Tri-M Systems HE104 User's Manual
Contents
1. WinSystems An Employee Owned Company WinSystems partners with Tri M Systems WinSystems is pleased to be partnered with the Tri M industrial power supply group Tri M is a leader in industrial PC 104 DC DC power supplies With Tri M s outstanding reputation for support we recommend all technical and RoHS inquiries regarding their modules be sent to Tri M directly As always the WinSystems Applications Engineering department is available to assist as needed HE104 TRI M Technical Manual Tri M Systems and Engineering Inc WinSystems Inc Vancouver Sales Office 715 Stadium Dr Unit 100 Arlington TX 76011 1407 Kebet Way Port Coquitlam BC V3C 6L3 http www tri m com http www winsystems com Canada Telephone 604 945 9565 Email info winsystems com Toll free 800 665 5600 Phone 817 274 7553 2008 WinSystems Inc All rights reserved PC 104 Vehicle Power Supply High Efficiency amp Smart Charging Vehicle Power Supply DC to DC Convertor Manufactured by TRI M ENGINEERING Engineered Solutions for Embedded Applications Technical Manual P N HE104MAN V8 Revision 23 June 2005 TRI M ENGINEERING 1407 Kebet Way Unit 100 Port Coquitlam BC V3C 6L3 Canada http www Tri M com Tel 604 945 9565 North America 800 665 5600 Fax 604 945 9566 TRI M 23 June 2005 HE104MAN V8 Manual CHAPTER WHICH elle el BEEN 4 SEN EE EE El Eed A CH E NI 5 USR lieu le NND ULM 6 22. eeeeeee nennen nennen nean nnn nnn nann mean nai sanas a esas aa saa a as KENNEN sas aae aaa aae a aa 16 S INPUTPOWERPROFTEGTIONaS nup I MI sue SAT A ST SA N SA SIS I NI LE SAN UP ana NE 16 9 2 SWITCHING REGULATOR 5 DG aa Si rira II SITS TG a AT SAS A ANG SIR E ae EPI EVI M PI S P LI SPP INI NAP EID SII DID TTS KH 16 3 3 SWITCHING REGULATOR EE RE 17 em CHARGE PUMP Sioe Gan NG 17 3 5 FILTER CAPACITORS aaa ana naka anu Ed a ane A Cpu Coen Redux onda ido dedicate dicun Eo aa a aie ade n d e n nue e di eae tu n 18 3 0 BUS TERMINATION OPTIONAL sanan aaa ana 19 APPENDIX 1 HE104 5V REGULATOR BLOCK DIAGRAM eeeeeeee nennen nennen nnnm angene naen amena aaa a anna 20 APPENDIX 2 ADVANTAGES OF USING AC TERMINATION eeeeeeeee enne nnne nnnm nn nnne nana nean anna a naa 22 APPENDIX 3 INSTALLATION HINTS FOR THE HE104 POWER SUPPLY eeeeeee eene nennen nnn nana 23 APPENDIX 4 VEHICLES ARE AN ELECTRONICS NIGHTMARE eeeeeeee nennen nnne nnn nnn annnm nana aaa a naa 23 Tri M Engineering Tel 800 665 5600 604 945 9565 2 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual PREFACE This manual is for integrators of applications of embedded syste
3. Get battery charging voltage let Batt_V AD PWM Chrg Limit Trickle LVL 1000 Turn on Trickle current Low Chrg_Limit Trickle to minimum current 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 Bart 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 AO1 LVL 1000 first apply charge current then check for charge termination Tri M Engineering Tel 800 665 5600 604 945 9565 30 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M TRI M 23 June 2005 HE104MAN V8 Manual Distributed By Tri M Engineering Tel 800 665 5600 604 945 9565 31 T R g RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com
4. Low Noise is for low ripple noise To change the factory default setting to Low Q operation the small jumper connecting JP2 1 to JP2 2 must be cut using the tip of a sharp knife and solder a jumper across the pads JP2 2 to JP 3 To return to Low Noise operation remove the jumper between JP1 2 and JP2 3 and re install the jumper connecting JP2 1 to JP2 2 2 6 4 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 Tri M Engineering Tri M Engineering Tel 800 665 5600 604 945 9565 11 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com E HE104MAN V8 Manual e ic H1 10 Mezzanine Connectors 1 i8 zZz 9 g 5 NS Ja 7 5 6 Figure 2 3 HE104 Mezzanine Connectors Connector CN5 Pinout Connector CN6 Pinout 1 45V 10 5V 1 PM104 P1 10 Main Pwr Input 2 Common 9 Common 2 Common 9 Common 3 Battery Input 8 Main Pwr Input 3 PM104 P7 8 PM104 P2 4 Ext Signal 1 7 12V 4 PM104 P6 7 PM104 P3 5 Ext Signal 2 6 5V 5 PM104 P5 6 PM104 P4 2 7 PC 104 Bus Interrupts Optional Interrupts to the PC 104 bus require the installation of the optional power management mircrocontroller PM104 The PM104
5. 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 ESR e Vout e 1 Vout Vin Vp p L1 e frequency Tri M Engineering Tel 800 665 5600 604 945 9565 18 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com HE104MAN V8 Manual ENGINEERING 23 June 2005 Note that only the ESR of the output capacitor is used in the formula lt is assumed that the capacitor is purely resistive at the frequencies about 20kHz Worst case output ripple is at highest input voltage Ripple voltage is independent of load for continuous mode Example Vout 5V Vin 28V L1 55uH frequency 50kNz and three 330uF capacitor with 27 mohm ESR in parallel 0 009 e 5e 1 5 Vp p 28 55 e 10E6 0 5 10E5 3 6 Bus Termination Optional AC bus termination is provided by 5 RC SOIC packages 3 only
6. WINTRODUGTION ETT EE E 7 22 POWERGONSIDPERATONS agin aa aa nane aa en na a Be a Da Ba TA TANG E DAN Na a E ENG KE ANG a a D a DA RE TE KE Ba Ga DAN NA GEN ANG KE NRG a DKE NA E TE Ka Da Ka DENK ga 8 23 HE IOA ERNEIEREN 8 2 3 1 Main Input Power CGonmechor nnhhs sss s nsn n ANEKA seni tran nnns sss nenen anane 8 2 3 2 Output Power CGonnechor n AANE KANANE nsns isses ssa tran nnns s sss ssi nnns ssa 9 2 3 3 Battery Power Connector Optional 9 2 3 4 Onboard PC Boost Adaption Coiional sessi nens seen n inris nnn 9 2 4 BUS TERMINATION OPTIONAL ENEE 10 2 5 INSTALLATION ONTO PC TOA MODULES 552 cix SNG taa Le dava caeca n da ea da C ena Ra Cav aaa ea aua daa aua Dea tua ea d ua EY UE a CRM RE 10 2 0 JUMPER SELECMON METTE 10 AONIESSESUtlo gmiEUMBIEEIU EEE 10 2 6 2 5VDC Low Q Noise Q quiescent sasae anan anaa a anana eee nnh ns sss n nara nagane nass inan nnns 11 216 38 FIZVOC LOW GAMME 11 2 6 4 Mezzanine Expansion Headers esssssississsssss sessi Naga aana n sinn asnhhs sss s sinn nans enhn sans sinn a nnns 11 2 7 POOABU SINTERRUPTS OPTIONAL s eto ten ten tete ttt ttd ds 12 2 8 POWER MANAGEMENT CONTROLLER PM104 OPTIONAL cssssssssesseeeeeeeeenenn nennen nnnnemrnn nennen nn nnnner nsns nnn nnns 13 2 9 LOW Ee e 14 2 10 HE104 EFFICIENCY AND HEAT DISSIPATION CALCULATION cccccceceeececeeeceeeecaeneceeeaeeeeeeeueeeeeeaeaeeeeeaeeeeeeauaeeeeeaaeeeanes 15 CHAPTER 3 THEORY OF OPERATION
7. a low heat sink temperature The input voltage and output load is determined by the system application This leaves only the heat sink temperature that System Intergrators adjust to maximize efficiency Either the forced flow fans which thermally couples the HE104 heat sink to enclosures or external heat sinks can improve the efficiency of the HE104 An improvement of 3 to 4 percent can be obtained by good thermal management in which the results are 35 percent less heat dissipated A Heat Dissipated HD Input Power Actual Load Where Input Power Input Voltage Input Current and Actual Load 5V load 12V load 5V load 12V load Load measured in watts B Estimated Heat Dissipated ESD can be calculated based on 90 percent efficiency EHD 5V load 12V load 12V load 0 9 0 1 C If the Battery Input option is installed or the Reverse Diode Protection RDP option installed additional heat will be dissipated RDPD Total Load Input Voltage 0 7V diode drop D If the Battery Charger Option is installed the heat dissipated from it will vary according to the current charge current Maximum heat dissipation will occur when charging at maximum current and can be estimated by BCD Maximum Charge Current Charge Voltage 0 2 Based on 80 percent efficiency Tri M Engineering Tel 800 665 5600 604 945 9565 15 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info
8. asny yndu gt JOSO 190 q 2 a veo 7 Bunad dul U01 99 01g 3UaISUEJ pue dung peo1 indu 33AOF 0 20A9 V1 40jonpuj esueg juang ECH J0 sISe Bue ndino ai lt CH oe o 9 S Tri M Engineering Tel 800 665 5600 604 945 9565 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com G Canada Web site www tri m com 20 Ce E el lt 09 gt r o S We Current Sense y 5V from 5V regulator Resistor R23 Inductor L1 Current SC Diode Output Filtering SS S 5 CBA B RC EE EEN Sg S Sz 5 To IC1 amp ICH Regulators docs S Upper Mosfet Q7 Level Shifting Circuit E E m amp Driver C13 C19 D6 D13 ae I2VDC Output 010 amp R26 9 oo U o Q GND E 92 SYDE Plugin amp VDC Output Ze s Charge Pump DZS I2 Switching 12VDC input 4 di 2 5 Regulator g 8 E sob c EFES C22 Timing Capacitor GND 23 June 2005 9 D u L 9 A u e L ka TRI M 23 June 2005 HE104MAN V8 Manual APPENDIX 2 ADVANTAGES OF USING AC TERMINATION One of the requirements of embedded electronics is 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 driv
9. be plugged to prevent mis alignment with other PC 104 modules however this is left up to the customer 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 of the pins or cutting the person separating the modules Tri M Engineering recommends the use of the PC 104 removal tool model 5535 is available from Tri M Engineering 2 6 Jumper Selection This section describes the function the location of it the default setting and how to change each jumper on the HE104 V8 2 6 1 LED Jumper Enable Disable The jumpers that are located behind each LED allow the LEDs to be disabled which are most likely to be used when absolute minimum power consumption is maintained such as when operating off a limited battery source 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 Tri M Engineering Tel 800 665 5600 604 945 9565 10 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 2 6 2 5VDC Low Q Noise Q quiescent This jumper allows the 5VDC regulator IC1 to be changed from the l
10. can be programmed to power low battery voltage or to provide indication to the PC 104 of program operation provide indication of loss of input CPU to begin an orderly shutdown 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 Inti can be set to IRQ6 or IRQ7 while interrupt Int2 can be set to IRQ4 or IRQ5 by installing an appropriate jumper on jumper selections block J4 Jumper block J4 is located adjacent to the PC 104 bus on the opposite side where the power LEDs are located Tri M Engineering Tel 800 665 5600 604 945 9565 12 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual t D D C ca ca E Cr Ce i E i old A 21 ld Selection of Im 1 IRQ o 6 e 82 o of o elt o ri Ja F JA F J E E E old e Je old Selection of Imz IRG o o o o 8 elt o elt o e 7 og o4 7a J4 7 i 4 E CA Un C cr ce Figure 2 2 Interrupt IRQ Selection 2 8 Power Management Controller PM104 optional The Power Management Controller PM104 is a microcontroller plug in module for timed on off control of the HE104 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
11. float voltage is obtained No load should be present when adjusting Tri M Engineering Tel 800 665 5600 604 945 9565 26 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual m bak C had E Fir Ws o flee eLurrert Livi Sec F lize vulia 4 Jim p1 um UM Jis m 4 Je 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 Pwr Status 0 Status of input power SYMBOL Pwrp Status pinO Pin number of status of input power SYMBOL PSU On Off 1 OnOff control of power supply SYMBOL PSUp_OnOff pint SYMBOL CS1 2 Chip select A D on Battery Charger O active SYMBOL CS1p pin2 SYMBOL Int2 3 PC 104 bus interrupt SYMBOL Int2p ping SYMBOL DIO 4 Pin number of data input output SYMBOL DIOp pin4 Variable name of date input output SYMBOL CLK 5 Clock to ADC out on rising in on falling edge SYMBOL CLKp pin5 SYMBOL Inti 6 PC 104 bus interrupt SYMBOL Intp pin6 SYMBOL Chrg Limit 7 PWM output for current limit SYMBOL Chrgp_Limit pin7 SYMBOL Bat_Set bi
12. for 8 bit PC 104 bus HE 104s RC1 to RC5 and discrete components C20 and C27 Each RC package contains 16 resistor capacitor combinations of 47R and 47PF with a common bus connected to the signal ground RC1 RC2 RC3 RC4 RC5 1 GND GND GND GND GND 2 SMEMW IRQ10 BACK6 SA11 SA3 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 Ion 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 SA1 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 Tri M Engineering Tel 800 665 5600 604 945 9565 19 T RII RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com mememe 23 June 2005 HE104MAN V8 Manual APPENDIX 1 HE104 5V Regulator Block Diagram 1 1 HE104 12V 12V amp 5V Regulator Block Diagram aNd TRI M RQ lt g O 3 ki joyoedey Huw 1 Jojyeinbay Buana L3 rO Jayson Joddp
13. is put into sleep mode again When low quiescent power mode is enabled regulator IC2 Burst mode operation will begin at approximately 0 3 ampere output Note Low quiescent power mode should only be selected if absolute minimum current consumption is required At output currents about 0 3 amperes low quiescent power mode will not increase efficiency and may result in regulator IC2 jumping into Burst mode resulting from noise on the 12VDC output No harm to IC2 will occur from this but increased ripple on the 12VDC output will occur 3 4 Charge Pumps The 12VDC is generated by first charging capacitor C13 to 12VDC when mosfet Q7 is turned off Diode D6 provides a path to common for the charge current When mosfet Q7 is turned on the charge on C13 is transferred to the 12VDC output capacitor C9 through mosfet Q10 Mosfet Q10 is synchronized with mosfet Q7 through a level shifter C19 D13 and R26 The 5VDC is generated by a secondary coil on inductor L1 By design the inductor in a buck regulator will maintain the output voltage across it The secondary winding having the same number of turns as the primary will also have the same output voltage across it By referencing the positive end of the secondary coil to common 5V is created Diode D3 and capacitor C14 improve the regulation Capacitor C16 provides output filtering The 5V is rated at 500mA however for best regulation the 5V load should be limited to 1
14. modules plugged into the mezzanine header connectors Connect to the HE104 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 40V input The two external signals are fed into the 12 bit analog to digital convertor and will accept voltages up to 40V The sample program requires the External signal 1 Terminal 3 be connected to Positive Battery voltage Terminal 2 for battery voltage sensing Tri M Engineering Tel 800 665 5600 604 945 9565 25 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual A variety of temperature sensors can be connected including thermistors and conditioned sensors such as LM35s The 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 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 Conne
15. 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 aircraft 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 Tri M Engineering s High Efficiency PC 104 Vehicle Power Supply employs a Diode Inc part 5KP43A allowing an input voltage range of 6V to 40V 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 ambients 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 alt
16. tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 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 10 ampere pico fuse F1 limits the current draw from the power source A series of devices toroid coil L3 transorb D4 and filter capacitors C8A C8B and C8D filters and clamps the input power Transorb D4 is a 5KVA heavy duty transient suppressor Transorb D4 provides zener type protection and has an avalanche voltage of 43V 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 switching regulator IC1 generates the 5VDC output which operates in a buck mode synchronous switching regulator configuration It does this by using inductor coil L1 upper mosfet Q4 lower mosfet Q5 schottky diode D8 input filter capacitors C8A C8B C8C C8D and output filter capacitors C2 C3 C9A C9B and C9C Regulator IC1 is a current mode controller that adjusts the switching cycle by the sensed current instead of directly by the output voltage sensing error amplifier in regulator IC1 This further sets the current trip level Operating frequency is set by cap
17. 0 percent of the 5V load Tri M Engineering Tel 800 665 5600 604 945 9565 17 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 3 5 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 The filter capacitors absorb the switching ripple current with their 100m0hm ESR that absorbs a 5A ripple current and will dissipate 2 5W of heat The capacitors used for filtering in the HE104 are organic semiconductor OS CON capacitors The OS CON is an aluminium solid capacitor with organic semi conductive electrolyte used as 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 the temperature acceleration coefficient 2 for a 10C increase while the OS CON has a temperature acceleration coefficient 2 10 for a 20C increase
18. 104 multiple output DC to DC 50 watt converter is a high efficiency high performance unit that can be supplied with 5V 12V outputs only or can include features such as Power Management Universal Battery Charger AC Bus termination 5V output 12V output and custom output voltages from 42V to 42V The HE104 is designed for low noise embedded PC 104 computer systems which has a wide input range of 6 to 40V gt 6 1 and is ideal for battery or unregulated input applications The HE104 is specifically designed for vehicular applications and has heavy duty transient suppressors 5000W that clamp the input voltage to safe levels Further it is able to maintain normal power supply operation The HE104 is a state of the art MOSFET based design that provides outstanding line and load regulation with efficiencies up to 95 percent Organic Semiconductor Capacitors provide filtering which reduces ripple noises below 20mV The low noise design makes the HE104 ideal for use aboard aircraft military applications or 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 so it can operate without dropout from 6 to 40V input and supply 2A The 5VDC output is protected from output shorts by a high speed pulse by pulse current limit circuit Furthermore 12V
19. 5V output 10A I 5 I 12 2 4 I 12 e 2 4 0 The 5V switching regulator is rated at 10A maximum output however the 5V output supplies power to the 12VDC 5VDC and 12VDC regulators To obtain the usable range of 5V output derate according to the use of 12VDC 5VDC and 12VDC Use the following formulae to calculate the maximum usuable output Where I 5 5VDC current load I 12 12VDC current load I 12 12VDC current load Assuming 90 percent convertor efficiency actual efficiency may vary 2 3 HE104 Connectors 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 6VDC to 40VDC Unregulated vehicle power is connected as follows Terminal 1 hot polarity Terminal 2 Common OVDC CAUTION To allow operation at the lowest possible input voltages 6VDC and for the best efficiency there is no input Reverse Polarity Diode RPD provided on the HE104 without a battery charger option If input RPD is required add RPD to the HE104 part number Example HE 104 512 16 RPD Note Adding the RPD results in an increased power loss For heat dissipation estimation please refer to section 2 11 Tri M Engineering Tel 800 665 5600 604 945 9565 8 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3
20. C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 2 3 2 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 Terminal 4 12VDC output optional Terminal 5 5VDC output optional 2 3 3 Battery Power Connector Optional Batteries are connected to the screw terminal block CN3 The HE104 accepts DC battery voltages in the range of 6 5V to 40DVC 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 HE104 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 4 2 3 4 Onboard PC Boost Adaption Optional An optional converter Boost pump model NMHO5XXS XX output voltage 5V 9V 12V 15V can be installed in location VR3 to provide custom output voltages The NMH charge pumps have an isolated positive and negative output and a maximum 2 watt capacity A minimum load of 10 percent is required for proper operation By connecting the charge pump to other voltages the user can cr
21. 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 sglDif 1 SYMBOL msbf 1 SYMBOL AO1 LVL gt SYMBOL Bay Max 1100 SYMBOL Chrg Time Max 210800 SYMBOL Neg DeltaV 8 SYMBOL Trickle LVL 0 SYMBOL Bay Min 740 Main Loop Init Low PSU OnOff TRI M Tri M Engineering 1407 Kebet Way Unit 100 ENGINEERING Canada Port Coquitlam BC V3C 6L3 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 Tel 800 665 5600 604 945 9565 Fax 604 945 9566 E mail info tri m com Web site www tri m com 29 TRI M 23 June 2005 HE104MAN V8 Manual Let Bat1 chrg 0 Main Ban Low PSU OnOff Just making sure PSU stays on If Bat1 Chrg 1 then Batt Trickle is battery already charged Goto Bat Chrg Batt Trickle debug trickle gosub Chk Pwr let D1 0 let DO 0 gosub Convert
22. DC output is protected from shorts by the current limiting of the 5VDC controller A plug in Universal Battery Charger BC104 is available for the HE104 to charge Lead Acid NiCd and NiMH batteries Charge currents can be up to1 5A and battery charging voltages range from 6 to 40V The Power Management controller PM104 allows for timed on off control of the HE104 bus interrupts on impending power failure current limit setting and intelligent charge termination for the BC104 The HE104 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 available for off board use through a screw terminal block PC 104 AC bus termination is an option that is available on the HE104 that provides the cleanest possible signals on the PC 104 bus The HE104 can be configured to meet almost any power supply need for embedded PC 104 applications This could be a simple 5V application which provides for back lighted LCD panels or a full UPS un interruptible power supply configuration Tri M Engineering Tel 800 665 5600 604 945 9565 4 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 1 2 Features e DC to DC convertor for PC 104 bus equipped produ
23. N V8 Manual Current rating includes current supplied to 12V 12V amp 5V regulators Measured on the 5V output EDS disabled Low Quiescent mode enabled Not including passthrough pins T Tri M Engineering Tel RII RA 1407 Kebet Way Unit 100 Fax Port Coquitlam BC V3C 6L3 E mail ENGINEERING Canada 800 665 5600 604 945 9565 6 604 945 9566 info tri m com Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual CHAPTER 2 CONFIGURATION AND INSTALLATION 2 1 Introduction This chapter describes the configuration and installation of the HE104 power supply In addition section 2 2 provides a formula to calculate the available 5VDC Figure 2 1 shows the HE104 connectors jumpers and other options 12U adjust ccustom voltages only 5U ouput 5U Low B No1se 12U ouput Jumper pads 12U ouput Common 5U ouput CN2 Connector Connector CN3 Common Battery Input ansion Bus Ji 8 Bit PC 104 Exp J2 16 Bit PC 104 Expansion Bus 5 h 12 H2 Pouer Management J4 IRQ Selection Power LEDS Microcontroller Jp3 LED CN4 Power Management Program Connector Enable Disable Jumpers Tri M Engineering Tel 800 665 5600 604 945 9565 7 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 2 2 Power Considerations Usable
24. a 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 Tri M Engineering Tel 800 665 5600 604 945 9565 28 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 Let DIOp DO Pulsout CLK 2 Low CS1 Input DIO Pulsout CLK 2 Input DIO Pulsout CLK 2 Let AD 0 For Adbits 1 to 13 Pulsout CLK 2 Let AD AD 2 DIOp Next Adbits High CS1 Return HE104MAN V8 Manual next bit of command Activate the LTC 1594 Get ready for input from LTC 1594 Dummy statement for delay Sampling requires two clocks Clear old ADC result Get null bit 12 data bits Clock next data bit in Shift AD left add new data bit Get next data bit Turn off the ADC 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 0 is usually jumpered to
25. acitor C5 A total of 15 amperes can be supplied to the connected 5VDC load and 12VDC regulator the 5VDC 12VDC charge pumps and the invertors The 5VDC power is available on the PC 104 expansion bus and screw terminal connector CN2 At start up a low dropout 4 5V source located in regulator IC1 provides the operating voltage Vcc for the mosfets and control circuitry After start up regulator IC1 is in a sleep mode whenever the output level is within the burst mode voltage limits As soon as the 5VDC output drops below the burst low level voltage normal switching regulator operation begins and continues until the 5VDC output reaches the upper burst level voltage Then regulator IC1 is put into sleep mode again When low quiescent power mode is enabled regulator IC1 burst mode operation will begin at approximately 1 5 ampere output The output ripple when regulator IC1 is operating in burst mode is 50millivolts The 5VDC regulator functions fully down to 6VDC input Below 6VDC input the 5VDC output will track the input and have a drop proportional to the resistive losses on the HE104 The HE104 operates up to 40VDC input Tri M Engineering Tel 800 665 5600 604 945 9565 16 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 3 3 Switching regulator 12VDC A switching regulator IC2 g
26. ct 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 power 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
27. cts e Load Dump transient suppression on input power supply Operates from 6VDC to 40VDC input e Stacks onto the PC 104 bus e Passthrough or non passthrough 8 bit and 16 bit versions e 5V 12V standard 12V 5V and battery charger optional e Highly compact 100 percent PC 104 conforming e AC bus termination available e Screw terminals provide off board connection to output voltages 3250 mil d k Seu m 3575 mil 3775 mil 400 mil 200 m1 gt gt L COMI C2 ats eres zis 7 200 m1 05D nii 3350 m1 3550 mil Figure 1 1 HE104 Dimensions 1000milz1in Tri M Engineering Tel 800 665 5600 604 945 9565 5 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com 23 June 2005 1 3 Specifications Power Supply Specifications Model HE104 5V output 10A 12V output 2A 5V output 400mA 12V output 500mA Input Voltage Range 6 to 40V Load Regulation 60mV Line Regulation 40mV Output temp drift 40mV Switching Frequency 75kHz Max Input Transient 125V for 100msec Output Ripple 20mV Conducted Susceptibility gt 57db Efficiency up to 95 Temp Range 40 to 85C Quiescent current 2mA Size PC 104 form factor compliant 3 55 W x 3 75 L x 0 6 Height HE104MA
28. e 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 This disadvantage to reducing drive current is the increasing possibility for noise to infiltrate 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 had 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 makin
29. eate more or less supplies as well as elevated and negative voltages i e The charge pump OV is not connected to the HE104 common Terminal 1 Common of battery Terminal 2 V output Terminal 3 ON Terminal 4 V output Tri M Engineering Tel 800 665 5600 604 945 9565 9 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual Examples of NMH0515S can generate the following voltages 15V by connecting NMH OV to HE104 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 as it improves the reliability of the bus The resistor capacitor combination only conducts a current during the few nanoseconds when the bus signal is changing state See appendix B 2 5 Installation Onto PC104 Modules The PC 104 bus on the HE104 is keyed according to the standards as set out by the PC 104 Consortium Guidelines Pin B10 of the 8 bit bus and pin C20 of the 16 bit bus are removed It is important to note that the female sockets are not plugged Although it is highly recommended the female sockets
30. enerates the 12VDC output and operates in a Boost mode switching regulator configuration which uses inductor coil L2 mosfet Q7 schottky diode Q6 input filter capacitors C9A C9B C9C and output filter capacitors C15A and C15B Capacitors C9A C9B and C9C work as an output filter for the 5VDC and as an input filter for the 12VDC regulator IC2 Regulator IC2 is a current mode controller and adjusts the switching cycle by the sensed current rather than directly by the output voltage Using the output of a voltage sensing error amplifier in regulator IC2 does control the output voltage which is sensed by resistors R18 and R19 This further sets the current trip level If a custom output voltage is ordered variable resistor R21 in series with R19 will adjust the feedback voltage Operating frequency is set by capacitor C22 A total of 2 amperes can be supplied to the connected 12VDC load and the 12VDC invertor The 12VDC power is available on the PC 104 expansion bus and screw terminal connector CN2 A low quiescent power mode uses the built in Burst mode feature of the regulator IC2 Low quiescent power mode reduces power by placing regulator IC2 in a sleep mode whenever the output level is within the Burst mode voltage limits As soon as the 12VDC output drops below the burst low level voltage normal switching regulator operation begins and continues until the 12VDC output reaches the upper burst level voltage Then regulator IC2
31. ents 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 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 Tri M Engineering Tel 800 665 5600 604 945 9565 23 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 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 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
32. g it more likely that 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 off 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 Tri M Engineering Tel 800 665 5600 604 945 9565 22 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual APPENDIX 3 Installation Hints for the HE104 Power Supply 1 To minimize noise induced into the power supply connect the HE104 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 HE104 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 HE104 power supply on to the top of the HE104 card stack This will allow better dissipation of heat from the heat sink If additional cooling is required use eithe
33. hough 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 APPENDIX 5 BC104 Battery Charger and PM104 Power Management Units 1 Description When the BC104 and PM104 units are both installed on either the V104 or HE104 hereafter referred to as PSU as 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 Tri M Engineering Tel 800 665 5600 604 945 9565 24 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mai
34. l info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual 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 trickly charge current 1 20 to 1 30 of battery capacity Addition of a battery temperature sensor will allow charge termination when 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 battery backup power for a set time tracking power consumption so that backup battery charging can be terminated when same amount restored to the battery These features are left to the OEM integrate into their design 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 H e H1 1 Mezzanine Connectors l 1g es i5 a NS e Nz in the range of 6 5 to 20VDC through the Battery Power Connector CN3 Two external signals can be connected to the battery terminal block for use by add on
35. language called Pbasic To program the PM104 connect the program cable PM104 Cable to connector CN4 on the HE104 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 HE104 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 Tri M Engineering Tel 800 665 5600 604 945 9565 13 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com 23 June 2005 Table 2 1 IC3 PINZ PM104 Microcontroller Description IC3 PM104 Supply Voltage HE104MAN V8 Manual PM104 Pin Number and I O Functions HE104 Function or Connection HE104 Supply Voltage Battery Charger Function Common Common PCO PC out Connector CN4 3 PCI Pc in Connector CN4 4 plus5V input output No connection Reset No connection PO Input Output Pin 0 Input Voltage Status P1 Input Output Pin 1 HE104 On Off Control HE104 On Off control Oo old OT oc BP WO DY P2 Input Output Pin 2 Connector CN6 8 Analog Digital Chip Select zech e P3 Input Output Pin 3 Int2 C
36. ms It contains information on hardware requirements and interconnection to other embedded electronics DISCLAIMER Tri M Engineering 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 Tri M Engineering 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 Tri M Engineering 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 Tri M Engineering at the address listed on the title page of this document COPYRIGHT 2000 03 22 TRI M ENGINEERING No part 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 Tri M Engineering Tri M Engineering Tel 800 665 5600 604 945 9565 3 T R E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M 23 June 2005 HE104MAN V8 Manual CHAPTER 1 INTRODUCTION 1 1 GENERAL DESCRIPTION The HE
37. onnector CN6 7 Spare Input Output P4 Input Output Pin 4 Connector CN6 6 Data Input Output Line N P5 Input Output Pin 5 Connector CN605 Data Clock zech Wi P6 Input Output Pin 6 Int1 Connector CN6 4 Spare Input Output zech AZ P7 Input Output Pin 7 Connector CN6 3 Analog Current Limit H Interrupt function is not used this PM104 line can be used for general purpose Input Output 2 9 Low Input Alarm This output signals the Power Management circuit PM104 or external circuitry that main input power has failed The Low Input Alarm signal has a 100K current limiting resistor in a series If the PM104 is not installed then external circuitry can access the Low Input Alarm output on connector IC3 7 Tri M Engineering Tel il E E RA 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com 800 665 5600 604 945 9565 14 TRI M 23 June 2005 HE104MAN V8 Manual 2 10 HE104 Efficiency and Heat Dissipation Calculation The average efficiency for the 5V output of the HE104 is 90 percent The efficiency however at any specific input voltage output load and ambient temperature many be higher or lower Typical efficiency is between 88 and 94 percent Best efficiency occurs at mid input voltage ranging from16 to 18V mid output loads are from 20 to 30 watts and
38. ow ripple noise mode into the low quiescent power mode This option is most likely to be used when absolute minimum power consumption must be maintained such as when operating off a limited battery source It is recommended that the 12vDC Low Noise mode be selected whenever the 5VDC Low Q mode is not required The PCB jumper trace is located on the bottom of the circuit board between two pads Location of the jumper is identified on the left side of the heat sink by Low Q Noise Refer to figure 2 1 for exact location of 5VDC Low Q Noise jumper The factory default setting for Low Q Noise is for low ripple noise To change the factory default setting to Low Q operation the small PCB jumper trace must be cut using the tip of a sharp knife To return to Low Noise operation solder a jumper connecting the jumper pads 2 6 3 12VDC Low Q Noise This jumper allows the 12VDC regulator IC1 to be changed from low ripple noise mode into the low quiescent power mode This option is most likely to be used when absolute minimum power consumption must be maintained such as when operating off a limited battery source The PCB jumper trace is located on the bottom of the circuit board between two pads of jumper block JP2 Location of the jumper is identified on the right side of the heat sink by Low Q with Low Noise directly below it Refer to figure 2 1 for exact location of 12VDC Low Q Low Noise jumper The factory default setting for Low Q
39. r forced air ventilation or mount the PC 104 power supply so that the heat sink can dissipate heat to the enclosure APPENDIX 4 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 Electronics 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 transi
40. t1 SYMBOL Adbits b1 SYMBOL Bat1_Chrg bit1 Counter variable for serial bit reception SYMBOL DO bit2 SYMBOL D1 bit3 LSB of ADC channel selection second bit of ADC channel selection Tri M Engineering Tel 800 665 5600 604 945 9565 27 1407 Kebet Way Unit 100 Fax 604 945 9566 Port Coquitlam BC V3C 6L3 E mail info tri m com ENGINEERING Canada Web site www tri m com TRI M TRI M 23 June 2005 HE104MAN V8 Manual D1 0 DO 0 channel 0 input ping of connector ONG D1 0 DO 1 channel 1 input pin4 of connector CN3 1 on max cell voltage 2 on time 3 ve delta V 4 cell temperature next TCnt let D1 0 let DO 0 gosub Convert Get battery charging voltage let Batt_V AD debud charge if AD gt BattV_Max then Batt_Chrg_Term Chrg_Time Chrg_Time 1 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 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 dat
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