IPWR104HR-35W - RTD Embedded Technologies, Inc.
Contents
1. Wide input voltage range 18 36V DC or 36 to 72V DC 35W output power without additional cooling 40 to 85C ambient temperature 60W peak output power guaranteed with adequate cooling 85 SV peak efficiency for 18 36V version 79 SV peak efficiency for 36 72V version Remote ON OFF operation Power output IPWR104HR 35 5V 12V 12V 5v Standard floppy power output connector Fully PC 104 compliant Extended operating temperature 40 to 85 C The following paragraphs briefly describe the major features of the IPWR104HR 35 A more detailed discussion is included in Chapter 3 Hardware description Board installation is described in Chapter 2 Board Installation Power supply units The IPWR104HR 35W isolated power supply unit offers a complete reliable power subsystem for your computer and peripherals To improve reliability in noisy environments the IPWR104HR 35W is designed using an isolated power supply module for the computer and the peripheral system components This enables reliable system operation in distributed industrial installations The high peak output power of 60W ensures adequate current at high transient loads The main 5V computer power supply is designed using a monolithic switching regulator module providing high output current 15A with a high efficiency under all conditions The secondary peripheral power supplies are designed using 12V and 12V converters The IPWR104HR 35W can be switched off from a2. t RS tir Em Dn atl Fig 2 2 IPWR104HR H35W shown power supply power connections IPWR104HR 35W 11 RTD Embedded Technologies Inc Connector descriptions e JI Raw input power to the IPWR104HR 35 Input 18 36V or 36 72V DC Note The module input power may be 45 W 2 5A peak This current will require a cable wire AWG 26 Make sure this input wire is kept as short as possible to reduce voltage drops Twist the input leads to reduce input inductance s J2 5V Output of the main power supply s Jil 12V Output Only on 2 versions of IPWR104HR 35 s JA 12V Output Only on 2 versions of IPWR104HR 35 e JI2 Floppy power output connector 5V and 12V outputs Pin 1 5V 2 3 GND and pin 4 12V e XI Remote ON OFF close this jumper to disable the IPWR104HR 35W IPWR104HR 35W 12 RTD Embedded Technologies Inc Chapter 3 HARDWARE DESCRIPTION This chapter describes the major features of the IPWR104HR 35W which are e The main 5V converter for the computer and PC 104 bus e The secondary power output converters 12V and 12V for peripheral devices e Fuses and protection e Output power calculations IPWR104HR 35W 13 RTD Embedded Technologies Inc 18 36V DC INPUT Input Protection Galvanically Isolated 5V 7A DC DC Converter to PC 104 bus and peripherals Power Ouputs for Peripheral Devices PC 104 16 bit Bus Fig 3 1 Block diagram of the IPWR104HR 35W IPWR104HR 35W 14 RTD Embedded Techno
3. 5 perte Eee terit repe E eter eerte a dire p epe eene ipee eaaet 15 Secondary 12V and 12V converters for peripherals 4 eeeeeee eee eese eee eese en seta seta seta staat ta seta sete stato setas etn 16 Fuses and protection P 16 Output T3uIe d Eel ELIOD I TR 17 CHAPTER A IPWR104HR 35W SPECIFICATIONS eere ener 18 Host erageet sapra dod ae io ioe Pa codo 1o oudot sovo dee Eege ENEE 18 AO oU ME TITO CU COL RRRRR 18 COMME CHOI T 18 ElectPomech ani Gal ec 18 CHAPTER 5 RETURN POLICY AND WARRANTY cerent 19 R turn uullo ME 19 CHAPTER 6 LIMITED WARRANTY eere nennen nennen nnns nnns anestesia nan 21 IPWR104HR 35W 4 RTD Embedded Technologies Inc List of Illustrations ERE ERR ER BER RR RERUM RII EN Illustrations Fig 2 1 IPWR104HR 35W integrated in a PC 104 RTD cpuModule stack Fig 2 2 IPWR104HR 35W power supply power connections Fig 3 1 IPWR104HR 35W Block diagram IPWR104HR 35W 5 RTD Embedded Technologies Inc Chapter 1 INTRODUCTION This user s manual describes the operation of the IPWR104HR 35W low cost embedded galvanically isolated power supply unit for automotive and industrial applications Features Some of the key features of the IPWR104HR 35W include
4. IPWR104HR 35W Isolated PC 104 Power supply module User s Manual TIGU RTD Embedded Technologies Inc Real Time Devices Accessing the Analog World BDM 610020006 ISO9001 and AS9100 Certified IPWRIOAHR 35W Power supply module User s Manual RTD Embedded Technologies INC 103 Innovation Blvd State College PA 16803 0906 Phone 1 814 234 8087 FAX 1 814 234 5218 E mail sales rtd com techsupport rtd com Web site http www rtd com IPWR104HR 35W 2 RTD Embedded Technologies Inc Revision History 30 05 2000 HW Release 1 0 15 01 2001 Board renamed from IPWR30 to IPWR104HR 35 10 07 2001 Corrections for Ver 2 1 and formatting Rev A New manual naming method Rev B Modified references to high input modules Published by RTD Embedded Technologies Inc 103 Innovation Blvd State College PA 16803 0906 Copyright 1999 2002 2003 2004 2005 by RTD Embedded Technologies Inc All rights reserved Printed in U S A The RTD Logo is a registered trademark of RTD Embedded Technologies cpuModule and utilityModule are trademarks of RTD Embedded Technologies PhoenixPICO and PheonixPICO BIOS are trademarks of Phoenix Technologies Ltd PS 2 PC XT PC AT and IBM are trademarks of International Business Machines Inc MS DOS Windows Windows 95 Windows 98 and Windows NT are trademarks of Microsoft Corp PC 104 is a registered trademark of PC 104 Consortium All other trademarks appearing in this documen
5. ITED 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 RTD Embedded Technologies acts of God or other contingencies beyond the control of RTD Embedded Technologies OR AS A RESULT OF SERVICE OR MODIFICATION BY ANYONE OTHER THAN RTD Embedded Technologies 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 RTD Embedded Technologies 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 REMEDY SHALL BE REPAIR OR REPLACEMENT AS PROVIDED ABOVE UNDER NO CIRCUMSTANCES WILL RTD Embedded Technologies 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 A
6. N 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 IPWR104HR 35W 21 RTD Embedded Technologies Inc IPWR104HR 35W RTD Embedded Technologies Inc 103 Innovation Blvd State College PA 16803 0906 USA Our website www rtd com 22 RTD Embedded Technologies Inc
7. iliar with technical details of the problem or situation along with their phone and fax numbers address and e mail address if available List your shipping address Indicate the shipping method you would like used to return the product to you We will not ship by next day service without your pre approval Carefully package the product using proper anti static packaging Write the RMA number in large 1 letters on the outside of the package Return the package to RTD Embedded Technologies Inc 103 Innovation Blvd State College PA 16803 0906 USA IPWR104HR 35W 19 RTD Embedded Technologies Inc IPWR104HR 35W 20 RTD Embedded Technologies Inc Chapter 6 LIMITED WARRANTY RTD Embedded Technologies Inc 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 RTD Embedded Technologies INC This warranty is limited to the original purchaser of product and is not transferable During the one year warranty period RTD Embedded Technologies 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 RTD Embedded Technologies All replaced parts and products become the property of RTD Embedded Technologies Before returning any product for repair customers are required to contact the factory for an RMA number THIS LIM
8. logies Inc Main 5V converter for computer The main 5V output is implemented with a monolithic switch mode DC DC converter module Ericsson PKG 4611 PI or PKG 2611 PI 60W converter The peak output current of this unit is 14A This converter has excellent dynamic and transient response capabilities making it ideal for high speed computer power supplies The output current is internally limited against over current and short circuit faults The module is temperature protected to shut down at temperatures above 115 C The output has over voltage protection at 6V The input of this converter is fused with a 10A thermal fuse This will protect the unit from long lasting overload conditions This fuse has a thermal trip of 125 C no matter what current is flowing The input of this converter is protected with a transient absorber diode and a schottky diode These devices are necessary to protect the input in automotive and industrial installations against over voltage spikes and reverse voltage transients These situations exist in vehicle systems that use electrically controlled hydraulic or pneumatic inductive valves The main 5V DC DC converter is galvanically isolated This improves reliability in airborne and industrial applications The peak isolation voltage is 1 5 KV The main 5V converter feeds the PC 104 AT bus 5V pins with power This power can be taken from the board from an external terminal block J2 See previous section for locati
9. on of J2 Current Limit To protect the device against fault or short circuit conditions the 5V DC DC converter module is equipped with a current limiting circuitry to provide continuous overload protection After reaching the current limit point typically 10 to 2596 over the rated peak current the voltage output will range between the rated output and zero depending on the amount of overload At this point the output current will be typically 25 to 30 96 of its maximum value 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 the top edge of the board is the remote ON OFF selection switch Closing this connection will disable the IPWR104HR 35W and place the primary side circuits OFF In this condition the IPWR104HR 35W wvill consume approximately 0 1W of power IPWR104HR 35W 15 RTD Embedded Technologies Inc Secondary 12V and 12V converters for peripherals A 5V to 12V step up converters with 87 efficiency generates 12V for peripheral devices such as EL or TFT panels Hard drives motors etc The 12V converter is 70 efficient The 12V output delivers 2 0A of current and the 12V delivers 500 mAmps The 12V power is available from terminal block J4 The 12V power is available from terminal block J11 See previous section for location of J4 11 The 12V and 12V supplies also power the PC 104 bus power pin
10. ower supply unit to malfunction or even cause permanent damage General installation guidelines e Touch the grounded metal housing of your computer to discharge any e 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 e table on an antistatic surface e Install your board in your system and wire the power supply correctly Failure to do so may cause the power supply unit to malfunction or even cause permanent damage to the device e Check all wiring connections once and then once more again e Check the input power to the board is 18 to 36V DC or 36 to 72V DC e Apply power to your IPWR104HR 35 Installation integrated with a PC 104 module stack e Secure the four PC 104 installation holes with standoffs e Connect the board to the power supplies using the power interfacing connectors IPWR104HR 35W 9 RTD Embedded Technologies Inc IPWR104HR 35W CMMG66866X233HR 32 RTD dataModule Fig 2 1 IPWR104HR 35W integrated in a RTD PC 104 cpuModule stack Note For full output power performance install your IPWR104HR 35W at the top of your PC 104 system and make sure adequate cooling is provided IPWR104HR 35W 10 RTD Embedded Technologies Inc External power connections JN IPWR104HR H35W Kal e eta UepeMS ul epejv Z 01 9g W Lu D Npoy Mod 90 9 TENTAT JOLOMIF A ON AG PEN e e e
11. remote source If the X1 jumper is closed the power supply will become inactive while still powered IPWR104HR 35W 6 RTD Embedded Technologies Inc Board options The IPWR104HR 35W is available in two main input configurations as set out below IPWR104HR 35WL 5V 12V 12V 5V outputs 18 36V input range IPWR104HR 35WH 5V 12V 12V 5V outputs 36 72V input range Mechanical description The IPWR104HR 35W is designed on a PC 104 form factor An easy mechanical interface to both PC 104 and EUROCARD systems can be achieved Stack your IPWR104HR 35W directly on a PC 104 compatible computer using the onboard mounting holes and standoffs Connector description The power connections can be 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 What comes with your board Your IPWR104HR 35W package contains the following items IPWR104HR 35W board with mating connectors for the power connections User s manual If any item is missing or damaged please call RTD Embedded Technologies Inc customer service department at the following number 814 234 8087 IPWR104HR 35W 7 RTD Embedded Technologies Inc Using this manual This manual is intended to help you install your new IPWR104HR 35W module and get it working quickly while also providing eno
12. s There is an additional 5 volt linear regulator cascaded from the 12V that delivers 100 mAmps Fuses and protection To protect your power supply from extensive overload an input fuse has been installed e Fusel F2 Thermofuse 104A trip fuse for IPWR104HR 35W Bottom of board Note The 12V converters are not fused IPWR104HR 35W 16 RTD Embedded Technologies Inc Output power calculations The maximum available peak power for the 5V computer system can be estimated using the following conservative formula The of the main converter is 12A The following calculations assume a 35Watt load on the 5V module L1 12V output current L2 12V output current L3 5V output current E1 12V efficiency 87 max E2 12V efficiency 70 max E3 5V efficiency 77 or 85 high input or low input respectfully L Total load E1 87 E2 0 7 E3 Li should not exceed 35Watts Note Even though the total output peak power of 14A 5V is not exceeded you must remember not to overload an individual output Care must be taken not to thermally overload the unit The IPWR104HR 35W is rated to 35W aggregate continuous output power over the complete specified operating temperature range without additional cooling The maximum peak output power may not be available WITHOUT heat sinking or additional airflow See the following passage for more information on thermal behavior of your IPWR104HR 35W The absolute ma
13. t are the property of their respective owners IPWR104HR 35W 3 RTD Embedded Technologies Inc TABLE OF CONTENTS CHAPTER 1 lINTRODUCTION eere e eren nnne nennen nennen ates nn stans nn atas ssa nn 6 lum Bee ER M oroso esss esssS oeoo 6 Some of the key features of the IPWRIOA4HR 35W include essere nennen 6 Power SUPPLY UNIS ecc neo asoson 6 Mechanical description ssscccscscsssssessssssssssssesscoscssssscesenessssnscesssssossessnessssnescessessessessnssessnessesscssossossnssessnessesooss 7 Connector MESCHIP LOM 0255 oie eter ent etes roba es ote st caovahensacesseassessendsuasduesavosagesindeod aseassesssedeca seas aves cose doi ans saisis Siors 7 What Comes with your board 2 enin ee eere orones eno ron nonae on rae En boob nan ena aan pond on e bed on bn bee aa petu a e een a inen akon Pao roisse ossosa 7 Wh n RER 8 CHAPTER 2 BOARD INSTALLATION eere enne nnn nnne nnne nnn nnn nnns nnn nnan 9 Board installatiOM eL 9 General installation guidelines 4 eee ecce tee aee better eode ne erede ee bie oeste sb deas 9 Installation integrated with a PC 104 module stack 9 CHAPTER 3 HARDWARE DESCRIPTION eren rennen nennen nnn 13 Current Lait os tend EE 15 Remote On Off control 1
14. ugh 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 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 814 234 8087 during East Coast business hours Alternatively send a FAX to 814 234 5218 or Email to sales rtd com When sending a FAX or Email request please include the following information Your company s name and address your name your telephone number and a brief description of the problem IPWR104HR 35W 8 RTD Embedded Technologies Inc Chapter 2 BOARD INSTALLATION The IPWR104HR 35W 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 EUROCARD boards is achieved This chapter tells you step by step how to install your IPWR104HR 35W 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 p
15. ximum long term output figures over the 40 to 84Ctemperature 412V gt 2 0A 12V gt 500mA AN gt 7 0A IPWR104HR 35W 17 RTD Embedded Technologies Inc Chapter 4 IPWR104HR 35W SPECIFICATIONS Host interface 16 bit PC 104 bus only power pins connected Power supply specifications Input voltage range Output Power 35W continuous Efficiency Output voltage unloaded Output voltage fully loaded Short circuit input power Connectors Power connectors Host bus Optionally no bus connector Electromechanical Operating temperature range Base plate temperature Max Heat sink material IPWR104HR 35W 18 70W 18 36V DC for IPWR104HR 35WL version 36 72V DC for IPWR104HR 35WH version 5V 7 0A 12V 2 0A 12V 500mA 85 maximum efficiency at 7 0A 19V 5 20V max 5 04V min 7 5A Phoenix Contact Combicon Series MSTB 2 5 plugs Mini floppy connector AT PC 104 bus 40 to 85 C 4100 C Aluminum anodized RTD Embedded Technologies Inc Chapter 5 RETURN POLICY AND WARRANTY Return Policy If you wish to return a product to the factory for service please follow this procedure Read the Limited Warranty to familiarize you with our warranty policy Contact the factory for a Return Merchandise Authorization RMA number Please have the following available Complete board name e Board serial number A detailed description of the board s behavior List the name of a contact person fam
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