Tri-M Systems V104 user guide

V104 Vehicle Power Supply

A PC/104 DC to DC Converter

Manufactured by

TRI-M ENGINEERING

Engineered Solutions for Embedded Applications

Technical Manual

P/N: V104MAN-V7

Revision: 12 September 2006

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]

12 September 2006 V104 Manual

CHAPTER 1 - INTRODUCTION.......................................................................................................................................................................................4

1.1

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

1.2

FEATURES....................................................................................................................................................................................................5

1.3

SPECIFICATIONS .........................................................................................................................................................................................6

CHAPTER 2 - CONFIGURATION AND INSTALLATION.................................................................................................................................................7

2.1

INTRODUCTION.................................................................................................................................................................................................7

2.2 Power Considerations....................................................................................................................................................................................8

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

2.3.2 AC Input Power Connector .........................................................................................................................................................................8

2.3.3 Output Power Connector.............................................................................................................................................................................9

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

2.3.5 Onboard DC "Boost" Convertor (Optional)…………………………………………………………………………………………..9

2.4 Bus Termination (Optional) ………………………………………………….………………………………………………………….10

2.5 Installation onto PC/104 modules ……………………………………………………………………………….…………………...…10

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

2.6.2 Mezzanine Expansion Headers ………………………………………………………………….…………………………………….11

2.6.3 PC/104 Bus Interupts (Optional) ………………………………………….……………………………………………………….....12

2.7 V104 Efficiency and Heat Dissipation Calculation ………………………………………………………………………………..…13

2.8 Power Management Controller PM104 (Optional) …………………………………………………………………………….…....14

CHAPTER 3 -THEORY OF OPERATION………………………………………………………………………………………………….…….15

3.1 Input power protection ……………………………………………………………………………………….……………………...…...15

3.2 Switching regulator, +5VDC …………………………………………………………………………………..………………..………15

3.3 Switching regulator, +12VDC ………………………………………………………………………………….……………….….…...15

3.4 Filter Capacitors ………………………………………………………………………………………………………………..…………16

3.5 Bus Termination (Optional) …………………………………………………………………………………………………… ..……….17

APPENDIX 1………………………………………………………………………………………………...…18
APPENDIX 2………………………………………………………………………………………………...…19
APPENDIX 3…………………………………………………………………………………..……………….19
APPENDIX 4…………………………………………………………………………………..……………….21

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12 September 2006 V104 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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12 September 2006 V104 Manual

CHAPTER 1 - INTRODUCTION

1.1 GENERAL DESCRIPTION

The V104 multiple output DC to DC 25 watt converter is a versatile, “bullet-proof” unit that can be
supplied with as a +5V, outputs only or can include features such as Power Management, Universal
Battery Charger, AC Bus termination, +12V output, -5V output, -12V output and custom output
voltages from –42V to +42V. The V104, designed for embedded PC/104 computer systems, has a
wide input range of 8 to 30V (>6:1) and is ideal for battery or unregulated input applications or low
voltage AC inputs. The V104 is specifically designed for vehicular applications. It has heavy-duty
transient suppressors (5000W) that clamp the input voltage to safe levels, while maintaining normal
power operation. Battery, DC and AC input configurations from 8 to 30V are all handled by the V104
automatically.

The V104 is a “simple switcher” based design that provides outstanding line and load regulation with
efficiencies up to 80 percent. Organic Semi conductor capacitors provide filtering that reduces ripple
noises below 30mV. The low noise design makes the V104 ideal for applications 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 and therefore can operate without
dropout from 8 to 30V input and supply 1A.

A “plug-in” Universal Battery Charger (UBC104) is available for the V104 to charge Lead-Acid, NiCd
and NiMh batteries. Charge currents can be up to 1.5A and battery charging voltages from 8 to 30V.

The Power Management controller (PM104) allows timed on/off control of the V104, bus interrupts on
impending power failure, current limit setting and intelligent charge termination for the UBC104.

The V104 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 all also available for off-board use through a screw terminal
block. PC/104 AC bus termination is optionally available on the V104, which provides the cleanest
possible signals on the PC/104 bus.

The V104 can be configured to meet almost any power supply need for embedded PC/104
applications, whether that be a simple +5V application, providing power for back lighted LCD panels
or a full UPS (uninterruptible power supply configuration).

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12 September 2006 V104 Manual

1.2 FEATURES

- DC to DC converter for PC/104 bus equipped products.

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

- Operates from 8VDC to 30VDC input.

- “Stacks” onto the PC/104 bus.

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

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

- Highly compact, 100 percent PC/104 conforming.

- AC bus termination available.

- Screw terminals blocks for off-board connection to outputs.

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12 September 2006 V104 Manual

1.3 SPECIFICATIONS

Power Supply Specifications

Model V104

5V output* 5A

12V output 1A

-5V output 400mA

-12V output 160mA

Input Voltage Range 8 to 30V

Load Regulation ** <30mV

Line Regulation ** + 40mV

Output temp. drift ** <10mV

Switching Freq. 100kHz
Output Ripple** <40mV

Conducted Susceptibility** >57db

Efficiency** Up to 80%

Temp Range 0 to 70C

Quiescent current*** 22mA

Weight 150 grams

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.
****Not including passthrough pins.

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12 September 2006 V104 Manual

CHAPTER 2 – CONFIGURATION AND INSTALLATION

2.1 Introduction

This chapter describes the configuration and installation of the V104 power supply. In addition,
section 2.2 provides a formula to calculate the available +5VDC. Figure 2-1 shows the V104
connectors, jumper and other options.

Figure 2-1, V104 Connector and Jumpers

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12 September 2006 V104 Manual

2.2 Power Considerations

The +5V switching regulator is rated at 5A maximum output however, the +5V output supplies power
to the +12, -5 and –12VDC regulators. The usable range of the +5V output can be calculated using
the following derating formula.

Usable +5VDC output = 5A-(I[-5] +I[12]*2.4) /0.80)
Where: I[-5] = -5VDC current load

I[-12] = -12VDC current load
I[12] = 12VDC current load

Assuming 80 percent converter efficiency (actual efficiency may vary).

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 8VDC to
30VDC.

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 (8VDC) and for the best efficiency, there is
NO input reverse-polarity diode provided on the V104 main DC input connector. If reverse-

polarity protection is required, connect to the AC input connector. See section 2.3.2

2.3.2 AC Input Power Connector (Optional)

Low voltage AC is connected to the V104 on screw terminal block, CN7. The V104 accepts AC
power in the range of 6VAC to 20VAC however, 12VAC to 16VAC is the recommended range. The
input capacitor on the V104 is 1000uF and is adequate for low power applications drawing one amp.
Connect an additional 1000uF capacitor to connector CN1 (terminal 1, positive, terminal 2 negative)
for greater loads.

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12 September 2006 V104 Manual

2.3.3 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 output (optional)

- Terminal 4: -12VDC output (optional)

- Terminal 5: -5VDC output (optional)

2.3.4 Battery Power Connector (Optional)

The batteries are connected to the screw terminal block, CN3. The V104 accepts DC battery
voltages in the range of 8V to 30VDC 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 V104 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 2.3.5

2.3.5 Onboard DC “Boost” Converter (Optional)

Three optional converter “boost” pumps (model NMH05XXS, XX = output voltage, +5V, +9V, +12V,
+15V) can be installed on the V104. The NMH charge pumps have a maximum 2 watt capacity, but
require a minimum load of 10 percent for proper operation.

The –5V output is generated by installing a NMH0505S in location VR4 and adding capacitor C7.
The –5V output is available on the PC/104 bus (B-7) and on connector block CN2, terminal 4.

The third optional converter is used for generating custom voltages, which is installed in location VR3
and adding capacitors C4 and C8. The NMH charge pumps have an isolated positive and negative
output. By referencing (connecting) the charge pump to other voltages, the user can create +/­supplies, elevated and negative voltages (ie. The charge pump “0V” is not connected to the V104
common).

- Terminal 1: Common of battery

- Terminal 2: -V output

- Terminal 3: 0V

- Terminal 4: +V output

Tri-M Engineering Tel: [phone]

1407 Kebet Way, Unit 100 Fax: [phone]

Port Coquitlam, BC V3C 6L3 E-mail: [e-mail]
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