MPS/100 PC/104 Power Supply Module User Manual
Contents
1. MeTIUM MPS 100 PC 104 Power Supply Module User Manual Note The power supply is supplied as shown in the photograph No additional heatsink is required M amp TIUM Revision History Rev Data Changes DRN CHK APP 1 20 Oct 04 Initial release AW AW AW Document Number 108 04 MN 01 A Whilst every care has been taken in the preparation of this document inaccuracies due to typographical or other errors may be present No warranty of accuracy or reliability is given in relation to any advice or information contained in this document and no responsibility for any loss or damage whatsoever arising in any way for any representation act or omission whether express or implied including responsibility to any person by reason of negligence is accepted by Motium or any officer agent or employee of Motium Motium reserve the right to alter the specifications of this product at any time without prior notice This document is copyright and all rights are reserved This document may not in whole or part be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form without the prior consent in writing from Motium Copyright 2004 Motium Pty Ltd MPS 100 User Manual 2 M amp TIUM Table of Content 1 e lj r 4 1 1 IMteENGSd Applications e eey 4 1 2 Ordering OPTIONS hen LEER2. of a voltage They do not indicate if the voltage is within tolerance 2 2 1 Disabling the LEDs Figure 2 AI A ay VIN jov SV ie PC 104 Vehicle Power Supply Location of indicator LEDs green and jumpers orange It is possible to disable the LEDs to reduce power consumption The signal to each LED passes through a 2 pin 2mm pitch jumper LK1 for Vin LK2 for 12V LK3 for 5V and LK4 for 12V The jumper is not fitted in the factory However a short track on the bottom side of the PCB shorts the pins of each jumper To disable the LEDs cut the track between the two pads of each jumper To enable the LED solder a wire link between the pads or fit a piece of 2mm pitch header strip and fit a jumper for each LED 2 3 Jumper LK5 LK5 is only fitted with the Intelligent Power On off Control option Configuration of LK5 is described elsewhere in this manual MPS 100 User Manual M amp TIUM 3 Mechanical details The figure below shows a top view dimensioned mechanical drawing of the MPS 100 Its main purpose is to identify the position of connectors Figure 3 MPS 100 Top view showing various dimensions All dimensions in inches MPS 100 User Manual 13 M amp TIUM 4 Installation considerations This chapter discusses issues to consider when using the MPS 100 in a system 4 14 ESD handling precautions Standard ESD handling precautions should be used with the MPS 100
3. typical upper input voltage limit of 30VDC to 32VDC This still provides ample headroom for 24V powered vehicles Depending on design requirements and system design goals transient protection may not be necessary or it may be more appropriate to place it elsewhere in the system In this case the MPS 100 can be ordered without the MPS 100 For maximum protection the safest approach is to leave the transient suppressor fitted 4 6 Power supply efficiency The two figures below show typical efficiencies for the 5V and 12V output supplies Power supply efficiency varies with input voltage and load current The plots do not include LED current draw or the loss if the reverse polarity protection option is fitted Efficiency does vary with ambient temperature reducing at higher temperatures 98 00 96 00 5V 13A 5V 7A 35 5V 3 5A K 45V 2 2A 94 00 92 00 90 00 Figure 4 5V typical efficiency curves showing efficiency variation with input voltage and load current MPS 100 User Manual 15 96 00 94 00 H 412V 5A 12V 4A 35 12V 3 5A K 412V 3A 9 12V 9 2 5A 92 00 90 00 88 00 86 00 84 00 82 00 Figure 5 12V typical efficiency curves showing efficiency variation with input voltage and load current An
4. 12V outputs short circuit protected and automatically recover when the short circuit is removed e 30 C to 85 C operating range e Automotive connectors maximise reliability in harsh environments e Transient and load dump protection e Intelligent power on off control option 1 4 Specifications The specifications for the MPS 100 are listed in the table below Regulator Performance 45V 12V 12V Output Current 14A maximum 5A maximum 500mA maximum 8A continuous at 4A continuous at 300mA continuous 70 C with no fan 70 C with no fan cooling cooling Output Ripple 20mVp p 200mVp p Line Regulation 1 1 10 Load Regulation 1 1 10 Efficiency 94 typical 93 typical 88 typical Overload Protection Short circuit protected Overall Input Voltage 6VDC to 36VDC Input current The maximum input current depends on the output power It should be limited to 14A continuous Output power 120W maximum 82W 5V 8A and 12V 3 5A fanless MPS 100 User Manual 6 M amp TIUM Environmental Characteristics Operating Temperature 30 C to 85 C Storage Temperature 40 C to 85 C Humidity 1096 to 9096 non condensing Physical Characteristics Dimensions PC 104 format module Overall 90mm 3 55 wide x 95mm 3 75 long plus connectors Component height Max top side 12mm M
5. 4 2 Installation onto PC 104 stacks Take the usual care when plugging the MPS 100 into the female connector on a PC 104 module to ensure that the four rows of pins mate correctly onto the four rows of sockets on the target module Because of the number of rows in the connector it is easy to misalign the modules when plugging them together resulting in one row of pins hanging in air Prior to plugging the modules together it is good practice to check that no pins have been bent due to handling on the PC 104 connector Keying pins B10 and C19 are not fitted on the MPS 100 ensuring the module can be readily plugged into PC 104 modules which have the keying plugs fitted in the female portion of their PC 104 connector 4 2 1 Install at the top of the stack Where possible make the MPS 100 the last card in i e at the top of a PC 104 stack This should provide the best result for convection cooling If the system is fan cooled ensure the air passes horizontally over the MPS 100 and that the air flow is not blocked by the PC 104 connector Ideally air should flow in the same orientation as the PC 104 connector i e the fan should be perpendicular to the PC 104 connector 4 3 Input voltage wiring The system designer needs consider the gauge of wire used when connecting the MPS 100 to the voltage source such as a vehicle s battery At high input currents voltage drop along the wires can be significant Always use the largest practi
6. and 12V outputs without risk of the MPS 100 running too hot DC DC Converter Modules which regulate the input voltage to 5V and then up convert the 5V to 12V are less efficient typically 10 to 15 less efficient on the 12V output and therefore run hotter Input and output power connectors are designed for automotive use with a locking mechanism ideal for high vibration environments like vehicles unlike screw terminals Transient and load dump protection is provided via a 5kW transient suppressor and filter circuit on the power supply input A sophisticated intelligent power on off control function is provided by an optional on board microcontroller Configurable functions provided include e Time delay between when vehicle is turned on and output power goes on e Time delay between when vehicle is turned off and output power goes off e Output power off if the vehicle s engine is not running and the vehicle s battery voltage falls below a specified voltage Configuration is via an RS232 data port using Motium s configuration utility Windows and Linux versions available The RS232 port can also be used to collect status information from the power supply 1 1 Intended applications The MPS 100 was designed primarily to be integrated in equipment designed for use in vehicles cars trucks busses aircraft and boats Its wide input voltage range high output current efficiency and wide operating temperature range al
7. applications staff can provide guidance Minimum order quantities may apply nT Vehicle transient suppressor A 5kW transient suppressor is fitted as standard This is for transient and load dump protection The transient suppressor results in a typical upper input voltage limit of 30VDC to 32VDC The transient suppressor can be removed in non vehicle applications Higher 12V output current In 24V vehicle applications where the 12V and 12V supply does not need to be maintained if the input voltage falls below 12V the topology of the 12V regulator can be changed to provide high output currents with typical efficiency of 97 No PC 104 connector The MPS 100 can also be embedded in industrial equipment which must be powered from 24VDC In these applications the PC 104 connecter may not be required The MPS 100 can be supplied without the PC 104 connector Minimum order quantities apply OEM configurations OEM configurations with different performance characteristics Minimum order quantities apply Table 1 MPS 100 ordering options MPS 100 User Manual M amp TIUM 1 3 Features Key features of the MPS 100 are e 120W PC 104 Power Supply Module e Very high efficiency Up to 95 e 6 VDC to 36 VDC input range e 45V 14A e 12V Q 5A e 12V Q 0 5A e NO forced air cooling required at 5V 8A and 12V 3 5A e 12V is NOT derived from 5V output e 45V and
8. order option for the MPS 100 is for a 12V output with a typical efficiency of 94 across the input range This is only available where 12V is not required for input voltages below 12 4V in 4 7 Input fuse considerations The MPS 100 allows a PCB mount fuse to be fitted A wire link is fitted as standard Depending on design requirements and system design goals a fuse may not be necessary or it may be more appropriate to place it elsewhere in the system or it can be ordered as an option with the MPS 100 The customer needs to specify the fuse rating our applications engineer can provide guidance Things to consider during fuse selection are e Slow blow vs fast blow e Maximum input current at the input voltage range The higher the input voltage the lower the input current Typical operational input voltage ranges in vehicle applications are 12VDC 11 5V to 14 8V 24VDC 18V to 27V e Input current during the time the voltage drops during engine start 5 intelligent power on off control Currently this section is only available on request by customers who order the Intelligent Power On off option MPS 100 User Manual 16
9. 2Vout 2 GND Table 5 J5 pin assignments MPS 100 User Manual M amp TIUM 2 1 5 J6 12V Output Connector 12V out of the MPS 100 is carried on the PC 104 connector J1 and J6 The MPS 100 can be ordered with no connector or a 2 pin connector in this position Pin Signal 1 GND 2 12Vout Table 6 J6 pin assignments 2 1 6 J7 External Control Connector J7 is only fitted with the Intelligent Power On off Control option The MPS 100 is turned on and off in response to e Anexternal Push Button a momentary contact push button wired between PB In and GND e The vehicle s Accessory circuit Both control inputs can be used at the same time Operation and configuration of the power on off function is described elsewhere in this manual Pin Signal 1 PB In 2 GND 3 ACC In Table 7 J7 pin assignments 2 1 7 J10 RS232 Interface Connector J10 is only fitted with the Intelligent Power On off Control option It is an RS232 compatible serial port and is used to configure the power on off function described elsewhere in this manual Pin Signal 1 DCD Low Battery 2 TXD Out 3 RXD In 4 DTR UPS Shutdown 5 CTS AC Fail Out 6 GND Table 8 J10 pin assignments MPS 100 User Manual 2 2 Indicator LEDs Four indicator LEDs show the presence of e Vin e 12Vout e 5Vout e 2Vout The LEDs show the presence or absence
10. 5 1 3 i Liu tpee I ete eee ade eee 6 1 4 Specifications m 6 1 5 Intended uTe I e 7 2 Connectors Links and LEDS 11 cce LLL Le LLL L LLL Lr reise e ecr cere ra anna ananas mnn r casas nuns 8 2 1 To o ez elo REED REDE 8 2 1 1 J1 and J2 PC 104 connectors sesessssssseeeeeeeennn eene nnne nennen nnne 9 2 1 2 J3 Input Power Connector ssssssssssseseeeeeeeeeeneee nennen nennen nennen enne 10 2 1 3 JA 45M Output Connector icici iiie ertet Aen ibid AER REEL RU 10 2 1 4 J5 412V Output Connector ssssssssssseeeeeeneeeeee nennen nennen enne nnnen nent 10 2 1 5 J6 12V Output Gonnector tacere deccei iiiaae 11 2 1 6 J7 External Control Connector eene nnne nennen nnne 11 2 1 7 J10 RS232 Interface Connector ener nnne nennen nennen 11 2 2 Indicator LEDS TEE 12 2 2 1 Disabling the LEDS eiit reete enean eed lost t nnn 12 2 3 Jumper LAS vacos edie 12 Mechanical details sssrin NEERA AAAA 13 Installation considerations eene n nennt nn nennen 14 4 1 ESD handling precautions essessesesseseeeeneeeeneennennenen nennen nene nnne nren enne nennen 14 4 2 Installation onto PC 104 stacks 2 tieni cette eee Ici reta e eaaet ee ieee 14 4 2 1
11. Install at the top of the stack eene mener nnne 14 4 3 Input voltage WINING 3 ere rr rb rn rena repete tr hastens teu eee sepe MUR esie hax 14 4 4 Reverse polarity protection ee EHE Lee A es 14 4 5 Transient suppressor considerations ssesseeeneeeeene nee 15 4 6 Power supply efficienGyY e 15 4 7 INPUT tuse considerations sienien esseiste E PE eR ar aitala ERE rani Onea iaa 16 5 Intelligent power on off control eene enne nnne nnne nennt nnnm 16 MPS 100 User Manual 3 M amp TIUM 1 Overview Motium s MPS 100 is a PC 104 format power supply DC DC converter module Itis designed for use as e a mezzanine power supply module for single board computers SBCs e a power supply module within a PC 104 stack Its wide input voltage range of 6VDC to gt 30VDC makes it ideal for vehicle car bus truck aircraft and marine battery and unregulated input applications Its unique design results in very high efficiencies allowing for high output currents at high ambient temperatures For example no fan cooling is needed at 82W output power 12V 3 5A and 5V 8A even at ambient temperatures of 70 C An important feature is that the 12V and 5V regulators are separate independent regulators The 12V regulator does not take power from the 5V supply This means that high output currents can be simultaneously supplied from the 5V
12. J4 5V GND Output GND S GND J6 12V x 12V Output e X Y r t xx X jt Fam saa GND Output HEHI PC 104 Vehicle Power Supply 108 04 D EE a LKS Figure 1 MPS 100 Top view showing connector LED and jumper positions 2 1 Connectors There are 8 user accessible connectors e Jl and J2 are the PC 104 connector e J3isthe power input connector e JA J5 and J6 are power output connectors Output power primarily passes through the PC 104 stack However the MPS 100 can provide more power than the maximum current allowed to pass through the PC 104 connector pins Typically these connectors are used to power devices that are not part of the PC 104 stack e J7 and J10 are used for intelligent power on off control e J8 is for factory use only The pins are near the center of the PCB No connector is fitted in this position Do not attach anything to the pads MPS 100 User Manual 8 M amp TIUM Useful information 2 1 1 Pin 1 is indicated by a square pad Connector number and positive pins are indicated on the top side component overlay All power connectors are 2 pin or 4 pin JST B2PS VH series right angle 7A pin crimp pin locking type They are readily available including from catalog companies such as Farnell J7 and J10 are Molex KK series connectors right angle 0 1 inch 2 54mm pitch crimp pin friction lock They are readily available including from catalog companies such as Farnell J1 and J2 PC 104 con
13. ax bottom side 3mm Weight 115g net 160g gross PC 104 Connector Stack through connector Keying pins B10 and C19 removed Keying plugs not fitted Specifications are subject to change without notice The input voltage range is based on no transient protection With vehicle transient protection the top end of the input range is 30V to 32V Che actual maximum available output power depends on several system factors Refer to the MPS 100 User Manual for information on this The actual efficiency varies with input voltage Refer to the MPS 100 User Manual for specific information on this Whilst the 12V regulator works with an input voltage down to 6V it is not intended to operate for extended periods of time at 6Vin and high output current In this situation the power supply will become very hot 1 5 Intended audience This manual is written for system integrators and system designers It contains information on installation configuration and operation of a power supply module MPS 100 User Manual M amp TIUM 2 Connectors Links and LEDs The figure below shows the location of the various connectors jumpers and LEDs on the MPS 100 This chapter describes the connectors their functions and pin assignments 410 RS232 Interface j Se e EE Ram 2 S erna wn Contro c 95 c 3 J3 Input Voltage oOotoorooan 909 Zmz O zZz zZ QSr bhr a T 100 Fuse 5V 5V
14. cal wire size to ensure minimum voltage drop across the wires Remember input voltage drop is the sum of current flowing in both the Vin and GND wires So wire resistance needs to be calculated for both the Vin and GND wires 4 4 Reverse polarity protection Input reverse polarity protection is not fitted as standard on the MPS 100 Depending on design requirements and system design goals reverse polarity protection may not be necessary or it may be more appropriate to place it elsewhere in the system or it can be ordered as an option with the MPS 100 The MPS 100 uses a MOSFET instead of a diode The benefits are e Significant efficiency improvement Diodes typically have a voltage drop across them of 0 6V to 1V compared with less than 0 06V for a MOSFET Note the voltage drop varies with input current and ambient temperature MPS 100 User Manual 14 M amp TIUM e A MOSFET removes the hot spot caused by the power loss across a diode e A MOSFET has little impact on the performance at the low end 6VDC of the input range 4 5 Transient suppressor considerations In vehicle computing applications voltage transients are caused each time the engine is started Transients are also caused when the vehicle is jump started and due to load dumps an energy surge caused by disconnecting the battery whilst it is being charged A 5kW transient protector is fitted as standard on the MPS 100 The transient suppressor results in a
15. low it to be used in a wider variety of applications including battery powered equipment and industrial equipment MPS 100 User Manual 4 M amp TIUM 1 2 Ordering options The table below lists the ordering options for the MPS 100 Order Code Option Description Intelligent power on off control The MPS 100 can be supplied with intelligent power on off control This function is not fitted as standard Minimum order quantities apply Power Connectors The MPS 100 is supplied standard with e A2 pin connector fitted in positions J3 Input Power and J4 5V output 4 pin connectors can be fitted in these positions e J6 12V not fitted A 2 pin connector can be fitted in this position Minimum order quantities may apply Reverse polarity protection Input reverse polarity protection is not fitted as standard It is an order option The MPS 100 uses a MOSFET instead of a diode resulting in e Significant efficiency improvement e AMOSFET removes the hot spot caused by the power loss across a diode typical voltage drop across a diode is 0 6V to 1V e Has little impact on the 6VDC input range The voltage drop across the MOSFET is typically less than 0 2V and is directly proportional to input current Fuse The MPS 100 allows a PCB mount fuse to be fitted A wire link is fitted as standard A fuse can be supplied as an option The customer needs to specify the fuse rating our
16. nectors J1 and J2 are the PC 104 connectors J1 is 64 pins and J2 is 40 pins The pin assignments are listed in the table below To ensure maximum compatibility with all PC 104 cards keying pins B10 and C19 and the associated keying plugs are not fitted to allow cards which do not have the keying pins removed to be easily plugged into the MPS 100 J1 J2 Pin Signal Pin Signal Pin Signal Pin Signal A1 GND B1 GND A2 nc B2 nc A3 nc B3 45V A4 nc B4 nc A5 nc B5 nc A6 nc B6 nc A7 nc B7 12V A8 nc B8 nc A9 nc B9 12V CO GND DO GND A10 nc B10 Key no pin C1 nc D1 nc A11 nc B11 nc C2 nc D2 nc A12 nc B12 nc C3 nc D3 nc A13 nc B13 nc C4 nc D4 nc A14 nc B14 nc C5 nc D5 nc A15 nc B15 nc C6 nc D6 nc A16 nc B16 nc C7 nc D7 nc A17 nc B17 nc C8 nc D8 nc A18 nc B18 nc C9 nc D9 nc A19 nc B19 nc C10 nc D10 nc A20 nc B20 nc C11 nc D11 nc A21 nc B21 IRQ7 C12 nc D12 nc A22 nc B22 IRQ6 C13 nc D13 nc A23 nc B23 IRQ5 C14 nc D14 nc A24 nc B24 IRQ4 C15 nc D15 nc A25 nc B25 nc C16 nc D16 45V A26 nc B26 nc C17 nc D17 nc A27 nc B27 nc C18 nc D18 GND A28 nc B28 nc C19 Key nopin D19 GND A29 nc B29 45V A30 nc B30 nc nc no connect A31 nc B31 GND A32 GND B32 GND Table 2 MPS 100 J1 and J2 pin connections MPS 100 User Manual M amp TIUM 2 1 2 J3 Input Power Connector Po
17. wer into the MPS 100 is supplied through connector J3 J3 has a maximum rating of 7A per pin The MPS 100 can be ordered with a 2 pin or 4 pin connector fitted The deciding factor is total output power which determines total input power and therefore maximum input current For operation in 24V vehicles typically only the center two pins need to be connected Pin Signal 1 Vin 2 Vin 3 GND 4 GND Table 3 J3 pin assignments 2 1 3 J4 5V Output Connector 5V out of the MPS 100 is carried on the PC 104 connector J1 and J2 and J4 The MPS 100 can be ordered with no connector or a 2 pin or 4 pin connector in this position The deciding factor is total output power at 5V J4 has a maximum rating of 7A per pin A typical PC 104 connector has a maximum rating of 2A or 3A per pin 6A or 9A from the PC 104 stack The MPS 100 s PC 104 connector has a rating of 3A per pin Pin Signal 1 5Vout 2 5Vout 3 GND 4 GND Table 4 J4 pin assignments 2 1 4 J5 12V Output Connector 12V out of the MPS 100 is carried on the PC 104 connector J1 and J5 The MPS 100 can be ordered with no connector or a 2 pin connector in this position The deciding factor is total output power at 12V J5 has a maximum rating of 7A per pin A typical PC 104 connector has a maximum rating of 2A or 3A per pin The MPS 100 s PC 104 connector has a rating of 3A per pin Pin Signal 1 1
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