Tri-M Systems HE104 User Manual

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HE104 TRI-M® Technical Manual

Tri-M Systems and Engineering, Inc.

Vancouver Sales Ofce

Unit 100
1407 Kebet Way
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WinSystems, Inc.

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© 2008 WinSystems, Inc. All rights reserved.

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 [phone]

North America 800.665.5600

Fax [phone]

23 June 2005 HE104MAN-V8 Manual

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

1.1 GENERAL DESCRIPTION.....................................................................................................................................4

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

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

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

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

2.3 HE104 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

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

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

2.6 JUMPER 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

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

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

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

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

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

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

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

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

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

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

3.6 BUS 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

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23 June 2005 HE104MAN-V8 Manual

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.

COPYRIGHT © 2000-03-22 TRI-M ENGINEERING

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.

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23 June 2005 HE104MAN-V8 Manual

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).

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23 June 2005 HE104MAN-V8 Manual

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

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23 June 2005 HE104MAN-V8 Manual

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.

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23 June 2005 HE104MAN-V8 Manual

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.

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23 June 2005 HE104MAN-V8 Manual

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.

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23 June 2005 HE104MAN-V8 Manual

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

Tri-M Engineering Tel: [phone]

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Port Coquitlam, BC V3C 6L3 E-mail: [e-mail]
Canada Web site: www.tri-m.com

9