ACU6. Technical Reference Manual. Specifications Interfacing Dimensions. Document topics. ANSARI Controller Unit Type 6 technical reference manual

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1 ACU6 Technical Reference Manual ANSARI Controller Unit Type 6 technical reference manual Document topics Specifications Interfacing Dimensions Document Version: January 2013 By ANSARI GmbH Friedrich-Ebert-Damm Hamburg info@ansari.de Tel.: +49 ( Fax: +49 (

2 (ACU6 Table of Contents 1 Introduction of ACU Description Features Block diagram Applications Specifications External Signal Interface Schematics Sensor Interface Schematics Printed Circuit board (PCB design Dimensions Assembly Interfacings Electrical Pin Description This document contains confidential and proprietary information of ANSARI GmbH

3 (ACU6 1 Introduction of ACU6 Front and back side views of ACU6 1.1 Description ANSARI controller Unit Type 6 (ACU6 is designed to build a sensor and/or actor module in the field to cover many customer requirements in a very small form factor. One of the major advantages of this module is the ability to communicate over the power line with speeds up to baud. If ACU6 is used as a sensor module it is capable of storing sensor data locally using an onboard serial Flash up to 64MByte of capacity. Together with each record, the ACU6 can also store a time stamp and the temperature of the sensor at the recording time. The form factor of ACU6 is kept so small, that it can be integrated into a very small housing. The PCB is optimized to be fitted into M12 screw housing usual in the industry. This document contains confidential and proprietary information of ANSARI GmbH

4 (ACU6 The communication over power line reduces harness and connector size, increases reliability, saves node costs and increases the network throughput. The transceiver operates as an AC/DC power line transceiver that replaces the RS232 transceivers thus eliminating the extra data wires. It contains a host UART interface, modem and line driver and receivers. A virtual network is created over the power line, which consists of a Master and Salves. Unlimited number of ACU6 modules can be networked together over 2 wires of power line to build complex virtual groupings of sensors and actors. Each module may operate as a slave in a multiplex network. Multiple networks may operate concurrently over the same power line by using different carrier frequencies. Supported channel frequencies are: 4.5 MHz, 5.5 MHz, 6 MHz and 6.5 MHz, but only two of the frequencies are supported in a configuration at a time, which is definable at assembly time. Data transfer rates are software selectable between 9.6 kbps and 57.6 kbps. Each module is able to operate without a need of a host. Digital processing and interfacing of the module is based on a 16-bit RISC processor with 16 MIPS, 128 kbyte Flash and 10 kbyte SRAM. The ADC module is a 200 ksps fast 12-bit SAR analog-to-digital converter with reference generator for sensor biasing if needed. Powerful signal conditioning at input stage allows interfacing of various types of sensors to this module. The analog input is a current-feedback instrumentation amplifier that consists of two auto-zeroed input stages. These two input stages are operated in a ping-pong fashion: as one stage is auto-zeroed the other stage provides the path between the input pins and the output. The auto-zeroing decreases offset, offset drift, and 1/f noise while the ping-pong architecture provides a continuous path between the input and the output. ACU6 can support many different digital type of I/O signals to cover various small signal controlling and driving requirements in an actor. It can also build a gateway between power line data and I²C, SPI or UART interfaces. 1.2 Features General Very small form factor: only 49 x 8 mm 16-bit mixed signal RISC microcontroller with 16 MIPS 128kByte code Flash, 10Kbyte SRAM and additional 4MByte external serial Flash 12-bit 200ksps Analog-to-Digital converter with Reference voltage and auto scan Basic timers with real-time clock feature and time stamp for logging purposes SPI controlled programmable gain amplifier with input multiplexer Local long term logging capability for up to 8 Million records with time & temperature stamps Power Line Data Interface Noise robust UART over power line transceiver Four selectable carrier frequencies Selectable bit rate between 9.6 kbps and 57.6 kbps Operates as master or slave in a multiplex network Multiple networks may operate over the same power line Communicates over wide range of AC/DC voltage lines This document contains confidential and proprietary information of ANSARI GmbH

5 (ACU6 Features continued Sensor Input Interface Low Noise: 28nV/ Hz Offset: 10µV (max Zerø Drift: 50nV/ C Input Offset Current: 2nA max Gain Error: 0.15% max Gains: 10, 20, 50, 100, 200, 500, 1000 Operating temperature range -40 C to 125 C GBW: 8kHz to 8MHz Input channel MUX Min CMRR 110 db Max non-linearity 100 ppm Max gain drift 16 ppm/ C Input fault detection 1.3 Block diagram 1.4 Applications There are 3 major focuses for ACU6: Sensor module able to handle two sensing channels for any combination of sensors like: Light-, IR-, Gas-, Motion-, Temperature-, Humidity-, Smoke-, Magnetic- or other sensors/detectors applications. Actor module able to handle driving signals for many actions in the environment like turning a device on or off, driving a DC- or Step-motor, driving magnetics for mechanical motions, etc. Gateway module Being a gateway between different interfaces like SPI, I²C, UART and the power line communication Of course mixing of mentioned capabilities listed above, is also supported as long as I/Os are given. This document contains confidential and proprietary information of ANSARI GmbH

6 (ACU6 In general, the major applications supported are those, which get attractive when communication over power line is desired. Especially virtually grouping of modules and networked modules, unlimited in the number, over same power line wires are well supported applications by ACU6 on system interfacing side. On the local interfacing side many known applications can be covered by the analog and digital interfaces realized in the electronic. The figure above shows the ACU6 module implemented into M12 housing. The front of M12 tube can be assembled with a desired sensor or actor as needed. Using a SMA type connector to connect the power line to the module is an option to secure more the modulated data over the power line against a noisy environment. The room between the SMA connector body and the M12 tube itself allows the LED lights on the board to illuminate the status of the module to outside world if a transparent adhesive material is used to fix the module inside the tube. If desired a shielded or non-shielded cable can be directly soldered to the module and be fixed together into the housing to reduce material cost. The ACU6 is also as an add-on module available to be connected into other equipment over header connectors as shown in the figure on the right side. The pinning of the connectors is compiled in a way, so that many applications can be realized using only one or two of shown connectors in the figure to operate fully in a desired application. The connectors may be selected as male or female types. The switching mode power supply on the board (SMPS generates 5V out of the input voltage and is capable to drive up to 300mA current. The board itself needs only about 60mA of this current internally. The carrier board can use this 5V for its needs as long as the current consumed doesn t exceed 220mA. This document contains confidential and proprietary information of ANSARI GmbH

7 (ACU6 2 Specifications 2.1 External Signal Interface Schematics Serial data link is realized over µcontroller s UART, which passes through the modem device U2. Serial bit streams are modulated or demodulated on one of available carrier frequencies and runs through some protection and filtering components to the power line pin #16. The corresponding ground is pin #15. Over the same pins the applied power is routed to the SMPS (U10, which generates 5V at output, capable of driving 300mA in total. The maximum input voltage to the SMPS should not exceed 28V. Therefore V1 is protecting the circuit in the input stage against higher voltage spikes. The output of the DC-DC converter is available on pin #17 for external usages. Since the module itself needs about 60mA, external load should not exceed 220mA. The modulated data is not only available on pin #16, but also on pin #11 for such cases, when ACU6 is powered over pin #11. Pin #16 and XF1 are electrically same PWRmain signal. On the local side many of the µcontroller pins are feeding the pin #1 through pin #10 of the ACU6 board. They are multifunction pins and are activated based on actual application / hardware needs. Also JTAG programming pins are routed to these pins to program and debug the module while developing. Over the µcontroller specific interrupt, analog and port-mode pins, almost every desired application may be realized as long as the number of available pins is not limiting the realization of the desired function. This document contains confidential and proprietary information of ANSARI GmbH

8 (ACU6 2.2 Sensor Interface Schematics As shown in the schematic above a sensor can be connected to pin #12 and pin #13. Biasing voltage is over software configuration available. R12, R14 and R18 are impedance matching resistors and may be required dependent to used sensor element. The MUX in U4A allows selecting between one differential input signal and two switched single ended input signals for measurements. R20 is placed on the PCB near to sensor pins to observe the temperature as near as possible to the sensor. The ADC can sample with 200ksps in total. If sensor and temperature values both need to be sampled, then the sampling rate reduces to 100ksps for each in average if same time slot is taken. The whole dynamic range of the ADC is 4096 steps (due to 12 bit-adc between Vref+ and Vref-. The Vref+ is internally set to 1,5V or 2.0V or 2,5V. The Vref- can be set between GND and 1,3V in 8mV steps using the digital potentiometer U6A. Independently over U6B a sensor ground voltage can also be defined in 8mV steps to eliminate any DC offset values given by the sensor, when the offset is out of focus of the application. The programmable gain amplifier (PGA U4 can also control the signal bandwidth to the ADC between 8 khz and 8 MHz, which is gain dependent. The PGA can be programmed to the gains of: 10, 20, 50, 100, 200, 500 and 1000 in differential mode. In single ended mode a divider by 50 reduces the possible signal gains to 0.2, 0.4, 1, 2, 4, 10 and 20. With changing C23, R16 and R19 values other gain and signal bandwidths can be created for special applications. Pin #11 has special current driving capability. It can be driven by peripherals available with their pins available in port mode section of the µcontroller like the timer peripheral. As a result special clocking shames can be generated and drive an actor element with +Vin up to 480mA. The pins #12 and #13 can also be configured as digital pins and also available to the port mode signals given by the µcontroller. At the same time these two pins may be configured as interrupt or comparator input pins for the µcontroller. This document contains confidential and proprietary information of ANSARI GmbH

9 (ACU6 2.3 Printed Circuit board (PCB design The PCB design is done on 6 layers, in 100µm technology. The board has a total number of 121 plated drilling holes. The PCB has a thickness of approx. 1mm PCB CAD design view: PCB CAD-photo (Top view: PCB CAD-photo (Bottom view: 2.4 Dimensions This document contains confidential and proprietary information of ANSARI GmbH

10 (ACU6 2.5 Assembly PCB CAD-assembly (Top view: PCB CAD-assembly (Bottom view: 2.6 Interfacings This document contains confidential and proprietary information of ANSARI GmbH

11 (ACU6 2.7 Electrical Pin Description PIN # Name Type Description Note 1 TDO Int3 PM7 In JTAG mode: data out pin In normal mode: either as an interrupt input pin or as a normal pin or in special port mode as a desired peripheral pin 2 Reset Input µcontroller Reset pin Low active 3 TDI Int2 PM6 4 SenAct IO3 5 TMS Int1 PM3 Analog In JTAG mode: data input pin In normal mode: either as an interrupt input pin or as a normal pin or in special port mode as a desired peripheral pin µcontroller analog input pin for ADC/Comparator or general purpose I/O pin In JTAG mode: TMS pin In normal mode: either as an interrupt input pin or as a normal pin or in special port mode as a desired peripheral pin 0 V ref + 6 SenAct SGV Power Sensor Ground Voltage(SGV, configurable in 8mV steps mv 7 TCK Int0 8 SenAct IO2 Analog In JTAG mode: Clock pin In normal mode: either as an interrupt input pin or as a normal pin µcontroller analog input pin for ADC/Comparator or a general purpose I/O pin or in special port mode as a desired peripheral pin or negative analog sensor input signal (same as pin#13 9 GND Power Ground pin 0V 10 SenAct PWR Power 11 SenAct PWR Power 12 SenAct IO1 13 SenAct IO2 Analog Analog 14 GND Power Ground pin 15 Vin Power Ground pin Power Supply for connected sensor or actor element or main power supply switched over Q2 (and body diode of Q2 Same as pin #11 Power Supply for connected sensor or actor element or main power supply switched over Q2 (and body diode of Q2 Same as pin #10 µcontroller analog input pin for ADC/Comparator or a general purpose I/O pin or in special port mode as a desired peripheral pin or negative analog sensor input signal (same as pin#13 µcontroller analog input pin for ADC/Comparator or a general purpose I/O pin or in special port mode as a desired peripheral pin or negative analog sensor input signal (same as pin#8 0 SGV 0 28 V 0 28 V 0 V ref + 0 SGV 16 Vin+ Power Main Input Power Supply 0 28 V 17 +5Vout Power +5V regulated output supply ( for loads up to 220mA +5V ±10% This document contains confidential and proprietary information of ANSARI GmbH