V104 User Manual - Diamond Systems Corporation
Contents
1. Data Input Output Line _ N Input Output Pin 5 Connector CN605 Data Clock s P1 P2 P3 Input Output Pin 3 P4 Input Output Pin 4 P5 P6 Input Output Pin 6 Int1 Connector CN6 4 Spare Input Output AZ P7 Input Output Pin 7 Connector CN6 3 Analog Current Limit e f interrupt function is not used this PM104 line can be used for general purpose Input Output V104 User Manual Rev A www diamondsystems com Page 14 0ramono SYSTEMS CHAPTER 3 THEORY OF OPERATION 3 1 Input power protection Input power is connected to the screw terminal block CN1 which is removable from the socket connector on the circuit board A seven ampere pico fuse F1 limits the current draw from the power source A series of devices toroid coil L3 transorb D4 and filter capacitor C12 filters and clamps the input power Transorb D4 is a 5KVA heavy duty transient suppressor that provides zener type protection and has an avalanche voltage of 33V It is electrically located before fuse F1 to prevent activation of the fuse during a load dump or large transient Sustained voltages greater than the avalanche voltage must not be applied or transorb D4 will fail 3 2 Switching regulator 5VDC A simple switcher regulator VR1 generates the 5VDC output operating in a buck mode switching regulator configuration using inductor coil L1 schottk2. There are a number of methods for clamping over voltages but the most efficient and cost effective is to shunt the current to ground using a surge suppressor The surge suppressor relies on the vehicle s wiring and alternator impedance as the current limit and it remains in a high impedance state until an over voltage condition occurs Standard devices such as transorbs P6KE or 1 5KE will not survive the high energy discharge of a load dump Special automotive suppressors must be used to use up the 20A to 30A peak currents being shunted Several manufacturers such as Motorola Harris and Seimens manufacture suppressors specifically for V104 User Manual Rev A www diamondsystems com Page 19 piamono SYSTEMS automotive applications Some devices provide zener diode style protection while others provide back to back zener diode bidirectional protection Each type has advantages but unless they are used correctly they will fail to protect the electronics Ratings on the transient suppressors can be confusing A suppressor with an avalanche voltage of 24V to 32V will have a clamp off voltage of over 40V In addition ambient temperature can vary from 40C to 70C and can result in the avalanche voltage being several volts lower at 40C and a clampoff several volts higher at 70C Not all vehicles have 12V battery systems Some trucks use 24V batteries aircraft use 28V and trains from 45V to 85V Transient suppressors for airc
3. DIAMOND SYSTEMS CORPORATION V104 Vehicle Power Supply PC 104 DC to DC Converter Technical Manual P N V104 MAN Revision 30 Jun 2009 Revision Date Comment A 6 26 2009 Initial version Copyright June 2009 FOR TECHNICAL SUPPORT Diamond Systems Corporation PLEASE CONTACT 1255 Terra Bella Ave Mountain View CA 94043 USA support diamondsystems com Tel 1 650 810 2500 Fax 1 650 810 2525 www diamondsystems com APPENDIX APPENDIX APPENDIX APPENDIX 0ramono SYSTEMS 2 INTRODUCTION i italia iii A E A 7 2 2 Power C onslderatioris s za sen conicere aeta rca a erret a Ce e C rer D be aer ONE Rl ke UR Fete db Rr o Der 8 2 3 L Main Input Power Connectors an arent tet tete arent i DR d Od not t 8 2 3 2 AC In pubP OWer C ONET ase rernm E re ERO aaa 8 2 3 2 Qutput Power Connector acean ced ien ceto ra de gre nid ier rem de on i ir ca n RO e n RE Fa ER e E eran 9 2 3 4 Battery Power Connector Optional ocior erret rni re e tr rd e Rep e eu rue er ER EE 9 2 3 5 Onboard DC Boost Convertor ee 2 4 Bus Termination Optional 2 5 Installation onto PC 104 modules ee 641 LED Jumper Enable Disable i tede tercie ikea aud once i dic enia wean shah Bidston d Ret ER ER RT BE eod 2 Mezzanine Expansion Headers icing a HH DA QUA RR EE Reb De ane ates 2 2 6 2 6 3 PC 104 Bus Interupts Optional 2 7 2 8 3 2 Switching regulator 5VDC 3 3 Switching regulator 12VDC 3 4 Filter Capaci
4. 0 is usually jumpered to CN3 term2 for monitoring battery voltage Note channel 2 tracks main power input when greater than battery voltage Note channel 2 approx 0 6V less than battery voltage when main input less than battery voltage SYMBOL AD w1 SYMBOL Chrg Time w2 SYMBOL Batt Peak w3 SYMBOL TCnt b8 SYMBOL Batt_V w5 SYMBOL sgIDif 1 SYMBOL msbf 1 SYMBOL AO1 LVL 5 SYMBOL BattV Max 1100 SYMBOL Chrg Time Max 10800 SYMBOL Neg DeltaV 8 SYMBOL Trickle LVL 0 SYMBOL BattV Min 740 Main Loop Init Low PSU OnOff Let Bat1 chrg 0 Main Battl Low PSU OnOff If Bat1 Chrg 1 then Batt Trickle Goto Bat Chrg Batt Trickle debug trickle gosub Chk Pwr let D1 0 let DO 0 gosub Convert let Batt_V AD PWM Chrg Limit Trickle LVL 1000 Low Chrg_Limit 12 bit ADC conversion result 16 bit timer Peak voltage detected Single ended two channel mode Output Os after data transfer is complete Maximum current level 50 1A 75 1 5A Maximum battery pack charge voltage Maximum battery charging time 10 800 3hr AD convertor points for deltaV 74pt V IE 0 2V 18pts Trickle Charge Level 12 25A See below Minimum battery voltage 10V Turn PSU on Just making sure PSU stays on is battery already charged Get battery charging voltage Turn on Trickle current Trickle to minimum current V104 User Manual Rev A www diamondsystems com Page 26 0ramono
5. 20 ee 0ramono SYSTEMS APPENDIX 4 BC104 Battery Charger and PM104 Power Management Units 1 Description When the BC104 and PM104 units are both installed on either the V104 hereafter referred to as PSU a universal battery charger can be setup and the PSU unit made into an UPS uninterruptible power supply The BC104 is a constant current buck switching regulator with an adjustable float voltage The float voltage is adjusted via a potentiometer The PM104 is programmed by the user using a control basic called Pbasic A sample program is supplied to show a typical NiCd charging control Before using the BC104 and the PM104 the battery charging program must be set up for the intended battery pack The sample program has separate settings for normal charge current and trickle charge current In addition the charge termination methods should be set including maximum charge time negative delta V The user must set these for the type and size of battery to be charged Typically charge currents will be 1 3 to 1 6 of battery capacity and trickle charge current 1 20 to 1 30 of battery capacity Addition of a battery temperature sensor will allow charge termination with elevated battery temperatures which indicates battery is fully charged The PM104 can be programmed for many additional features not included in the sample program Features such as setting a PC 104 bus interrupt when main power fails stopping the PSU after running on bat
6. As the input voltage and output load is determined by the system application this leaves only the heat sink temperature that System Integrators adjust to maximize efficiency Either forced flow fans or thermally coupling the V104 heat sink to enclosures or external heat sinks can improve the efficiency of the V104 Good thermal management can obtain an improvement of 3 to 4 percent The results are that 35 percent less heat is dissipated A Heat Dissipated HD Input Power Actual Load Where Input Power Input Voltage Input Current And Actual Load 45V 12V load 5V load 12V load load measured in watts B Estimated Heat Dissipated ESD can be calculated based on 80 percent efficiency EHD 5V load 12V load 5V load 12V load 0 8 0 2 C If the Battery Input option is installed additional heat will be dissipated BID Total Load Battery Voltage 0 7V diode drop D If the AC Input option full bridge is used additional heat will be dissipated ACID Total Load Voltage 1 4 V 2 diode drop E If the Battery Charger Option is installed the heat dissipated from it will vary according to the current charge current and can be estimated by BCD Maximum Charge Current charge Voltage 0 1 based on 90 percent efficiency V104 User Manual Rev A www diamondsystems com Page 13 Q piamonn SYSTEMS 2 8 Power Management Controller PM104 optional The Power Management Controller PM104 is
7. SYSTEMS Goto Main Batt1 Chk Pwr Let D1 1 Let DO 0 Gosub Convert debug AD Batt_V Get battery charging voltage if AD lt Batt_V then No_ Power return No_Power debug no pwr pause 50 let Bat1 Chrg 0 Indicate battery has been discharged PWM Chrg Limit 0 50 turn off charge current Goto Main Batt1 Battery Charger Program Batt_Chrg Let Chrg_Time 0 Initialize charge timer counts in sec Chrg_Lp Gosub Chk_Pwr For TCnt 0 to 1 PWM Chrg_Limit A01_LVL 1000 first apply charge current then check for charge termination V104 User Manual Rev A www diamondsystems com Page 27
8. a microcontroller plug in module for timed on off control of the V104 control of the optional battery charger and generation of interrupts to the PC 104 host CPU The PM104 is programmed in a high level controller basic language called Pbasic To program the PM104 connect the program cable PM104 Cable to connector CN4 on the V104 and to the parallel port of any PC compatible computer PM104 programs can be directly downloaded or updated using the PM104 utility software Connector CN4 Pinout PM104 Program Connector Terminal 1 PM104 Power leave disconnected if V104 powered Terminal 2 Common connect to pin 25 of PC parallel port Terminal 3 PCO connect to pin 11 busy of PC parallel port Terminal 4 PCI connect to pin 2 DO of PC parallel port Table 2 1 PM104 Pin Number and I O Functions PM104 Microcontroller Description IC3 PM104 Supply Voltage IC3 PIN V104 Function or Connection V104 Supply Voltage Battery Charger Function Common Common PCO PC out Connector CN4 3 PCI Pc in Connector CN4 4 Plus 5V input output No connection Reset No connection PO Input Output Pin 0 Input Voltage Status Input Output Pin 1 V104 On Off Control V104 On Off control ool joc n5no m 2 Input Output Pin 2 Connector CN6 8 Analog Digital Chip Select e Int2 Connector CN6 7 Spare Input Output Connector CN6 6
9. battery has been charged Goto Main Batt1 Convert ADC Interface Pins The LTC 1594 uses a four pin interface consisting of chip select clock data input and data output In this application we tie the data lines together and connect to the PM104 pin designated DIO Here s where the conversion occurs The PM104 first sends the setup bits to the LTC1594 then clocks in two bits followed by sample time one null bit a dummy bit that always reads 0 followed by the conversion data High CS1 Deactivate the ADC to begin High CLK Clock data on rising edge so start with CLK high High Dio Pulsout CLK 2 Low DIO Pulsout CLK 2 Let DIOp D1 next bit of command Pulseout CLK 2 Let DIOp DO next bit of command Pulsout CLK 2 Activate the LTC1594 Low CS1 Get ready for input from LTC 1594 Input DIO Pulsout CLK 2 Dummy statement for delay Input DIO Sampling requires two clocks Pulsout CLK 2 Let AD 0 Clear old ADC result For Adbits 1 to 13 Get null bit 12 data bits Pulsout CLK 2 Clock next data bit in Let AD AD 2 DIOp Shift AD left add new data bit Next Adbits Get next data bit High CS1 Turn off the ADC V104 User Manual Rev A www diamondsystems com Page 25 Return Q piamonn SYSTEMS Return to program D1 1 DO 0 channel 2 input monitors input voltage of battery regulator D1 1 DO 1 channel 3 input monitors battery charging current Note channel
10. 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 V104 U
11. Set bit1 SYMBOL Adbits b1 SYMBOL Bati_Chrg bit1 SYMBOL DO bit2 SYMBOL D1 bit3 Status of input power Pin number of status of input power OnOff control of power supply Chip select A D on Battery Charger O active PC 104 bus interrupt Pin number of data input output Variable name of date input output Clock to ADC out on rising in on falling edge PC 104 bus interrupt PWM output for current limit Counter variable for serial bit reception LSB of ADC channel selection second bit of ADC channel selection D1 0 DO 0 channel 0 input pin3 of connector CN3 D1 0 DO 1 channel 1 input pin4 of connector CN3 next TCnt let D1 0 let DO 0 gosub Convert let Batt_V AD debud charge if AD gt BattV_Max then Batt_Chrg_Term Chrg_Time Chrg_Time 1 FON A on max cell voltage on time ve delta V cell temperature Get battery charging voltage V104 User Manual Rev A www diamondsystems com Page 24 0ramono SYSTEMS If Chrg Time gt Chrg Time Max then Batt Chrg Term Used maximum charge time If AD Batt Peak then Batt DeltaV Let AD AD Neg DeltaV If AD Batt Peak then Batt Chrg Term Detected negative deltaV in battery pack Insert battery pack temperature code here goto Chrg Lp Continue until charging terminated Batt Chrg Term PWM Chrg_ Limit 0 50 turn off charge current Let Bat1_Chrg 1 Indicate
12. a common bus connected to the signal ground RC1 RC2 RC3 RC4 RC5 1 GND GND GND GND GND 2 SMEMW IRQ10 BACK6 SA11 SAS3 3 AEN LA22 SD9 Refresh BALE 4 IOCHRDY IRQ11 DRQ6 SA12 SA4 5 SDO LA21 DACK7 DRQ1 IRQ3 6 SD1 LA20 SD11 SA13 SA5 7 SRDY IRQ15 DRQ7 DACK1 DACK2 8 SD2 LA19 SD12 SA14 SA6 9 SD3 LA18 as SA15 SA7 10 GND GND GND GND GND 11 GND GND GND GND GND 12 SD7 MEMR SD15 IOW IRQ6 13 SD6 LA17 SD14 SA17 SA9 14 SD5 LA18 SD13 IOR IRQ5 15 SD4 IRQ12 SD10 SA16 SA8 16 DRQ2 LA23 SD8 DACK3 IRQ4 17 SA19 IOCS16 DRQ5 DRQ3 DA2 18 SMEMR SBHE MEMW IRQ7 SAI 19 SA18 MEMCS16 DACK5 SA10 SAO 20 GND GND GND GND GND In addition the following signals are terminated with discrete components TC C1 330pF Reset C20 330pF V104 User Manual Rev A www diamondsystems com Page 17 0ramono SYSTEMS APPENDIX 1 Advantages of Using AC Termination One of the requirements of embedded electronics is for low power consumption One method of reducing power is to reduce the drive current available to power the expansion bus With over 80 signal lines any reduction in current load would have a large impact on overall requirements The PC 104 Consortium Guidelines for the expansion bus specify drive current can be as low as 4mA Compared with the 24mA for the standard desktop computer this is an 84 percent reduction in the drive current available The disad
13. al of one ampere can be supplied to the connected 12VDC load and the 12VDC inverter The 12VDC power is available on the PC 104 expansion bus B9 and screw terminal connector CN2 LED1 provides indication of 12VDC operation V104 User Manual Rev A www diamondsystems com Page 15 Q piamonn SYSTEMS 3 4 Filter Capacitors At 10kHz and above the impedance of filter capacitors is essentially their effective series resistance ESR and this parasitic resistance limits the filtering effectiveness of the capacitors Since the filter capacitors must absorb the switching ripple current capacitors with high ESR values will quickly overheat For example a capacitor with a 100mOhm ESR which is absorbing a 5A ripple current will dissipate 2 5W heat The capacitors used for filtering the 5V and 12V outputs in the V104 are organic semiconductor OS CON capacitors The OS CON is an aluminium solid capacitor with organic semi conductive electrolyte used as a cathode conductive materials The OS CON has many advantages over the conventional electrolytic Very low ESR values less than 8 times lower for same package High ripple current rating over 4 times higher for same package No degrade in operation at extended low temperatures ESR value of conventional electrolytics can increase 25 fold at 40C The life expectation for a filter capacitor is typically 2 000 to 6 000 hours 105C For a conventional electrolytic capacitor th
14. art 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 Diamond Systems V104 User Manual Rev A www diamondsystems com Page 3 0ramono SYSTEMS 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 gt 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
15. bus require the installation of the optional power management The PM104 can be programmed to provide indication of loss of input power low battery voltage or to provide indication to the PC 104 CPU to begin an orderly shutdown of mircrocontroller PM104 program operation Two separate interrupt requests can be generated and each interrupt request will remain active until the cause of the interrupt request returns to normal Interrupt Int1 can be set to IRQ6 or IrQ7 while Int2 can be set to IRQ4 or IRQ5 by installing a appropriate jumper on jumper selectons block J4 Jumper block J4 is located adjacent to the PC 104 bus on the opposite end where the power LEDs are located Selection Seleel Tori ct Gat Irt Int IRO TRO F gn I cal lo o OD ooo o o e oe ole None ooo ooo per E None cU in coool JED om RO dD 0 o00 EN IRQ4 Figure 2 2 Interrupt IRQ Selection F E CU E c Un T TROIS V104 User Manual Rev A www diamondsystems com Page 12 Q piamonn SYSTEMS 2 7 V104 Efficiency and Heat Dissipation Calculation The typical efficiency of the V104 is 80 percent for the 5V output but efficiency at any specific input voltage output load and ambient temperature may be higher or lower Typical efficiency is between 70 and 85 percent Best efficiency occurs at mid input voltage 16 to 18V mid output loads 10 to 18 watts and low heat sink temperature
16. cs located in that environment must withstand 600V transients and load dump situations Although the automotive market is growing about 2 percent yearly the amount of electronics being introduced into vehicles is much higher The electronics on a vehicle are no longer just the radio and engine computer but cellular phones portable computers faxes smart navigation with Global Positioning Receiver and car alarm systems The infamous load dump is an energy surge resulting from disconnecting the battery while being charged The alternator with a finite response time of 40msec to 400msec generates power with nowhere to go Thus an energy surge is formed much like a tidal wave that builds to an enormous height as it crashes the beach The resultant over voltage is the most formidable transient encountered in the automotive environment and is an exponentially decaying positive voltage The actual amplitude depends on alternator speed the level of alternator field excitation and can exceed 100V Each electronic component had its own power supply and it is the power supplies that must absorb the transients and energy surges What makes one transient more dangerous than another transient is not the voltage level but the amount of energy it carries A600V 1msec transient had much less energy than a 100V 400msec surge Regardless of the source all over voltages must be clamped and prevented from passing through to the rest of the electronics
17. e temperature acceleration coefficient 2 for a 10C increase while the OS CON has a temperature acceleration coefficient 210 for a 20C increase For example a capacitor rated for 2 000 hours 105C would have an expected life of for conventional electrolytic capacitor 32 000 hours 3 6 years 65C 128 000 hours 14 6 years 45C for OS CON capacitor 200 000 hours 22 years 65C 2 000 000 hours 220 years 45C This means that the OS CON has extremely longer life in practical use even under the same warranty of 2 000 hours 105C In a buck convertor output ripple voltage is determined by both the inductor value and the output filter capacitor for continuous mode Vp p ESR Vout Vout Vin L1 frequency EXAMPLE Vout 5V Vin 16V L1 55uH frequency 100kHz and 330uF capacitor with 27mohm ESR Vp p 0 027 5 1 2 16 17mV ripple 55 10E 6 10E5 V104 User Manual Rev A www diamondsystems com Page 16 piamono SYSTEMS Note only the ESR of the output capacitor is used in the formula It is assumed that the capacitor is purely resistive at frequencies above 20kHz Worst case output ripple is at highest input voltage and is independent of load 3 5 Bus Termination Optional AC bus termination is provided by 5 RC SOIC packages 3 only for 8 bit PC 104 bus RC1 to RC5 and discrete components C20 and C27 Each RC package contains 16 resistor capacitor combinations of 47R and 47PF with
18. er applied the screen will show a horizontal bar graph indicating the percent of program downloaded The red area of the bar graph is the portion used and the remainder is program space available 5 Program Command and Syntax Please refer to the Adobe files BSBOOK1 PDF and BSBOOK2 PDF 6 Adjusting the BC104 Float Limits When a PC 104 power supply is equipped with a BC104 and a PM104 the BC104 has a Float Voltage Adjust potentiometer However the Current Limit Adjust potentiometer is not installed and is controlled via the PM104 Using a small screwdriver flexible nylon works best turn the potentiometer until the desired float voltage is obtained No load should be present when adjusting V104 User Manual Rev A www diamondsystems com Page 23 Q piamonn SYSTEMS 7 Sample Battery Charging Program Listing The following program listing is intended for use as a guide to customizing the BC104 and PM104 operation Additional functions and features can be added including temperature monitoring are left up to the OEM to implement BC104 Battery Charger Sample program code SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL SYMBOL Pwr_Status 0 Pwrp_Status pin0 PSU_On Off 1 PSUp_OnOff pin1 CS1 2 CS1p pin2 Int2 3 Int2p pin3 DIO 24 DIOp pin4 CLK 5 CLK p pin5 Inti 26 Intp pin6 Chrg Limit 2 7 Chrgp Limit pin7 SYMBOL Bat
19. ff the signal transitions on the bus The result is a quieter bus which has fewer high frequency effects such as crosstalk to other bus lines Reduced EMI Busses with AC termination tend to generate less EMI than resistively terminated buses due to the reduction in high frequency components of signal transitions V104 User Manual Rev A www diamondsystems com Page 18 Q piamonn SYSTEMS APPENDIX 2 Installation Hints for the V104 Power Supply 1 To minimize noise induced into the power supply connect the V104 power supply direct to the power supply source battery with dedicated wires This makes use of the vehicle battery as a filter 2 Always use large gauge hook up wires to connect the V104 power supply to the vehicle power source battery This minimizes any voltage drop caused by the resistance of the wire Use minimum of AWG 16 for lengths less than 10 feet and AWG 14 for longer lengths 3 Wherever possible install the V104 power supply on to the top of the V104 card stack This will allow better dissipation of heat from the heat sink If additional cooling is required use either forced air ventilation or mount the PC 104 power supply so that the heat sink can dissipate heat to the enclosure APPENDIX 3 Vehicles Are An Electronics Nightmare Under the hood of a vehicle is an electronics nightmare EMI spraying and RFI sparking is everywhere and electrical transients run amuck zapping the embedded electronics Electroni
20. he 5V output LEDs disabled Not including passthrough pins V104 User Manual Rev A www diamondsystems com Page 6 0ramono SYSTEMS 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 CN1 Connector 5U output Common 12U output 12U output 5U output CN2 Connector onnector CN3 Common Battery Input Ji 8 Bit Signal 1 Expansior Signal 2 i J2 16 Bit ilo oo 00000 000000000000000000000 9 Expansion ilo 0000000000000 0000000000000000t0 piter e soccoceccccoccoocccoh imo o o Cim o o e 060000000 ojoo 15 5 12412 Power Management J4 IRQ selection Pouer LEDs Micrecaniroller d JP3 LED CN4 Pouer Management Program Po Enable Disable Jumpers Figure 2 1 V104 Connector and Jumpers V104 User Manual Rev A www diamondsystems com Page 7 0ramono SYSTEMS 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 1 12 2 4 0 80 Where I 5 5VDC current load I 12 12VDC current load I 12 12VDC current load Assuming 80 percent conver
21. he LM35 series is particularly nice because their output voltage is directly proportional to temperature ie 10mV C or 10mV F In any case the OEM can experiment to determine what works best in their application V104 User Manual Rev A www diamondsystems com Page 22 0ramono SYSTEMS 3 Programming Cable The programming cable is plugged into the connector CN4 on the PSU and the other end into the 25pin DB parallel port connector on a PC The programming cable has the following connections CN4 1 No connection CN4 2 Connect to pin 25 on parallel port CN4 3 Connect to pin 11 parallel port CN4 4 Connect to pin 2 parallel port 4 Download and Edit Software All programs for the PM104 are written in a Control Basic program language and are saved into an ASCII file with a BAS extension Any text editor can be used to create edit and save these programs The Download program called Stamp exe also has simple editing capabilities After the program cable is connected between the PSU and the parallel port the PSU unit can be turned on thus providing power to the PM104 unit The Download program Stamp Exe is started by typing from DOS STAMP EXE The program to be downloaded is opened by pressing the keys ALT and L simultaneously Using the arrow keys select the desired file and press ENTER key To download the program press the keys ALT and R simultaneously If the cable is properly connected and pow
22. l 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 NMHO5XXS XX output voltage 45V 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 e
23. levated and negative voltages ie The charge pump OV is not connected to the V104 common Terminal 1 Common of battery Terminal 2 V output Terminal 3 OV Terminal 4 V output V104 User Manual Rev A www diamondsystems com Page 9 0ramono SYSTEMS Example NMH0515S 15V can generate the following voltages 15V by connecting NMH OV to V104 common 30V by connecting NMH V to common 30V by connecting NMH V to common 42V by connecting NMH V to 12V output Note When batteries or external signals are connected to CN3 the Plug IN Boost regulator VR3 cannot be installed See section 2 3 4 2 4 Bus Termination Optional AC bus termination minimizes power consumption while improving the reliability of the bus The resistor capacitor combination only conducts current during the few nanoseconds when the bus signal is changing state 2 5 Installation onto PC 104 The PC 104 bus on the V104 is keyed according to the standards as set out be the PC 104 Consortium Guidelines Male Pin B10 of the 8 bit bus and male pin C20 of the 16 bit bus are removed but the female sockets are not plugged Because of the large number of pins and sockets 104 total in the PC 104 bus caution must be used in separating the PC 104 modules to prevent bending the pins or hurting the person separating the modules Diamond Systems recommends the use of the PC 104 removal tool model 5535 available from Diamond S
24. raft cannot use the 12V system automotive components Instead a suppressor with an avalanche rating of 35V is needed to allow for low ambient temperature compensation but this results in clamp off of over 70V Diamond Systems V104 Vehicle Power Supply employs a Diode Inc part 5KP33A allowing an input voltage range of 8V to 30V If a high clamp off voltage cannot be tolerated other techniques must be used A series device such as a MOSFET can act as a pre regulator but it also must be selected to withstand transients In addition a series device adds to in efficiency and creates a heat dissipation problem especially at high ambient temperatures Load dumps occur infrequently in a vehicle s lifetime but any electronics wishing to survive in this environment must be designed to withstand the assaults Load dumps co operate slightly through their worst case voltage does not typically occur with worst case source impedance In fact although the total energy of a load dump may be 500 joules a transient suppressor capable of 70 joules typically will be adequate because of the distributed electronics in the vehicles That is provided the suppressor ratings are the same or larger than other suppressors throughout the vehicle A quick thinking engineer can take advantage of this and design his power supply to withstand higher voltages and thus let others transient suppressors do the work V104 User Manual Rev A www diamondsystems com Page
25. ser Manual Rev A www diamondsystems com Page 4 1 2 FEATURES 0ramono SYSTEMS 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 aeaa ee o rK350mil Ak A A lalo ool lt 200mil OBOMI 3350mil 2550mi l _ 3575mil 3775mil z V104 User Manual Rev A www diamondsystems com Page 5 1 3 SPECIFICATIONS 0ramono SYSTEMS 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 lt 30mV Line Regulation 40mV Output temp drift 10mV Switching Freq 100kHz Output Ripple 40mV Conducted Susceptibility gt 57db Efficiency Up to 80 Temp Range 0 to 70C Quiescent current 22mA Weight 150 grams Size PC 104 form factor complian bali 3 55 W x 3 75 L x 0 6 Height Current rating includes current supplied to 12V 12V amp 5V regulators Measured on t
26. ter 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 V104 User Manual Rev A www diamondsystems com Page 8 0ramono SYSTEMS 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 optiona
27. tery backup power for a set time tracking power consumption so that backup battery charging can be terminated when the same amount is restored to the battery These features are left to the OEM integrate into their design V104 User Manual Rev A www diamondsystems com Page 21 Q piamonn SYSTEMS 2 Connections The BC104 is mounted on two connectors under the PSU heatsink CN5 and CN6 The PM104 is factory installed directly in front of the PC 104 bus location IC3 Connector CN4 is for connection to a PC parallel port for programming Batteries are connected to the screw terminal block CN3 The PSU accepts DC battery voltages in the range of 8 to 20VDC through the Battery Power Connector CN3 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 normally connected to terminal 2 Terminal 4 External signal 2 0 to 30V input The two external signals are fed into the 12 bit analog to digital converter and will accept voltages up to 30V The sample program requires the External signal 1 Terminal 3 be connected to Positive Battery voltage Terminal 2 for battery voltage sensing A variety of temperature sensors can be connected including thermistors and conditioned sensors such as LM35s T
28. tors 3 5 Bus Termination Optional BWNF V104 Efficiency and Heat Dissipation Calculation as Power Management Controller PM104 Optional s s sss ces cee cee eee ene cee cee cee cee ne tne e een sus nn ee nene enn nnn CHAPTER 3 THEORY QT OPERA EIQN iecit uterine or riter ptr tette ene a Deer e FO OA ntn AR in ad 3 1 Input power Protection cina enm ede bereiten eret eek dee he Api etn ad a d eben buta stade V104 User Manual Rev A www diamondsystems com Page 2 0ramono SYSTEMS PREFACE This manual is for integrators of applications of embedded systems It contains information on hardware requirements and interconnection to other embedded electronics DISCLAIMER Diamond Systems 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 Diamond Systems 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 Diamond Systems 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 Diamond Systems at the address listed on the title page of this document COPYRIGHT 2009 Diamond Systems No p
29. vantage to reducing drive current is the increasing possibility for noise to infilitrate the bus The symptoms of noise induced problems are often flaky or unreliable operation Systems suffering from noisy busses are often difficult to diagnose and solve Programmers blame the hardware engineers and the hardware engineers blame the software programmers With reduced drive currents more attention must be paid to reducing the noise levels on the PC 104 bus One frequently used method is bus terminators Testing has proven the best way to terminate the PC 104 bus is to use AC terminators instead of resistive terminators This is the recommended termination method for Ampro CPU products The IEEE P996 PC Bus Standard recommends the AC bus terminating technique The use of AC terminators has several advantages over DC terminators Reduced power consumption DC terminators are typically in the 330 ohm to 1K ohm range and draw heavy currents This is significant when terminating the over 80 signals on the PC 104 bus AC terminators draw current only during the few nanoseconds when the bus signal is changing state resulting in negligible current drain Improved bus reliability DC terminators invariably increase the voltage level of the logic zero state This decreases noise immunity making it more likely a zero will be seen as a one AC terminators do not cause this shift resulting in a more reliable bus Reduced crosstalk AC terminators roll o
30. y diode Z1 input filter capacitors C12 and output filters capacitor C6 Regulator VR1 is a current mode controller and adjusts the switching cycle by the sensed current rather than directly by the output voltage Control of the output voltage is obtained by using the output of a voltage sensing error amplifier in regulator VR1 to set the current trip level A total of 5 amperes can be supplied to the connected 5VDC load to the inputs of the 12VDC regulator and the 5VDC and 12VDC charge pumps and invertors The 5VDC power is available on the PC 104 expansion bus B3 B29 and D16 and screw terminal connector CN2 LED2 provides indication of 5V operation 3 3 Switching regulator 12VDC Switching regulator VR2 generates the 12VDC output operating in a boost mode switching regulator configuration using inductor coil L2 Schottky diode D1 1 input filter capacitor C6 and output filters capacitor C3 Capacitor C6 works as an output filter for the 5VDC and as an input filter for the 12VDC regulator VR2 Regulator VR2 is a current mode controller and adjusts the switching cycle by the sensed current rather than directly by the output voltage Control of the output voltage sensed by resistors R5 and R6 is obtained by using the output of a voltage sensing error amplifier in regulator VR2 to set the current trip level If a custom output voltage is ordered variable resistor R21 in series with R5 will adjust the feedback voltage A tot
31. ystems 2 6 1 LED Jumper Enable Disable These jumpers allow the LEDs to be disabled This is most likely to be used when absolute minimum power consumption must be maintained such as when operating off a limited battery source The location of each LED jumper is immediately behind each LED Each LED is enabled by factory default To disable any LED remove the LED jumper or cut the small PCB trace if no jumper is installed associated with the LED To re enable any LED re install the associated jumper or solder a short jumper wire between each of the jumper pads V104 User Manual Rev A www diamondsystems com Page 10 0ramono SYSTEMS 2 6 2 Mezzanine Expansion Headers The mezzanine expansion headers are used for installation of the optional battery charger The mezzanine expansion headers can also be used for custom output voltages such as Vee for LCD panels If custom output voltages are required please contact Diamond Systems Figure 2 3 V104 Mezzanine Connectors Connector CN5 Pinout Connector CN6 Pinout 1 45V 10 45V 1 PM104 P1 10 Main Pwr Input 2 Common 9 Common 2 Common 9 Common 3 Battery Input 8 Main Pwr Input 9 PM104 P7 8 PM104 P2 4 Ext Signal 1 7 412V 4 PM104 P6 7 PM104 P3 5 Ext Signal 2 6 5V 5 PM104 P5 8 PM104 P4 V104 User Manual Rev A www diamondsystems com Page 11 2 6 3 PC 104 Bus Interrupts Optional 0ramono SYSTEMS Interrupts to the PC 104
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