HPWR104HR High efficiency PC/104 power supply module User`s
Contents
1. HPWR104HR 12 RTD Finland Oy User s Manual 8 30V DC INPUT Input Protection High Efficiency 5V 15A Converter to PC 104 bus and Peripherals Power Ouputs for Peripheral Devices PC 104 16 bit Bus Fig 3 1 Block diagram of the HPWR104HR 2 HPWR104HR 13 RTD Finland Oy User s Manual Main 5V converter for computer The main 5V output is implemented with a synchronous switch mode DC DC converter design The output current of this unit is 15A This converter has excellent dynamic and transient response capabilities making it an ideal high speed computer power suppy The output current is internally limited against over current and short circuit faults at 17A The input of this converter is protected with a 33V fast transient absorber diode and low loss forward schottky diodes These devices are necessary to protect the input in automotive and industrial installations against fast overvoltage spikes and reverse voltage transients These situations exist in vehicle systems that use for example electrically controlled hydraulic or pneumatic inductive valves and solenoids The main 5V converter feeds the PC 104 AT bus 5V pins with power This power can also be taken from the board from an external terminal block J2 See previous section for the location of terminal block J2 Current Limit To protect against fault or short circuit conditions the 5V DC DC converter module is equipped with a current limiting c2. damage to the device e Check all wiring connections once and then once more again e Check the input power to the board is in the range of 8 to 30V DC e Apply power to your HPWR104HR and make sure the diagnostic LED s indicate correct operation Installation integrated with a PC 104 module stack e Secure the four PC 104 installation holes with standoffs Connect the board to the power supply using the power interface connectors HPWR104HR 8 RTD Finland Oy User s Manual HPWRIO4 CMM626GX233HK 32 RTD dataModule Fig 2 1 HPWR104HR powering an RTD PC 104 cpuModule stack Note For full output power performance install your HPWR104HR at the top of your PC 104 system and make sure adequate cooling is provided You may increase airflow with the EFAN104 fan module available from Real Time Devices HPWR104HR 9 RTD Finland Oy User s Manual External power connections The illustration 2 2 below indicates the input and output power connections of the HPWR104HR board mounted in its IDAN enclosure frame This illustration also shows the RTD EMI filter that is required to meet CE compliance to EN55022 A Using IDAN systems the power devices are directly heat sunk to the frame this will give full rated output performance over the complete temperature range of 40 to 85 C Fig 2 2 HPWR104HR power supply power connections HPWR104HR 10 RTD Finland Oy User s Manual Connector descriptions e J1 Raw i
3. 12V 00 cceeeceeeeeeeseeeeeeeeeeeeeeeeeeeeees 14 Onboard status LED Ea ann he aa e e e a seen 14 O tp t protectio ma a E E A A A T N a aiaa 15 Output power calculations cccccccccccecececeeeeeeeeeeeeeeeeeeeeeeeeeeaaaeeaaeeeeees 16 Chapter 4 HPWR104HR Specifications 16 Chapter 5 Wartanty isk iis ciieninn iia 17 HPWR104HR 4 RTD Finland Oy User s Manual List of illustrations Fig 2 1 HPWR104HR powering an RTD PC 104 cpuModule stack Fig 2 2 HPWR104HR power supply power connections Fig 3 1 HPWR104HR Block diagram HPWR104HR 5 RTD Finland Oy User s Manual Chapter 1 INTRODUCTION This user s manual describes the operation of the HPWR104HR power supply unit for automotive and industrial applications Features Some of the key features of the HPWR104HR include Wide input voltage range 8 30V DC 75W output power guaranteed with adequate cooling minimum of 90 efficiency Outputs continuous short circuit protected Remote ON OFF operation Power output options include HPWR104HR 1 5V HPWR104HR 2 5V 12V 12V Two status LED s Standard floppy power output connector J12 Fully PC 104 compliant Operating temperature 40 to 85 C The following paragraphs briefly describe the major features of the HPWR104HR A more detailed discussion is included in Chapter 3 Hardware description The board installation is described in Chapter 2 Board Installation Power supply units Th
4. HPWR104HR High efficiency PC 104 power supply module User s Manual Hardware Revision 1 2 1 3 VITLA Real Time Devices Inc Accessing the Analog World p User s Manual HPWR104HR HPWR104HR Power supply module User s Manual REAL TIME DEVICES FINLAND OY LEPOLANTIE 14 FIN 00660 HELSINKI FINLAND Phone 358 9 346 4538 FAX 358 9 346 4539 E Mail sales rtdfinland fi Website www rtdfinland fi 2 RTD Finland Oy User s Manual Revision History 24 06 1999 Release 1 0 10 07 2001 Name of company and format Release 1 3 hardware release IMPORTANT Although the information contained herein has been carefully verified RTD Finland Oy assumes no responsibility for any errors that may occur for any damage to property or persons resulting from improper use of this manual or from the related software RTD Finland Oy also reserves the right to alter the contents of this manual as well as features and specifications of this product at any time without prior notice Notice We have attempted to verify all information in this manual as of the publication date Information in this manual may change without prior notice from RTD Finland Oy Published by Real Time Devices Finland Oy Lepolantie 14 FIN 00660 Helsinki Finland Copyright 1999 2001 Real Time Devices Finland Oy All rights reserved Printed in Finland PC XT PC AT are registered trademarks of IBM Corporation PC 104 is a reg
5. TIME DEVICES This warranty is limited to the original purchaser of product and is not transferable During the one year warranty period REAL TIME DEVICES will repair or replace at its option any defective products or parts at no additional charge provided that the product is returned shipping prepaid to REAL TIME DEVICES All replaced parts and products become the property of REAL TIME DEVICES Before returning any product for repair customers are required to contact the factory for an RMA number THIS LIMITED WARRANTY DOES NOT EXTEND TO ANY PRODUCTS WHICH HAVE BEEN DAMAGED AS A RESULT OF ACCIDENT MISUSE ABUSE such as use of incorrect input voltages improper or insufficient ventilation failure to follow the operating instructions that are provided by REAL TIME DEVICES acts of God or other contingencies beyond the control of REAL TIME DEVICES OR AS A RESULT OF SERVICE OR MODIFICATION BY ANYONE OTHER THAN REAL TIME DEVICES EXCEPT AS EXPRESSLY SET FORTH ABOVE NO OTHER WARRANTIES ARE EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND REAL TIME DEVICES EXPRESSLY DISCLAIMS ALL WARRANTIES NOT STATED HEREIN ALL IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTIES FOR MECHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THIS WARRANTY IN THE EVENT THE PRODUCT IS NOT FREE FROM DEFECTS AS WARRANTED ABOVE THE PURCHASER S SOLE REMED
6. Y SHALL BE REPAIR OR REPLACEMENT AS PROVIDED ABOVE UNDER NO CIRCUMSTANCES WILL REAL TIME DEVICES BE LIABLE TO THE PURCHASER OR ANY USER FOR ANY DAMAGES INCLUDING ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EXPENSES LOST PROFITS LOST SAVINGS OR OTHER DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE PRODUCT SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS AND SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE HPWR104HR 18 RTD Finland Oy
7. can answer questions about the problem 4 On the paper write a detailed description of the problem with the product Answer the following questions Did the product ever work in your application What other devices were connected to the product How was power supplied to the product What features did and did not work What was being done when the product failed What were environmental conditions when the product failed 5 Indicate the method we should use to ship the product back to you e We will return warranty repairs by UPS Ground at our expense e Warranty repairs may be returned by a faster service at your expense e Non warranty repairs will be returned by UPS Ground or the method you select and will be billed to you 6 Clearly specify the address to which we should return the product when repaired 7 Enclose the paper with the product being returned 8 Carefully package the product to be returned using anti static packaging We will not be responsible for products damaged in transit for repair 7 Write the RMA number on the outside of the package 8 Ship the package to Real Time Devices Finland Oy Lepolantie 14 FIN 00750 Helsinki FINLAND HPWR104HR 17 RTD Finland Oy User s Manual Limited Warranty Real Time Devices warrants the hardware and software products it manufactures and produces to be free from defects in materials and workmanship for one year following the date of shipment from REAL
8. dequate heat dissipation from the onboard heat sink in high output power installations Connector description The power connections are made using cable plug type terminal blocks This enables removing connections from the board without opening the cables from the terminal blocks A 4 pole floppy type connector is also available for easy wiring to PC peripherals The IDAN HPWR104HR boards always feature screw terminal blocks for inter frame wiring What comes with your board Your HPWR104HRHR package contains the following items HPWR104HR board with mating connectors for the power connections User s manual If any item is missing or damaged please call Real Time Devices Finland customer service department at the following number 358 9 346 4538 Using this manual This manual is intended to help you install your new HPWR104HR module and get it working quickly while also providing enough detail about the board and it s functions so that you can enjoy maximum use of it s features even in the most demanding applications When you need help This manual and all the example programs will provide you with enough information to fully utilize all the features on this board If you have any problems installing or using this board contact our Technical Support Department 358 9 346 4538 during European business hours Alternatively send a FAX to 358 9 346 4539 or Email to sales rtdfinland fi When sending a FAX or Email req
9. e HPWR104HR power supply unit offers a complete reliable power subsystem for your sophisticated computer and peripherals To improve reliability in noisy environments the HPWR104HR is designed using protection devices against over voltages noise spikes and reverse input voltage The output current of the 5V converter is limited to 15A This enables reliable system operation in distributed industrial installations The main 5V computer power supply is designed using a high efficiency switching regulator module providing high output current 15A with a high efficiency 90 under all conditions The secondary peripheral power supplies are designed using 12V and 12V Boost converters Low component count and extensive use of SMD technology ensures low weight and reliable operation The HPWR104HR can be switched off from a remote source If this switch jumper is closed the power supply will become inactive while still powered Board options The HPWR104HR is available in two main output configurations as set out below Option 1 HPWR104HR 1 5V output only upon Option 2 HPWR104HR 2 5V 12V and 12V outputs HPWR104HR 6 RTD Finland Oy User s Manual Mechanical description The HPWR104HR is designed on a PC 104 form factor An easy mechanical interface to both PC 104 and EBX systems can be achieved Stack your HPWR104HR directly on a PC 104 compliant computer using the onboard mounting holes Care must be taken to ensure a
10. ircuitry to provide continuous overload protection After reaching the current limit point typically 10 to 25 over the rated current the voltage output will range between the rated output and zero depending on the amount of overload Once the short circuit condition is removed the output will return to the nominal value without restarting the unit Remote On Off control Header connector X1 near one of the PC 104 mounting holes is the remote ON OFF selection switch Closing this connection will disable the HPWR104HR and place the converter OFF In this condition the HPWR104HR will consume minimum power This signal could be connected to the ignition key of an automobile or machine Secondary 12V and 12V converters for peripherals A 5V to 12V step up converters with 90 efficiency generates 12V for peripheral devices such as EL or TFT panels hard drives motors etc The 12V output delivers 2 0A of current 12V power is available from terminal block J4 The 12V power is available from terminal block J1 See previous section for location of J4 11 The 12V and 12V supplies also power the PC 104 bus Onboard status LED s The HPWR104HR is equipped with 2 indicator LED s The function of the LED s is described below e LED1 Green Indicates 5V power converter is alive e LED2 Green Indicates 12V converter is alive HPWR104HR 14 RTD Finland Oy User s Manual Overload protection The 5V converter
11. is current limited to 17A The current limit is higher that the maximum continuous output current to ensure reliable operation near the maximum rated output power Fast current surges are allowed over the rated 15A continuous current The 12V converter is rated to 2A and the 12V converter is rated for 500mA The 12V converter output is limited to 3A The 12V converter output is limited to 1A The outputs of the 12V and 12V converters feature a 13V zener diode to protect your system from external error conditions such as incorrect power connections These devices will allow short term error conditions and are not designed to accept long term overvoltage or reverse polarity Output power calculations The maximum available power for the 5V computer system can be estimated using the following conservative formula The output of the main converter is 15A I1 12V output current I2 12V output current _ bus 5V to bus 15A 11 0 88 12 0 82 2 5 _bus Note Even though the total output power figure of 15A 5V is not exceeded youmust remember not to overload an individual output Care must be taken not to thermally overload the unit The maximum specified output power may not be available if the ambient temperature rises and in this case additional heat sinking or additional airflow may be necessary The absolute maximum long term output figures are 12V gt 2A 12V gt 1A 5V gt 12A The absolute maximum o
12. istered trademark of PC 104 Consortium The Real Time Devices Logo is a registered trademark of Real Time Devices utilityModule is a trademark of Real Time Devices All other trademarks appearing in this document are the property of their respective owners HPWR104HR 3 RTD Finland Oy User s Manual Table of Contents List of illustrations ccceeeeee sees eens eeeeeeeeeeeeeeeeeees 5 Chapter 1 Introduction ccccccceeeeeseeessseeeeseeeeeees 6 PO ARUNGS scteste litte ds tadete tue tete tn e diee ee eli esate teddies ies 6 Power supply unit s 3 lt 0chcccasees eee ce ccenenchesedeastedatcacdenenebatedadeecdenenpeebeeedeedehees 6 Board options sees cece eden ede ee crear i es cee ad es ee cede bende cee 6 Mechanical description scat kaha i i RS ake te a 7 GONMECIONGESCNDTION sisareen Ee a atti E EEA 7 What comes with your DOaIG ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeseeenaneeeeeeeees 7 Using this manualz ps eane ea 7 When you need help cccccccceceeeseeeececeeeeeeeeeeeeeeeaeaeeeeeeeeseeseseneaeeeeeeees 7 Chapter 2 Board installation ccccceeeeeeeeeeees 8 B ard installati Mannen a E E E E 8 External power connections sesesssesessssrtterrtttssertrrtnrnrtnestrrtrrnnnnenenet 10 Power inputs and outputs Chapter 3 Hardware description ccccseeeee 12 Main 5V converter for COmMputer ccccceeeeeeeeeeeeeeeeeeenneeeeeeeeees 14 Secondary power outputs 12V
13. nput power to the HPWR104HR Input voltage range is 8 30V DC Overvoltage protected with transient absorber with cutoff at 33V DC Note The module input power may be up to 85 W 11A this will require a cable wire diameter of 2 to 3 sq mm Make sure this input wire is kept as short as possible to reduce voltage drops e J2 5V Output of the main DC DC power supply e J11 12V Output Only on 2 versions of HPWR104HR e J4 12V Output Only on 2 versions of HPWR104HR e J12 Floppy power output connector 5V and 12V outputs Pin 1 5V 2 3 GND and pin 4 12V e X1 Remote ON OFF close this jumper to disable the HPWR104HR Not shown in this figure The output voltages are also indicated on the silk screen on the solder side of the module under the terminal blocks Check these before making any external power connections The input of the HPWR104HR is protected against reverse voltages but will not withstand long term overvoltage The transient absorbers will clip all fast disturbance and noise on the input but may overheat if continuous overvoltage is present HPWR104HR 11 RTD Finland Oy User s Manual Chapter 3 HARDWARE DESCRIPTION This chapter describes the major features of the HPWR104HR which are the following The main 5V converter for the computer and PC 104 bus The secondary power output converters 12V and 12V for peripheral devices Onboard status LED s Overload protection Output power calculations
14. uest please include the following information Your company s name and address your name your telephone number and a brief description of the problem HPWR104HR 7 RTD Finland Oy User s Manual Chapter 2 BOARD INSTALLATION The HPWR104HR isolated power supply module is very easy to connect to your industrial or automotive control system Direct interface to PC 104 systems as well as EBX size boards is achieved This chapter tells you step by step how to install your HPWR104HR into your system Board installation Keep your board in its antistatic bag until you are ready to install it to your system When removing it from the bag hold the board at the edges and do not touch the components or connectors Please handle the board in an antistatic environment and use a grounded workbench for testing and handling of your hardware Before installing the board in your computer check the power cabling Failure to do so may cause the power supply unit to malfunction or even cause permanent damage General installation guidelines e Touch the grounded metal housing of your computer to discharge any antistatic buildup and then remove the board from its antistatic bag e Hold the board by the edges and install it in an enclosure or place it on the table on an antistatic surface e Install your board in your system and wire the power supply correctly e Failure to do so may cause the power supply unit to malfunction or even cause permanent
15. utput figures are 12V gt 3A 12V gt 2A 5V gt 17A HPWR104HR 15 RTD Finland Oy User s Manual Chapter 4 HPWR104HR SPECIFICATIONS Host interface 16 bit data bus with power pins 5V 12V connected to power outputs Power supply specifications Input voltage range guaranteed 8 30V DC Input voltage range under light load 25 6 30V DC Output Power 75W total 5V 15A 12V 2 0A 12V 500mA Efficiency 90 Output voltage unloaded 5 15V max Output voltage fully loaded 4 95V min 15A Connectors Power connectors Phoenix Contact Combicon Series Mini floppy connector Host bus AT PC 104 bus Optionally no bus connector Electromechanical Operating temperature range 40 to 85 C Heat sink temperature Max 85 C Internal power dissipation 14W Max Heat sink material Aluminum CE approval CE approved in an IDAN installation HPWR104HR 16 RTD Finland Oy User s Manual Chapter 5 RETURN POLICY AND WARRANTY Return Policy If the module requires repair you may return it to us by following the procedure listed below Caution Failure to follow this return procedure will almost always delay repair Please help us expedite your repair by following this procedure 1 Read the limited warranty which follows 2 Contact the factory and request a Returned Merchandise Authorization RMA number 3 On a sheet of paper write the name phone number and fax number of a technically competent person who
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