Hardware Manual - RTD Embedded Technologies, Inc.
Contents
1. 12V for peripheral devices e Onboard status LED s e Overload protection e Output power calculations HPWR104HR 13 RTD Embedded Technologies Inc 832V DC INPUT Input Protection 5V 15A Converter to PC 104 bus and Peripherals D pom PC 104 16 bit Bus Fig 3 1 Block diagram of the HPWR104HR HPWR104HR 14 RTD Embedded Technologies Inc 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 converter2. eere 18 ja Siirautie REP 18 Power s pply Specifications ea cierre terere eter Peta eee E Ub o6 S5 0b i Sosok eooo poo teeobe Sieb osse e SENS eU EDU serv odere PY E SENSIT 18 COMMECHONS enr TP E S 18 Electromie chanical ccccccscsiccccasisiscccctsciecceesestacedsvescecescdetaaiectaedcosed vededchstedssusutsssaebsutedcoeseasdcteductsstentbsdsedesasocescestedesthedtetastdeDesdesdeaceuteos 18 CHAPTER 5 RETURN POLICY AND WARRANTY eene nnne tentent nnns 20 IREtUEM POLICY e m RP M n 20 CHAPTER 6 LIMITED WARRANTY eere nente tentent tenete terns testen 22 HPWR104HR 4 RTD Embedded Technologies Inc List of Illustrations E 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 Embedded Technologies Inc 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 32V 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 T5V 12V 12V Two status LED s Standard floppy power output connector J12 Fully PC 104 compliant O
3. 104 compliant computer using the onboard mounting holes Care must be taken to ensure adequate 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 fom 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 HPWR104HR package contains the following items HPWRIOA4HR board with mating connectors for the power connections User s manual If any item is missing or damaged please call RTD Embedded Technologies 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 HPWR104HR 7 RTD Embedded Technologies Inc 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 814 234 8087 during European busin
4. A 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 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 LIMIT
5. ATIONS 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 22 RTD Embedded Technologies Inc HPWR104HR RTD Embedded Technologies Inc 103 Innovation Blvd State College PA 16803 0906 USA Our website www rtd com 23 RTD Embedded Technologies Inc
6. HPWR104HR High efficiency PC 104 power supply module User s Manual TIGO RTD Embedded Technologies Inc Real Time Devices Accessing the Analog World BDM 610020005 Rev A ISO9001 and AS9100 Certified HPWR104HR 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 HPWR104HR 2 RTD Embedded Technologies Inc Revision History 24 06 1999 Release 1 0 10 07 2001 Name of company and format Release 1 3 hardware release Rev A New manual naming method Published by RTD Embedded Technologies Inc 103 Innovation Blvd State College PA 16803 0906 Copyright 1999 2002 2003 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 utility Module 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 document are the property of their respective owners HPWR104HR 3 RTD Embedded Technologies Inc
7. TABLE OF CONTENTS CHAPTER 1 INTRODUCTION eren tette ttn sns stessa 6 CAGES PASADO IRR ERREUR GIRRENIS AED E E UE RURSUS IRE VENUE ESAE DOR R COEUR EA T E E ARDOR URN ER UETRT 6 CHAPTER 2 BOARD INSTALLATION sssssssssessessssssesueeseeseesusssesneestesucsuceseeseesuesseeneeaenseens 9 IAE WOBUCIEU RRRR 9 General installation guidelines sees tenente ttn ten entente tenen tenete aS ENES Era iEn 9 Installation integrated with a PC 104 module stack sss eene tnter tentent tenente tenente 9 Connector descriptions pe 12 CHAPTER 3 HARDWARE DESCRIPTION serere teret tenente tnt ten tense 13 Current Limit octo A Risa teet A ne tet Fee RU be nic a oda he 15 R mote Onm Off control ted tete pm dete SRS es 15 Secondary 12V and 12V converters for peripherals eere eere erect ee eere tenen etta ense tn suene en sn sensn suene nen sn ene nen ene 15 Overload protection ih Ee ettet teo eS eb osioon atese Doo ein vi SN nO Enor TE VEEE Vroe ve NEONO esae OSE Doa e SN Te eCR UNTEN 16 Output power Calculations NET Rr O 17 The absolute maximum long term output figures are sesesssseesessee eene tette terne tenente tenete te tenete te tenete te tenente 17 CHAPTER 4 HPWR104HR SPECIFICATIONS
8. The absolute maximum long term output figures are 12V gt 2A 12V gt 0 5A 5V gt 15A HPWR104HR 17 RTD Embedded Technologies Inc 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 Input voltage range under light load 2596 Output Power 75W total Efficiency Output voltage unloaded Output voltage fully loaded Connectors Power connectors Host bus Optionally no bus connector Electromechanical Operating temperature range Heat sink temperature Max Internal power dissipation Heat sink material HPWR104HR 18 8 32V DC 6 30V DC 5V 15A 12V 2 0A 12V 500mA 80 5 15V max 4 95V min 15A Phoenix Contact Combicon Series Mini floppy connector AT PC 104 bus 40 to 85 C 85 C 25W Max Aluminum RTD Embedded Technologies Inc CE approval CE approved in an IDAN installation HPWR104HR 19 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 yourself with our warranty policy Contact the factory for a Return Merchandise Authorization RMA number Please have the following available Complete board name Board serial number A detailed description of the board s behavior List th
9. e name of a contact person familiar 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 HPWR104HR 20 RTD Embedded Technologies Inc HPWR104HR 21 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 RM
10. er connections HPWR104HR 11 RTD Embedded Technologies Inc Connector descriptions e JI Raw input power to the HPWR104HR Input voltage range is 8 32V DC Overvoltage protected with transient absorber with cutoff at 33V DC Note The module input power may be up to 100 W 12 54 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 JII 12V Output Only on 2 versions of HPWR104HR e JA 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 XI 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 12 RTD Embedded Technologies Inc Chapter 3 HARDWARE DESCRIPTION This chapter describes the major features of the HPWR104HR which are the following e The main 5V converter for the computer and PC 104 bus e The secondary power output converters 12V and
11. ess 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 HPWR104HR 8 RTD Embedded Technologies Inc Chapter 2 BOARD INSTALLATION The HPWR104HR 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 correc
12. 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 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 HPWR104HR 15 RTD Embedded Technologies Inc Onboard status LED s The HPWR104HR is equipped with 2 indicator LED s The function of the LED s is described below e LEDI Green Indicates 5V power converter is alive e LED2 Green Indicates 12V converter is alive Overload pro
13. perating 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 The HPWR104HR power supply unit offers a complete reliable power subsystem for your sophisticated computer and peripherals To improve reliability in noisy environments he 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 HPWR104HR 6 RTD Embedded Technologies Inc 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
14. tection The 5V converter 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 HPWR104HR 16 RTD Embedded Technologies Inc 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 l2 12V output current B 45V output current bus 5V to bus 75W H 12 0 80 12 12 0 80 0 8 _bus 5 13 5 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
15. tly e 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 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 e Connect the board to the power supply using the power interface connectors HPWR104HR 9 RTD Embedded Technologies Inc Aluminium Heateink HPWRIO4 CMM626G6X233HR 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 10 RTD Embedded Technologies Inc 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 pow
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