Index by title

Power/Temp Monitor and Control System (EPS/ECLSS) Block Diagram


Power/Temp Monitor and Control System (EPS/ECLSS) Bill Of Materials

Schematic Description Package
C1 68uF Capacitor SMD
C2 120uF Capacitor Axial
Cf1 1uF capacitor SMD
Cf2 1uF capacitor SMD
D1 1N5817 Schottky diode SMD
L1 100uH Inductor SMD
Ra1 47k Ohm .25W Resistor SMD
Rb1 47k Ohm .25W Resistor SMD
Rb2 47k Ohm .25W Resistor SMD
Rf1 4.7 Ohm .25W resistor SMD
Rf2 4.7 Ohm .25W resistor SMD
Rf3 4.7 Ohm .25W resistor SMD
Rf4 4.7 Ohm .25W resistor SMD
RL1 180 Ohm .5W resistor SMD
RL2 180 Ohm .5W resistor SMD
Rs1 068 Ohm 10W resistor Axial
Rs2 068 Ohm 10W resistor Axial
U1 LM2594M-3.3/NOPB Voltage regulator SSOP-8
U2 TMP102 Temp sensor (I2C) SSOP-6
U3 INA226 Current and voltage sensor SSOP-10
U4 INA226 Current and voltage sensor SSOP-10
3 position jumper block Std
5mm barrel jack, 2.1mm center pole Std
8 position screw terminals Std
Populated Ethernet Booster Pack (MSP430 MCU) Board
EPS PC board Board

Power/Temp Monitor and Control System (EPS/ECLSS) Budget

Preliminary Budget

Schematic Description Prototype Cost Production Cost
C1 68uF Capacitor $.49 $1.15
C2 120uF Capacitor $0.62 $0.62
Cf1 1uF capacitor $0.14 $1.15
Cf2 1uF capacitor $0.14 $1.15
D1 1N5817 Schottky diode $0.27 $0.19
L1 100uH Inductor $0.18 $0.09
Ra1 47k Ohm .25W Resistor $0.37 $0.03
Rb1 47k Ohm .25W Resistor $0.37 $0.03
Rb2 47k Ohm .25W Resistor $0.37 $0.03
Rf1 4.7 Ohm .25W resistor $0.37 $0.03
Rf2 4.7 Ohm .25W resistor $0.37 $0.03
Rf3 4.7 Ohm .25W resistor $0.37 $0.03
Rf4 4.7 Ohm .25W resistor $0.37 $0.03
RL1 180 Ohm .5W resistor $0.37 $0.03
RL2 180 Ohm .5W resistor $0.37 $0.03
Rs1 068 Ohm 10W resistor $2.14 $2.14
Rs2 068 Ohm 10W resistor $2.14 $2.14
U1 LM2594M-3.3/NOPB Voltage regulator $2.70 $2.70
U2 TMP102 Temp sensor (I2C) $5.95 $1.69
U3 INA226 Current and voltage sensor $6.33 $3.38
U4 INA226 Current and voltage sensor $6.33 $3.38
3 position jumper block $.22 $.13
5mm barrel jack, 2.1mm center pole $4.95 $1.12
8 position screw terminals $2.45 $2.45
Populated Ethernet Booster Pack (MSP430 MCU) $25.00 $25.00
EPS PC board (in qty. 10) $0.00 $12.00
Subtotal $58.21 $60.75
Labor $1362.50 $135.52
TOTAL $1420.71 $196.27

Power/Temp Monitor and Control System (EPS/ECLSS) Design Review

After the design is reviewed by the client and peers, issues will be posted here. Once these issues have been addressed, all tasks have been completed, and the parts have arrived, construction will begin.

06FEB2013 Client requested an engineering change to increase the current capacity from 10A to 20, survivable to 30.


Power/Temp Monitor and Control System (EPS/ECLSS) Detailed Design

Introduction

This is a temperature and power monitoring system for the radio/battery cabinets on wireless internet service providers (WISP) repeaters. Other uses of this project are satellite and HAB payloads. Attention will be paid to make the project multi-role, but not at the expense of the primary stakeholders (WISPs). The PCB design needs to be completed before assembly can begin. This will be completed while parts are on order, as some have a 2-3 week lead time in the quantities required.

Design Criteria Review

Block Diagram

Schematic

Bill Of Materials

Control Board
Schematic Description Package
C1 68uF Capacitor SMD
C2 120uF Capacitor Axial
D1 1N5817 Schottky diode SMD
L1 100uH Inductor SMD
Rb1 47k Ohm .25W Resistor SMD
Rb2 47k Ohm .25W Resistor SMD
U1 LM2594M-3.3/NOPB Voltage regulator SSOP-8
CN1 Molex70555-0038 Locking connector thru hole
CN2 Molex70555-0038 Locking connector thru hole
CN3 Molex70555-0038 Locking connector thru hole
CN4 Molex70555-0038 Locking connector thru hole
CN5 Molex70555-0038 Locking connector thru hole
J1 5mm barrel jack, 2.1mm center pole Std
EPS Board (MSP430 MCU and MAC IC) Board
Current Sensor Board
Schematic Description Package
CN1 Molex70555-0038 Locking connector Thru hole
Cf1 1uF capacitor SMD
2 position screw terminals Std
Rf1 4.7 Ohm .25W resistor SMD
Rf2 4.7 Ohm .25W resistor SMD
RL1 220 Ohm .5W resistor SMD
Rs 3.9 mOhm 5W resistor Axial
Ra1 47k Ohm .25W Resistor SMD
Ra2 47k Ohm .25W Resistor SMD
S1,2 2 pos DIP switch Thru hole
U3 INA226 Current and voltage sensor SSOP-10
Current Sensor PC Board Board
Molex 50-57-9404 (mating connector for cable) Cable
Molex 50-57-9404 (mating connector for cable) Cable
Alpha Wire 1174c SL005 4cond 22ga Cable
Temperature Sensor Board
Schematic Description Package
CN1 Molex70555-0038 Locking connector Thru hole
U2 TMP102 Temp sensor (I2C) SSOP-6
Temperature Sensor PC Board Board
Molex 50-57-9404 (mating connector for cable) Cable
Molex 50-57-9404 (mating connector for cable) Cable
Alpha Wire 1174c SL005 4cond 22ga Cable

Preliminary Budget

Control Board
Schematic Description Prototype Cost Production Cost
C1 68uF Capacitor $0.49 $1.15
C2 120uF Capacitor $0.62 $0.62
D1 1N5817 Schottky diode $0.27 $0.19
L1 100uH Inductor $0.18 $0.09
Rb1 47k Ohm .25W Resistor $0.37 $0.03
Rb2 47k Ohm .25W Resistor $0.37 $0.03
U1 LM2594M-3.3/NOPB Voltage regulator $2.70 $2.70
CN1 Molex70555-0038 Locking connector 0.97 $0.96
CN2 Molex70555-0038 Locking connector $0.97 $0.96
CN3 Molex70555-0038 Locking connector $0.97 $0.96
CN4 Molex70555-0038 Locking connector $0.97 $0.96
CN5 Molex70555-0038 Locking connector $0.97 $0.96
J1 5mm barrel jack, 2.1mm center pole $4.95 $1.12
EPS Board (MSP430 MCU and MAC IC) $0.00 $12.00
Populated Ethernet Booster Pack (MSP430 MCU) $25.00 $25.00
Labor $1,362.50 $120.12
SUBTOTAL $1,402.30 $167.85
Current Sensor Board
Schematic Description Prototype Cost Production Cost
CN1 Molex70555-0038 Locking connector $0.97 $0.96
Cf1 1uF capacitor $0.14 $1.15
Phoenix Contact 1714971 two position screw terminals $1.34 $1.31
Phoenix Contact 1714971 two position screw terminals $1.34 $1.31
Rf1 4.7 Ohm .25W resistor $0.37 $0.03
Rf2 4.7 Ohm .25W resistor $0.37 $0.03
RL1 220 Ohm .5W resistor $0.37 $0.03
Rs 4 mOhm 4W resistor Ohmite 14AFR004E $1.98 $1.23
Ra1 47k Ohm .25W Resistor $0.37 $0.03
Ra2 47k Ohm .25W Resistor $0.37 $0.03
S1,2 2 pos DIP switch $0.53 $0.49
U3 INA226 Current and voltage sensor $6.33 $3.38
Current Sensor PC Board $0.00 $4.00
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Alpha Wire 1174c SL005 4cond 22ga $1.00 $1.00
Labor $225.00 $62.09
SUBTOTAL $241.84 $77.81
Temperature Sensor Board
Schematic Description Prototype Cost Production Cost
CN1 Molex70555-0038 Locking connector $0.97 $0.96
U2 TMP102 Temp sensor (I2C) $5.95 $1.69
Temperature Sensor PC Board $0.00 $2.00
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Alpha Wire 1174c SL005 4cond 22ga $1.00 $1.00
Labor $75.00 $29.21
SUBTOTAL $84.28 $35.60
Completed Assembly as Specified
Board Prototype Cost Production Cost
Control Board $1,402.30 $167.85
Current Sensor Board $241.84 $77.81
Current Sensor Board $241.84 $77.81
Temperature Sensor Board $84.28 $35.60
TOTAL COST $1969.96 $359.07

General Overview

Welcome

Welcome to the Power/Temp Monitor and Control System (EPS/ECLSS) project Wiki. This wiki contains documentation covering the design, development, fabrication, and use of the Power/Temp Monitor and Control System (EPS/ECLSS), a board designed to monitor power consumption and ambient temperature within an electronics enclosure and report it via Ethernet. The forums would be a good place to start if you have questions about the thought process behind an item. In most cases, links to the appropriate forum discussions will be included in the wiki pages.

Philosophy

The idea behind the Power/Temp Monitor and Control System (EPS/ECLSS) project is to start small and simple while meeting the existing need, and then build on what is learned when moving to more capable and complex systems later on. This is in line with Mach 30's philosophy of starting (literally) from the ground up to build the infrastructure required to facilitate safe, routine, reliable, and sustained access to space.

Getting Involved

If you're interested in getting involved a good place to start would be the Initial Questions page. There you will find the foundational questions that will guide the rest of the Power/Temp Monitor and Control System (EPS/ECLSS) design process. There is also the navigation bar at the right to help you find a specific section of the documentation quickly.

History

I was notified by a friend whom the client, a general manager for a Wireless Internet Service Provider (WISP), approached for a project which he wasn't sure could be done for a reasonable price. The challenge is to build a method of monitoring voltage, current, and temperature of a battery bank and the charge circuit. The reason this is a challenge is that it must be performed remotely at wireless repeater sites on remote mountaintops with the data being carried by the backhaul link back to a server. This was the start of the Power/Temp Monitor and Control System (EPS/ECLSS) project.

Other Uses

Other WISPs have similar needs, and the least expensive solution is around $2000.00 according to the client who recently attended an industry conference and conferred with his peers. The Power/Temp Monitor and Control System (EPS/ECLSS) project also has some substantial aerospace applications which will be addressed in the modular version 2.0 and beyond. This monitoring and control system may also be used to monitor power and temperature on High Altitude Balloons (HAB) and satellite payloads. This is the reason for the terms in the title enclosed in parentheses; EPS referrs to the Electrical Power Subsystem of a spacecraft, and ECLSS to the Environmental Control and Life Support Subsystem.


Power/Temp Monitor and Control System (EPS/ECLSS) Initial Questions

Q1. Why are we making this?

This product is being made on request by a local business, a Wireless Internet Service Provider (WISP) who needs to monitor charge rate, currents, voltages, and temperatures in enclosures to estimate battery life and become informed of issues. These enclosures are at the top of 13-14,000 foot mountains and up radio towers, so durability and remote diagnostic information are the key.

Q2. Who is this for?

Primary client is a WISP, but the system will also work for HAB and satellite payloads with similar needs.

Q3. How will this be used?

The unit will monitor voltages and currents to determine system health and charge/discharge rates. This data coupled with ambient temperature sensing will accurately indicate battery life as well as provide diagnostic information before driving hundreds of miles, climbing to the top of a radio tower on the top of a snow covered peak only to find that you need a part which you did not bring with you.

Q4. What features does it need to have (now)?

Q5. What features does it need to have (later)?

Q6. What are the legacy requirements?

Q7. Who's going to build this?

The production units for the client will be built in Aaron's lab facility which has a static safe workstation. As this is an open hardware design, anyone is welcome to build as many as they like.

Q8. How many do we want to make?

The initial production run is for about 40 units. As this is an open hardware design, anyone is welcome to build as many as they like.

Q9. What is the budget?

The price to beat for this system is $2000 per unit. My design goal is to keep it under $100 cost per unit which will be sold to the client at cost plus labor.

Q10. What is the timeline?

ASAP. This product was needed by the client before the onset of winter, but he didn't know it this was possible within his budget. Going to a national WISP conference, he determined that his need was common in the industry. The development schedule follows:

Q11. What waste products will be produced by the manufacture and/or operation of this?

Unknown. All E-waste must be handled in an environmentally responsible manner in compliance with applicable law.


Navigation

Power/Temp Monitor and Control System (EPS/ECLSS)

Systems Engineering Process

  1. Initial Questions
  2. Requirements Document
  3. Block Diagram
  4. Architecture Study
  5. Preliminary Design
  6. Detailed Design
  7. Design Review
  8. Procurement/Manufacture
  9. Assembly
  10. Testing
  11. Deployment
  12. Disposal

Documentation

  1. Budget
  2. Timeline
  3. BOM
  4. Schematics and PCB Files
  5. Software Source Code
  6. Assembly Instructions
  7. Operating Manual
  8. Safety Procedures
  9. Software/Firmware Summary
  10. Meeting Minutes
  11. Licensing and Attribution
  12. Errata

EPS Preliminary Design

Introduction

This design document is broken down in to multiple sections: the Preliminary Design Criteria Review, the Preliminary Schematic, the Preliminary Bill of Materials, and finally the Preliminary Budget. Each of these sections has information which is preliminary in nature, yet attempts have been made to make these as accurate as possible.

Preliminary Design Criteria Review

Preliminary Schematic

Preliminary Bill Of Materials

Control Board
Schematic Description Package
C1 68uF Capacitor SMD
C2 120uF Capacitor Axial
D1 1N5817 Schottky diode SMD
L1 100uH Inductor SMD
Rb1 47k Ohm .25W Resistor SMD
Rb2 47k Ohm .25W Resistor SMD
U1 LM2594M-3.3/NOPB Voltage regulator SSOP-8
CN1 Molex70555-0038 Locking connector thru hole
CN2 Molex70555-0038 Locking connector thru hole
CN3 Molex70555-0038 Locking connector thru hole
CN4 Molex70555-0038 Locking connector thru hole
CN5 Molex70555-0038 Locking connector thru hole
J1 5mm barrel jack, 2.1mm center pole Std
EPS Board (MSP430 MCU and MAC IC) Board
Current Sensor Board
Schematic Description Package
CN1 Molex70555-0038 Locking connector Thru hole
Cf1 1uF capacitor SMD
2 position screw terminals Std
Rf1 4.7 Ohm .25W resistor SMD
Rf2 4.7 Ohm .25W resistor SMD
RL1 220 Ohm .5W resistor SMD
Rs 3.9 mOhm 5W resistor Axial
Ra1 47k Ohm .25W Resistor SMD
Ra2 47k Ohm .25W Resistor SMD
S1,2 2 pos DIP switch Thru hole
U3 INA226 Current and voltage sensor SSOP-10
Current Sensor PC Board Board
Molex 50-57-9404 (mating connector for cable) Cable
Molex 50-57-9404 (mating connector for cable) Cable
Alpha Wire 1174c SL005 4cond 22ga Cable
Temperature Sensor Board
Schematic Description Package
CN1 Molex70555-0038 Locking connector Thru hole
U2 TMP102 Temp sensor (I2C) SSOP-6
Temperature Sensor PC Board Board
Molex 50-57-9404 (mating connector for cable) Cable
Molex 50-57-9404 (mating connector for cable) Cable
Alpha Wire 1174c SL005 4cond 22ga Cable

Preliminary Budget

Control Board
Schematic Description Prototype Cost Production Cost
C1 68uF Capacitor $0.49 $1.15
C2 120uF Capacitor $0.62 $0.62
D1 1N5817 Schottky diode $0.27 $0.19
L1 100uH Inductor $0.18 $0.09
Rb1 47k Ohm .25W Resistor $0.37 $0.03
Rb2 47k Ohm .25W Resistor $0.37 $0.03
U1 LM2594M-3.3/NOPB Voltage regulator $2.70 $2.70
CN1 Molex70555-0038 Locking connector 0.97 $0.96
CN2 Molex70555-0038 Locking connector $0.97 $0.96
CN3 Molex70555-0038 Locking connector $0.97 $0.96
CN4 Molex70555-0038 Locking connector $0.97 $0.96
CN5 Molex70555-0038 Locking connector $0.97 $0.96
J1 5mm barrel jack, 2.1mm center pole $4.95 $1.12
EPS Board (MSP430 MCU and MAC IC) $0.00 $12.00
Populated Ethernet Booster Pack (MSP430 MCU) $25.00 $25.00
Labor $1,362.50 $120.12
SUBTOTAL $1,402.30 $167.85
Current Sensor Board
Schematic Description Prototype Cost Production Cost
CN1 Molex70555-0038 Locking connector $0.97 $0.96
Cf1 1uF capacitor $0.14 $1.15
Phoenix Contact 1714971 two position screw terminals $1.34 $1.31
Phoenix Contact 1714971 two position screw terminals $1.34 $1.31
Rf1 4.7 Ohm .25W resistor $0.37 $0.03
Rf2 4.7 Ohm .25W resistor $0.37 $0.03
RL1 220 Ohm .5W resistor $0.37 $0.03
Rs 4 mOhm 4W resistor Ohmite 14AFR004E $1.98 $1.23
Ra1 47k Ohm .25W Resistor $0.37 $0.03
Ra2 47k Ohm .25W Resistor $0.37 $0.03
S1,2 2 pos DIP switch $0.53 $0.49
U3 INA226 Current and voltage sensor $6.33 $3.38
Current Sensor PC Board $0.00 $4.00
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Alpha Wire 1174c SL005 4cond 22ga $1.00 $1.00
Labor $225.00 $62.09
SUBTOTAL $241.84 $77.81
Temperature Sensor Board
Schematic Description Prototype Cost Production Cost
CN1 Molex70555-0038 Locking connector $0.97 $0.96
U2 TMP102 Temp sensor (I2C) $5.95 $1.69
Temperature Sensor PC Board $0.00 $2.00
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Alpha Wire 1174c SL005 4cond 22ga $1.00 $1.00
Labor $75.00 $29.21
SUBTOTAL $84.28 $35.60
Completed Assembly as Specified
Board Prototype Cost Production Cost
Control Board $1,402.30 $167.85
Current Sensor Board $241.84 $77.81
Current Sensor Board $241.84 $77.81
Temperature Sensor Board $84.28 $35.60
TOTAL COST $1969.96 $359.07

Power/Temp Monitor and Control System (EPS/ECLSS) Requirements Document

Introduction

This requirements document is currently being discussed on the forums here. The requirements list matches up to the Initial Questions in step one of the Systems Engineering process as shown below. Each requirement is labeled with GSR (Ground Station Requirement), followed by the number of the initial question that the requirement corresponds to, followed by a dot and then the ID number of the requirement.

Technical Requirements

Technical requirements are those requirements which include measurable performance values. Each technical requirement should be verified through testing to ensure the design meets the requirement.

Project Requirements

Project requirements are the remaining requirements which are not tied to specific performance values.

Future V2.0 Requirements

These specifications are for reference only so that future features can be accommodated in the current design where practical.

Version 2.0:

Beyond Version 2.0:

Glossary

ADC - Analog to digital converter.
Buffered - Indirect connection which allows input which would potentially be destructive to the unit to be handled safely.
Burn-in - A practice to test all production units under load for a proscribed time, causing and failures to occur during testing instead of after deployment.
Clipped - In this instance, preventing input which would be damaging to components from exceeding a certain level.
ECLSS - Environmental Control and Life Support Subsystem, a component block of a spacecraft or HAB payload.
EPS - Electrical Power Subsystem, a component block of a spacecraft or HAB payload.
GPIO - General Purpose Input and Output, a way of connecting a sensor to a computer or microcontroller.
HAB - High Altitude Balloon
Hall effect - The production of voltage transverse to an electric current in the conductor and a magnetic field perpendicular to the current.
Hall effect sensor - A sensor which uses the hall effect to detect a magnetic field or electric current.
Isolation - In this instance, the ability of a sensor to prevent high voltage from a sensed circuit from crossing over to the sensor's data connection.
MAC controller - A chip which contains all the electrical and logic circuits to connect to Ethernet connections.
Magnetics - The passive components on an Ethernet jack which prevent noise and cross talk from impacting the flow of high speed data.
Microcontroller - A small single purpose computer generally used for instrumentation and control applications.
Op-amp - An electronic component which can be used to change signal levels up or down to match the recipient component's abilities.
Resolution - In this instance, the number of bits used in the ADC divided by the full scale value. This yields the value per binary step.
Scaled - In this instance, the practice of using an op-amp to reduce a signal by a set percentage or ratio.
WISP - Wireless Internet Service Provider.


Power/Temp Monitor and Control System (EPS/ECLSS) Schematics and PCB Files

Schematic Diagram:

PCB Files

PCB layout will be complete by 25 FEB 2013.


Navigation

Power/Temp Monitor and Control System (EPS/ECLSS)

Systems Engineering Process

  1. Initial Questions
  2. Requirements Document
  3. Block Diagram
  4. Preliminary Design
  5. Detailed Design
  6. Design Review
  7. Procurement/Manufacture
  8. Assembly
  9. Integration
  10. Testing
  11. Delivery/Deployment
  12. Disposal

Documentation

  1. Budget
  2. Timeline
  3. BOM
  4. Schematics and PCB Files
  5. Software Source Code
  6. Assembly Instructions
  7. Operating Manual
  8. Safety Procedures
  9. Software/Firmware Summary
  10. Meeting Minutes
  11. Licensing and Attribution
  12. Errata
  13. Versions

Power/Temp Monitor and Control System (EPS/ECLSS) Timeline

Date Phase Status
29 JAN @ 1200 Project inception on ODE Completed
29 JAN @ 1400 SEP Step 1: Initial Questions Completed
29 Jan @ 1600 SEP Step 2: Requirements Document Completed
29Jan @ 1900 SEP Step 3: Block Diagram Completed
30 Jan @ 1700 SEP Step 4: Preliminary Design Completed
31 Jan @ 1700 SEP Step 6: Detailed Design Completed, PCB layout scheduled for 25 FEB 2013
01 Feb @ 0800 SEP Step 7a: Design Review (filed) Completed
04 Feb @ 1400 SEP Step 7b: Design Review (returned) -
04 Feb @ 1500 SEP Step 8: Parts ordering -
18 Feb SEP Step 9: Assembly -
NA SEP Step 10: Integration not necessary
18 Feb SEP Step 11: Testing begins immediately after assembly is complete and continues until delivery or deployment
04 Mar @ 0800 SEP Step 12: Delivery/Deployment -
15 Mar Market solution to other potential clients -
NA SEP Step 13: Disposal -

Wiki

Welcome to the Power/Temp Monitor and Control System (EPS/ECLSS) project Wiki. This wiki contains documentation covering the design, development, fabrication, and use of the Power/Temp Monitor and Control System (EPS/ECLSS), a board designed to monitor power consumption and ambient temperature within an electronics enclosure and report it via Ethernet. The forums would be a good place to start if you have questions about the thought process behind an item. In most cases, links to the appropriate forum discussions will be included in the wiki pages.

The idea behind the Power/Temp Monitor and Control System (EPS/ECLSS) project is to start small and simple while meeting the existing need, and then build on what is learned when moving to more capable and complex systems later on. This is in line with Mach 30's philosophy of starting (literally) from the ground up to build the infrastructure required to facilitate safe, routine, reliable, and sustained access to space.

If you're interested in getting involved a good place to start would be the Initial Questions page. There you will find the foundational questions that will guide the rest of the Power/Temp Monitor and Control System (EPS/ECLSS) design process. There is also the navigation bar at the right to help you find a specific section of the documentation quickly.