TRI-M ENGINEERING HE104 Manual de usuario

WinSystems partners with Tri-M Systems

WinSystems®is pleased to be partnered with the Tri-M®industrial

power supply group. Tri-M®is a leader in industrial PC/104 DC/DC

power supplies. With Tri-M®’s outstanding reputation for support,

we recommend all technical and RoHS inquiries regarding their

modules be sent to Tri-M®directly. As always, the WinSystems

Applications Engineering department is available to assist as

needed.

HE104 TRI-M®Technical Manual

WinSystems, Inc.

715 Stadium Dr.

Arlington, TX 76011

http://www.winsystems.com

Email: [email protected]

Phone: 817.274.7553

Tri-M Systems and Engineering, Inc.

Vancouver Sales Ofce

Unit 100

1407 Kebet Way

Port Coquitlam, BC V3C 6L3

http://www.tri-m.com

Canada Telephone: 604.945.9565

Toll free: 800.665.5600

PC/104 Vehicle

Power Supply

High Efficiency & Smart Charging

Vehicle Power Supply

DC to DC Convertor

Manufactured by

TRI-M ENGINEERING

Engineered Solutions for Embedded Applications

Technical Manual

P/N: HE104MAN-V8

Revision: 23 June 2005

TRI-M ENGINEERING

1407 Kebet Way, Unit 100

Port Coquitlam, BC V3C 6L3

Canada

http:// www.Tri-M.com

Tel 604.945.9565

North America 800.665.5600

Fax 604.945.9566

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

CHAPTER 1: INTRODUCTION........................................................................................................................................4

1.1GENERALDESCRIPTION.....................................................................................................................................4

1.2FEATURES...............................................................................................................................................................5

1.3SPECIFICATIONS.......................................................................................................................................................6

2.1INTRODUCTION.........................................................................................................................................................7

2.2POWER CONSIDERATIONS.........................................................................................................................................8

2.3HE104 CONNECTORS...............................................................................................................................................8

2.3.1 Main Input Power Connector...........................................................................................................................8

2.3.2 Output Power Connector.................................................................................................................................9

2.3.3 Battery Power Connector (Optional)................................................................................................................9

2.3.4 Onboard PC “Boost” Adaption (Optional).........................................................................................................9

2.4BUS TERMINATION (OPTIONAL)................................................................................................................................10

2.5INSTALLATION ONTO PC104 MODULES.....................................................................................................................10

2.6JUMPER SELECTION................................................................................................................................................10

2.6.1 LED Jumper Enable/Disable .........................................................................................................................10

2.6.2 +5VDC Low Q/ Noise (Q=quiescent).............................................................................................................11

2.6.3 +12VDC Low Q/ Noise..................................................................................................................................11

2.6.4 Mezzanine Expansion Headers.....................................................................................................................11

2.7PC/104BUS INTERRUPTS (OPTIONAL) .....................................................................................................................12

2.8POWER MANAGEMENT CONTROLLER PM104 (OPTIONAL)...........................................................................................13

2.9LOW INPUT ALARM .................................................................................................................................................14

2.10HE104 EFFICIENCY AND HEAT DISSIPATION CALCULATION.......................................................................................15

CHAPTER 3: THEORY OF OPERATION ......................................................................................................................16

3.1INPUT POWER PROTECTION......................................................................................................................................16

3.2SWITCHING REGULATOR,+5VDC............................................................................................................................16

3.3SWITCHING REGULATOR,+12VDC...........................................................................................................................17

3.4CHARGE PUMPS.....................................................................................................................................................17

3.5FILTER CAPACITORS...............................................................................................................................................18

3.6BUS TERMINATION (OPTIONAL)................................................................................................................................19

APPENDIX 1: HE104, +5V REGULATOR BLOCK DIAGRAM:......................................................................................20

APPENDIX 2: ADVANTAGES OF USING AC TERMINATION:.....................................................................................22

APPENDIX 3: INSTALLATION HINTS FOR THE HE104 POWER SUPPLY:.................................................................23

APPENDIX 4: VEHICLES ARE AN ELECTRONICS NIGHTMARE:...............................................................................23

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

PREFACE

This manual is for integrators of applications of embedded systems. It contains information on

hardware requirements and interconnection to other embedded electronics.

DISCLAIMER

Tri-M Engineering makes no representations or warranties with respect to the contents of this

manual, and specifically disclaims any implied warranties of merchantability or fitness for any

particular purpose. Tri-M Engineering shall under no circumstances be liable for incidental or

consequential damages or related expenses resulting from the use of this product, even if it has been

notified of the possibility of such damages. Tri-M Engineering reserves the right to revise this

publication from time to time without obligation to notify any person of such revisions. If errors are

found, please contact Tri-M Engineering at the address listed on the title page of this document.

No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or

translated into any language or computer language, in any form or by any means, electronic,

mechanical, magnetic, optical, chemical, manual, or otherwise, without the express written

permission of Tri-M Engineering.

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

CHAPTER 1: INTRODUCTION

1.1 GENERAL DESCRIPTION

The HE104 multiple output DC to DC 50 watt converter is a high efficiency, high performance unit

that can be supplied with +5V, +12V outputs only or can include features such as, Power

Management, Universal Battery Charger, AC Bus termination, -5V output, -12V output and custom

output voltages from -42V to +42V. The HE104 is designed for low noise embedded PC/104

computer systems, which has a wide input range of 6 to 40V(>6:1) and is ideal for battery or

unregulated input applications. The HE104 is specifically designed for vehicular applications and has

heavy-duty transient suppressors (5000W) that clamp the input voltage to safe levels. Further, it is

able to maintain normal power supply operation.

The HE104 is a state-of-the-art MOSFET based design that provides outstanding line and load

regulation with efficiencies up to 95 percent. Organic Semiconductor Capacitors provide filtering,

which reduces ripple noises below 20mV. The low noise design makes the HE104 ideal for use

aboard aircraft, military applications or wherever EMI or RFI must be minimized. The +5VDC and

+12VDC outputs are controlled by a constant off-time current mode architecture regulator, which

provides excellent line and load transient response.

The +12VDC boost regulator uses the +5VDC as input power, so it can operate without dropout from

6 to 40V input and supply 2A. The +5VDC output is protected from output shorts by a high-speed

pulse-by-pulse current limit circuit. Furthermore, +12VDC output is protected from shorts by the

current limiting of the +5VDC controller.

A “plug-in” Universal Battery Charger (BC104) is available for the HE104 to charge Lead-Acid, NiCd

and NiMH batteries. Charge currents can be up to1.5A and battery charging voltages range from 6 to

40V.

The Power Management controller (PM104) allows for timed on/off control of the HE104, bus

interrupts on impending power failure, current limit setting and intelligent charge termination for the

BC104.

The HE104 is provided in a PC/104 form factor compliant size, which includes the 8bit and 16bit

PC/104 expansion bus header. All generated voltages are provided to their related power supply pins

on the PC/104 expansion bus and are available for off-board use through a screw terminal block.

PC/104 AC bus termination is an option that is available on the HE104,that provides the cleanest

possible signals on the PC/104 bus.

The HE104 can be configured to meet almost any power supply need for embedded PC/104

applications. This could be a simple +5V application, which provides for back lighted LCD panels or

a full UPS (un-interruptible power supply configuration).

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

1.2 Features

•DC to DC convertor for PC/104 bus equipped products.

•“Load Dump” transient suppression on input power supply.

•Operates from 6VDC to 40VDC input.

•“Stacks” onto the PC/104 bus.

•Passthrough or non-passthrough 8 bit and 16 bit versions.

•5V, 12V standard, -12V, -5V and battery charger optional.

•Highly compact, 100 percent PC/104 conforming.

•AC bus termination available.

•Screw terminals provide off-board connection to output voltages.

Figure 1-1, HE104 Dimensions

1000mil=1in

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

1.3 Specifications

Power Supply Specifications

Model HE104

5V output* 10A

12V output 2A

-5V output 400mA

-12V output 500mA

Input Voltage Range 6 to 40V

Load Regulation ** <60mV

Line Regulation ** +40mV

Output temp.drift ** <40mV

Switching Frequency 75kHz

Max. Input Transient 125V for 100msec

Output Ripple ** <20mV

Conducted Susceptibility ** >57db

Efficiency ** up to 95%

Temp Range -40 to 85C

Quiescent current *** 2mA

Size, PC/104 form factor compliant **** 3.55"W.x 3.75"L x 0.6" Height

*Current rating includes current supplied to 12V, -12V, & -5V regulators.

**Measured on the 5V output.

***LEDS disabled, Low Quiescent mode enabled.

****Not including passthrough pins.

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

CHAPTER 2: CONFIGURATION AND INSTALLATION

2.1 Introduction

This chapter describes the configuration and installation of the HE104 power supply. In addition,

section 2.2 provides a formula to calculate the available +5VDC. Figure 2-1 shows the HE104

connectors, jumpers and other options.

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

2.2 Power Considerations

Usable +5V output =10A – (I [-5] + I [-12]

•

2.4 + I [12]

•

2.4)

0.8

The +5V switching regulator is rated at 10A maximum output however, the +5V output, supplies

power to the +12VDC, -5VDC and –12VDC regulators. To obtain the usable range of +5V output,

“derate” according to the use of +12VDC, -5VDC and –12VDC. Use the following formulae to

calculate the maximum usuable output.

Where: I[-5] = -5VDC current load

I[-12] = -12VDC current load

I[12] = 12VDC current load

Assuming 90 percent convertor efficiency (actual efficiency may vary).

2.3 HE104 Connectors

2.3.1 Main Input Power Connector

Input power is connected to the “pluggable” block, CN1, which is removable from the socket

connector on the circuit board. The power supply accepts DC input voltages in the range of

6VDC to 40VDC.

Unregulated vehicle power is connected as follows:

-Terminal 1: “hot” polarity

-Terminal 2: Common (0VDC)

!! CAUTION !!

To allow operation at the lowest possible input voltages (6VDC) and for the best efficiency, there is

no input Reverse Polarity Diode (RPD) provided on the HE104 without a battery charger option. If

input RPD is required, add RPD to the HE104 part number:

-Example HE 104-512-16-RPD

Note: Adding the RPD results in an increased power loss. For heat dissipation estimation please

refer to section 2.11.

23 June 2005 HE104MAN-V8 Manual

Tri-M Engineering Tel: 800.665.5600, 604.945.9565

1407 Kebet Way, Unit 100 Fax: 604.945.9566

Port Coquitlam, BC V3C 6L3 E-mail: info@tri-m.com

Canada Web site: www.tri-m.com

2.3.2 Output Power Connector

Output power is available for non-PC/104 use via connector CN2.

-Terminal 1: +5VDC output

-Terminal 2: Common

-Terminal 3: +12VDC

-Terminal 4: -12VDC output (optional)

-Terminal 5: -5VDC output (optional)

2.3.3 Battery Power Connector (Optional)

Batteries are connected to the screw terminal block, CN3. The HE104 accepts DC battery

voltages in the range of 6.5V to 40DVC through the Battery Power Connector. Two external

signals can be connected to the battery terminal block for use by add-on modules plugged into

the mezzanine header connectors. Connect to the HE104 Battery Terminal Block as follows:

-Terminal 1: Common of battery

-Terminal 2: Positive Battery Terminal

-Terminal 3: External signal 1

-Terminal 4: External signal 2

Note: When Optional Plug-IN Boost regulator (VR3) is ordered, batteries or external signals

cannot be connected to CN3. See section 2.3.4

2.3.4 Onboard PC “Boost” Adaption (Optional)

An optional converter Boost pump (model NMH05XXS, XX=output voltage, + 5V, +9V, +12V,

+15V) can be installed in location VR3 to provide custom output voltages. The NMH charge

pumps have an isolated positive and negative output and a maximum 2-watt capacity. A

minimum load of 10 percent is required for proper operation. By connecting the charge pump to

other voltages, the user can create more or less supplies, as well as elevated and negative

voltages (i.e.: The charge pump “0V” is not connected to the HE104 common).

- Terminal 1: Common of battery

- Terminal 2: -V output

- Terminal 3: 0V

- Terminal 4: +V output

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