REQUIREMENTS The user can input 14-50Vdc or 24-120VAC to get out 0-50Vdc or 0-120VAC. Separate adapter cables will allow for various power supplies to be connected to the UPB The UPB will sense the level/type of input power, then output a user-defined level/type of power. The UPB will be able to output 150 Watts of power. The UPB will be able to output 5 Amps of current.

Block Requirements

Power Control Matt Risic

Power Control Gerry Matt Maria Ethan Vanessa

Block Purpose The Power Control is the center of the Universal Power Box The programming is responsible for converting input waves into necessary output voltage waves Microprocessor will control the LCD display based on user input from the keypad Different scenarios will be performed based on the power conversion being performed

Standard Requirements Control Humidity Range 0%RH to 70%RH Block Cost <$15 Parts Count <20 Block Size <48cm2 Block Mass <95.5 grams Max Power Consumption <20W Operating Temperature Range 0C to 75C Storage Temperature Range 0C to 75C Operating Humidity 0-70% Reliability (MTBF) 3 Years

Performance Requirements Control Input Voltage +3.3V (+/- 3%) Full Scale Output Voltage +3.3V (+/- 3%) Minimum speed 1Mhz Desired Memory 1K SRAM Programming Language Assembly Number of Registers 32

Input/Output Voltages Sensor AC Sensor Switch Driver 0-3.3V 3.3V Power Control 0-3.3 V 6V Control Power 0.15 V Cooling 0.65-2.2V 0.15V LCD Display Keypad

Microprocessor Selection Atmel ATMega169v Microprocessor Advanced RISC Architecture 130 Instruction Set C and Assembly Coding 32 x 8 General Purpose Registers 16KB Programmable Flash 512 Bytes EEPROM 1KB SRAM 64 Pin Chip

Chip Size

CPU/ALU Timing Diagrams

SRAM Timing Diagram

Programming Examples

Memory Hierarchy

ATMega169v Operating Conditions Operating voltage between 1.8-5.5V Operating temperature between -40 to +85 degrees Celsius Up to 1 MHz Clock Speed Power Consumption At 1MHz consumes 1.8V, 400uA At 32 kHz consumes 1.8V, 20uA Power-down Mode is 0.5uA at 1.8V

Microprocessor Selection Selected over other considerations because of best benefits per cost ratio. Available locally or over Internet Dependable and respectable manufacturer. Manuals, examples and tutorials readily available.

Programming Software AVR Studio 4.08 Integrated Coding, Compiling and Debugging Software Configurable Memory Support for C, Pascal, BASIC and Assembly Simulate Port Activity Logging and Pin Input

Programming Software AVR Studio 4 Service Pack Adds support for the ATMega family Builds upon the AVR Studio 4 software Improved documentation and help features

Programming Software AVR LCD Visualizer Create and modify LCDs with editor Debug and visualize with AVR plug-in Real run-time updates

LCD Flowchart

Block Component Cost ATMega169v microprocessor - $10.81 STK500 Board - $79.00 STK502 Expansion Board - $99.00 AVR Studio 4.08 – FREE AVR Studio 4 Service Pack – FREE AVR LCD Visualizer - FREE

User Interface Maria Schlicht

User Interface Gerry Matt Maria Ethan Vanessa

User Interface

USER INTERFACE OVERVIEW The user interface will contain a 12-key numeric keypad to enter the voltage desired by the user. It will also contain a 16 x 2 LCD display. Display Capacity of 25 segment and 4 Common Terminals The inputs include: The User can select three modes of operation (AC–DC,DC-AC & DC-DC) User can defined level/Type of power The User will have access to review or modify terminal settings by NUMERIC keys, navigate through the configuration screen. Electrical Safety for User

USER INTERFACE IMPORTANCE Changing settings take affect immediately (without powering off the terminal) User can reset the interface without having to remove and then re-apply power or battery. User friendly

USER INTERFACE STANDARDS REQUIREMENTS Proto Cost $53.35 % Allocation 35.1% Production cost $20.00 % Allocation 5% Proto Parts Count 2 Unique Parts 0 Production Parts Count 2 Unique Parts 0 Max. Product Size (L x W in cm) (7 x 2) LCD (5 x 6.8) Keypad Max. Product Weight (kg) 0.50 Max. Power Consumption (W) 0.800 Max. Operating Temp Range (degrees °C) 0°C to 50°C Min. Operating Humanity Rage (rh%) <95%, non-condensing Reliability and Life (MTBF in yrs, %R 1 yr, %R 5yrs) 5 yrs, 1 yr at 2%, 5 yrs at 10% Disposal/Recycle/Maintenance (# of recycles parts, Hazards) European Standard, prEN13965-2 Safety and Regulatory Standards UL508C/CSA 22.2

USER INTERFACE PERFORMANCE REQUIREMENTS LCD Operating Values: Logic Supply Voltage Range: 3.5-5.0V LCD Supply Voltage Range: 2.6-3.35V Input High Voltage VIH: 2.2-5.1V Input Low Voltage VIL: 0.65V Output High Voltage VOH: 2.3V Output Low Voltage VOL: 0.5V Max. Input Current IDD: 1.2mA Temp. (Operating) TOPR: 0°C - 50°C Temp. (Storage) TSTG: -10°C - 60°C Viewable from 1 ft. Keypad Operating Values: Insulation Resistance: > 1.01k at 500V Max. Output Current IOUT: 5mA for .5 sec Temp. (Operating) TOPR: -30°C - 70 °C Temp. (Storage) TSTG: 150°C Contact Bounce: < 10mS Frequency: 65.1dB

USER INTERFACE BLOCK DIAGRAMS

USER INTERFACE PRODUCTIZATION REQUIREMENTS User Interface Controls: 12-button keypad: Digits 0-9, Pound sign, and Start key. Safety Features: Illuminated display indicates voltage present Temperature range as specified by overall product Components to be chosen to comply with temperature requirements Hand Assembly: Keypad and LCD display manually assembled, all other components can be automatically installed. Societal/legal/Monetary Aspects: Pushbuttons (ergonomic & friendly) Material Degradation Rust and corrosion Suitable for electrical conditions Disposability/Recycle ability: Parts recyclable as PCB assembly Reliability: Prototype: Length of project Production: 1 yr @ 2% 5 yrs @ 10%

KEYPAD SCHEMATICS

Inverter-Rectifier Gerry Callison

Inverter-Rectifier Gerry Matt Maria Ethan Vanessa

Inverter/Rectifier functionality H-bridge topology- allows for one circuit to function as inverter or rectifier. H-bridge topology features four power-electronic switches. IRF740A MOSFET Inverter- 2 phase pulse width modulated. Rectifier- full wave, uncontrolled (meaning voltage level is not adjusted in this converter).

Inverter/Rectifier Interfaces From Power Control: 0/3.3Vdc binary wave to drive PWM function. Goes through IR2181 high/low driver. To/from internal sensor: varying level of DC, depends upon user command. To/from filter: varying power, depending on functionality.

Standard Requirements Inverter-Rectifier Humidity Range 0 to 70 %RH Block Cost <$6.00 Parts Count <30 Block Size <20cm2 Block Mass <100grams Max Power Consumption <3W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70%RH Reliability (MTBF) 5 Years Allocations Cost 15% Parts 15% Unique Parts 14% Power Cons. 20% Mass 5% Area PCB 12%

Performance Requirements Inverter-Rectifier Input Voltage 14-170Vdc, 108-132VAC Full Scale Output Voltage 14-119Vdc, 108-132VAC Maximum Input current 5 amps Maximum Output Current 5 amps Maximum Power Passed 75 watts Inverter/Rectifier Life 5 years Amplitude Modulation Ratio .8 % Error <10%

SO WHERE DID THESE NUMBERS COME FROM !?!?!?!

Input Voltage: 14-170 Vdc, 108-132 VAC 108 VAC: 120 VAC – 10% = 108 VAC 132 VAC: 120 VAC + 10% = 132 VAC 14 Vdc: Voltage of current automotive systems 170 Vdc: To achieve 132VAC out with Ma = .8 Vdc max = V1 ÷ Ma = 132 ÷ .8 = 165 ~ 170 Vdc

Output Voltage: 14-85 Vdc, 108-132 VAC 108 VAC: 120 VAC – 10% = 108 VAC 132 VAC: 120 VAC + 10% = 132 VAC 14 Vdc: Voltage of current automotive systems 119 Vdc:

Maximum Input Current = 5 amps Maximum Output Current = 5 amps Maximum Power Passed = 150 watts Amplitude Modulation Index = .8 5 amps: Agreed upon by group 75 watts: Agreed upon by group .8 Amplitude Modulation Index: Forces to harmonics to higher frequencies, where they are easily filtered Causes Vin = 170 Vdc (V1 = Ma*Vdc), which components can easily handle.

TOPOLOGY

A standard H-bridge topology was used.

OPERATIONAL DIAGRAM

COMPONENT SELECTION

POWER SWITCHES (MOSEFETS) REQUIREMENTS (with error margins): Vdss of at least 350 Volts Current of at least 8 amps Gate threshold voltage of 3.3 Volts Switching Frequency of at least 100kHz CHOSE: International Rectifier IRF740A MOSFET, which exceeds all minimum requirements. IRF740A features built in diode to always allow for current to flow from source to drain

MOSFET DRIVERS REQUIREMENTS: 3.3 Volt logic level Maximum high-side voltage of at least 350 Volts Switching frequency of at least 100kHz CHOSE: International Rectifier IR2181 high and low side driver, which exceeds all minimum requirements.

DC to DC Converter Gerry Callison

DC to DC Converter Gerry Matt Maria Ethan Vanessa

DC to DC functionality Unique Challenge: Because of multidirectional flow of power, both ends needed to function as inputs or outputs. Solution: Dual ended flyback converter, which share some parts. A flyback converter can raise or lower DC voltage to a sufficient gain. Requires 2 IRFP350 MOSFETS. This converter is where the voltage is adjusted to user-commanded level.

DC to DC interfaces From Power Control: 0-3.3Vdc binary signal drives MOSFETs, manipulating output based upon duty cycle of signal. MOSFETs driven from power control through IR2181 high and low side driver chip. To/from DC sensor: Varying power, depending upon functionality. To/from internal sensor: Varying level of DC, depending upon user command.

Standard Requirements DC to DC Converter Humidity Range 0 to 70 %RH Block Cost <$4.00 Parts Count <20 Block Size <20cm2 Block Mass <60grams Max Power Consumption <3W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70%RH Reliability (MTBF) 5 Years Allocations Cost 10% Parts 10% Unique Parts 5% Power Cons. 20% Mass 3% Area PCB 7%

Performance Requirements DC/DC Converter Input Voltage 14-119Vdc Maximum Input Current 5 amps Full Scale Output Voltage 14-170Vdc Maximum Output Current 7 amps Maximum Power Passed 75 watts Inverter/Rectifier Life 5 Years % Error <10%

SO WHERE DID THESE NUMBERS COME FROM !?!?!?!

Input Voltage: 14-170 Vdc Output Voltage: 14-170 Vdc 14 Vdc: Voltage of current automotive systems 119 Vdc: Maximum output of Inverter/Rectifier Output Voltage: 14-170 Vdc 14 Vdc: Voltage of current automotive systems 170 Vdc: Required by Inverter/Rectifier to achieve 132 VAC

Maximum Input Current = 7 amps Maximum Output Current = 5 amps Maximum Power Passed = 75 watts To achieve 14V to 170V conversion, maximum voltage amplification = 12.2 75 watts ÷ 132 VAC = .57 amps at max voltage .57 amps * 12.2 = 7 amps 5 amps: Agreed upon by group 75 watts: Agreed upon by group

TOPOLOGY

Initially, a buck-boost topology was planned, but it was ruled out due to nonideal effects

A dual ended flyback topology was used

OPERATIONAL DIAGRAM

COMPONENT SELECTION

PULSE TRANSFORMER(S) REQUIREMENTS: Turns Ratio of at least 8:1 ET constant of at least 350 V*uS ET constant = pulse width*pulse magnitude CHOSE: C&D Technologies 1003 (must cascade 3 to achieve 8:1 turns ratio). Turns Ratio = 2:1:1 (when cascaded = 8:1:1) ET = 400 V*uS

POWER SWITCHES (MOSEFETS) REQUIREMENTS (with error margins): Vdss of at least 350 Volts Current of at least 9 amps Gate threshold voltage of 3.3 Volts Switching Frequency of at least 100kHz CHOSE: International Rectifier IRF740A MOSFET, which exceeds all minimum requirements. IRF740A features built in diode to always allow for current to flow from source to drain

MOSFET DRIVERS REQUIREMENTS: 3.3 Volt logic level Maximum high-side voltage of at least 400 Volts Switching frequency of at least 100kHz CHOSE: International Rectifier IR2181 high and low side driver, which exceeds all minimum requirements.

Power Ethan Spafford

Power Gerry Matt Maria Ethan Vanessa

Standard Requirements Power Humidity Range 0%RH to 70%RH Block Cost <$20 Parts Count <28 Block Size <12cm2 Block Weight <500grams Max Power Consumption N/A Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Reliability (MTBF) 1Year

Performance Requirements Power Input Voltage voltage input by user Full Scale Output Voltage +12Vdc (+/- 2%) Control Power Life 2Years Dual Power Supplies Supply connects made to both DC I/O, AC I/O and 12V Battery Switching circuit routes the user input voltage and disables output voltage connection AC Input path: Solid State Relay-Transformer-Rectifier-Solid State Relay -voltage Regulator-Sensors/Micro-Controller/Cooling/etc DC input path: Solid State Relay-Flyback Converter-Solid State Relay-Voltage Regulator-sensors/microcontroller/Cooling/etc Immediately after startup the AC or DC input will act as power supply to the rest of the unit

Control Power Circuit

Input Power Select Input Selected from Key Pad – Signal sent from PC Inverting Schmitt Trigger sends signals to solid state relays and to inverter to solid state relays PC Low Signal opens DC PC High Signal opens AC

DC Input Flyback Converter Converts Input DC Voltage from 14-50V to 12.6V Average Input current between 75mA-270mA

AC Input Step Down Transformer Rectifier Converts 120AC to 12.6Vdc Transformer steps down voltage from 170Vpk to 15Vpk Rectifier Vo,max = 13.6V ΔV = 1.3 Vo,avg = 12.3V

Component Costs Component amount Total Solid State Relays(low Voltage) 3 ≈$18.50 Solid State Relay(high Voltage) 1 ≈$21.00 AC Transformer 1 ≈$6.00 Fly-Back Transformer 1 ≈$6.00 Diodes/Resistors/Caps 18 ≈$5.00 Op amps 2 ≈$1.50 MOSFET 1 ≈$1.50

Temperature Control AC Filter Ethan Spafford

Temperature Control AC Filter Gerry Matt Maria Ethan Vanessa

Standard Requirements Temperature Control & AC Filter Humidity Range 0%RH to 70%RH Block Cost <$15 Parts Count <7 Block Size <40cm2 Block Weight <100grams Max Power Consumption <2W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Reliability (MTBF) 2 Years

Performance Requirements Temperature Control & AC Filter Input Voltage +12V (+/- 2%) Temp Cont Life 2Years Fan and Heat sinks PCB designed for ideal heat dissipation Temperature warning and shut down When Tmax reached warning light notifies user to turn off unit Unit shuts itself off when Tmax is reached AC Filter Input Voltage 14-50Vdc or 120VAC Full Scale Output Voltage 14-50Vdc or 120VAC Filter Life 2 Years

AC Filter Circuit Diagrams Single Low-Pass RLC Filter Use potentiometer R obtained experimental If necessary ladder network or composite filter can be easily added ωc slightly higher so that operating frequency is below the “knee” of attenuation (100Hz)

Component Costs Component amount Total Inductors/Resistors/Caps 18 ≈$2.50 Fan/HeatSinks/TmaxIC 6 ≈$15

Sensors Vanessa White

Sensors Overview Sensors provide electrical isolation from input power to controller components Measure voltage level of input – output a reduced level signal to processor Take advantage of on-board ADC in processor

DC Sensor Gerry Matt Maria Ethan Vanessa

DC Sensor Considerations Maximum tolerable signal to processor Nominal current expected for measurement Large input range makes determination of nominal voltage for sensor input difficult – may introduce large error

Standard Requirements DC Sensor Humidity Range 0%RH to 70%RH Block Cost (Production) <$10 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years

Performance Requirements DC Sensor Input Voltage: 14-50VDC Full Scale Output Signal Voltage (measured V to processor): +3.3V (+/-10%) Supply Voltage: +12V Current Input: 10mA (nominal) Current Consumption: < 50mA Response Time : < 2ms Accuracy @ 25C: < +/- 5% Linearity: < 0.5%

DC Sensor Block Interfaces From Input/Output: Receives input power (14-50VDC) From Internal Power: Receives +12VDC power supply To Controller: Passes voltage level signal (V measured, 0-3.3VDC) Internal Power +12V 0-3.3V 14-50 VDC DC Sensor Controller

Detail Design DC Sensor LEM Transducer – LV 20-P R1 – Calculated based on expected voltage to be measured and nominal current of 10mA

AC Sensor Gerry Matt Maria Ethan Vanessa

AC Sensor Considerations AC input only Nominal current expected for measurement Maximum tolerable signal to processor

Standard Requirements AC Sensor Humidity Range 0%RH to 70%RH Block Cost (Production) <$10 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years

Performance Requirements AC Sensor Input Voltage: 120VAC (+/- 10%) Output Signal Voltage (to processor): 3.3VDC Supply Voltage: +12VDC Current Input: 10mA (nom) Current Consumption: < 50mA Response Time : < 2ms Accuracy @ 25C: < +/- 5% Linearity: <0.5%

AC Sensor Block Interfaces To/From Input/Output: Receives input power (nominally 120VAC) From Internal Power: Receives +12VDC power supply To Control: Passes voltage level signal (V measured, 0-3.3VDC) Internal Power +12V 0-3.3V 120 VAC AC Sensor Controller

Detail Design AC Sensor LEM Transducer – LV 20-P R1 – Calculated based on expected voltage to be measured and nominal current of 10mA

Internal Sensor Gerry Matt Maria Ethan Vanessa

Internal Sensor Overview Monitors internal voltage between DC/DC Converter and Inverter-Rectifier Passes measured voltage level to processor for verification of level within tolerances and any corrections to be made

Internal Sensor Considerations Bi-directional system – measures both DC and AC levels Response time for corrections

Standard Requirements Internal Sensor Humidity Range 0%RH to 70%RH Block Cost (production) <$20 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years

Performance Requirements Internal Sensor Input Voltage : 14-50VDC , 120VAC (+/-10%) Full Scale Output Signal Voltage (to Processor): +3.3VDC Supply Voltage: +12VDC Current Input: 10mA (nom) Current Consumption: < 50mA Response Time : < 2ms Accuracy @ 25C: < +/- 5% Linearity: <0.5%

Internal Sensor Block Interfaces From Internal Power: Receives +12VDC power supply To Power Control: Passes measured voltage level signal (0-3.3VDC) To/From DC/DC Converter: Receives or sends internal DC power (14-50VDC) To/From Inverter-Rectifier: Receives or sends internal AC power (nominally 120VAC) Internal Power +12V 0-3.3V Controller Inverter-Rectifier 120 VAC Internal Sensor DC-DC Converter 14-50 VDC

Detail Design Internal Sensor LEM Transducer – LV 20-P R1 and R2– Calculated based on expected voltage to be measured and nominal current of 10mA

I/O Vanessa White

I/O Overview Provides circuit protection for sensors and electronic components of power conversion blocks Switching circuit prevents power flow into electronic components until measured voltage is determined acceptable

DC I/O Considerations Polarity reversal of input voltage Electrostatic discharge Inrush current Driving switch from controller current/voltage

Standard Requirements DC I/O Humidity Range 0%RH to 70%RH Block Cost (Production) <$10 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years

Performance Requirements DC I/O External Input Voltage: +14-50VDC Full Scale Output Voltage: +50VDC Control Voltage: 3.3VDC Input/Load Current: < 10A Switching Speed (Pickup/Dropout Time): < 3ms Pickup Voltage: 4VDC (max) Dropout Voltage: 1VDC (min)

DC I/O Block Interfaces To/from Input/Output: Receives DC input power (14-50VDC) or passes output power (14-50VDC) From Controller: Receives digital signal based on measured voltage (Vok) To/from DC/DC Converter: Passes input power (14-50VDC); passes output power to output DC-DC Converter 14-50 VDC 14-50 VDC 0/3.3V DC I/O Controller

Detail Design DC I/O Solid State Relay – current limiting and switching for input power flow BJT driver - drive current to relay Capacitance – ESD Thermistor – current limiting for sensors

AC I/O Considerations AC input only, but can be DC or AC out, depending on mode (DC-DC or DC-AC) Out of range input voltage (European or other supply voltage outside nominal 120VAC not permitted to pass) Electrostatic discharge Inrush current

Standard Requirements AC I/O Humidity Range 0%RH to 70%RH Block Cost (Production) <$10 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years

Performance Requirements AC I/O External Input Voltage: 120VAC (+/- 10%) Full Scale Output Voltage: 132VAC,+50VDC Control Voltage: 3.3VDC Input/Load Current :< 8A Switching Speed (Pickup/Dropout Time): < 3ms Pickup Voltage: 4VDC (max) Dropout Voltage: 1VDC (min)

AC I/O Block Interfaces To/From Input/Output: Receives input power (nominally 120VAC) or passes output power (nom. 120VAC or +14-50VDC) From Control: Receives digital signal based on measured voltage (Vok) To/From AC Filter : Passes input power (nominally 120VAC); passes output power to output AC Filter 120 VAC 14-50 VDC / 120VAC 0/3.3V AC I/O Controller

Detail Design AC I/O Solid State Relay – current limiting and switching for input power flow BJT driver - drive current to relay Capacitance – ESD Thermistor – current limiting for sensors

Timeline

Time Line Summary Man Completion Hours Date Basic Product Definition Compilation/Definition of 14 2/4 Team Logistics/Operation Team Resources Allocation 12 2/15 Product Level Requirements 14 2/4 Standard/Performance Proto-Type Block Diagram Block Diagram with 14 2/5 Assignments and Interfaces Block Review Team T/A 12 2/18 Productization Develop Product Level 16 4/10 Verification and Requirement Plan Compilation/Development of MFG 19 4/30 Processes, Block Diagrams Design Plans for Testing Disposal 18 4/19 and Service

Time Line Summary Documentation Est.Man Completion Hours Date Proto-Typing Integrate BL Proto-Type into 14 4/24 Product Level Proto-type Testing of Fully Integrated 20 4/24 Proto-type Execution of PL Verification/Validation 14 4/30 Plan Compilation of Resource Expenditure 22 5/5 and Budget Chart Documentation Compilation of Individual 25 5/5 MSWord Reports Compilation of Final MSWord Report 10 5/10 and PowerPoint Slide Show