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TRI-M ENGINEERING HE104 Technical Manual

Pc/104 vehicle power supply, high efficiency & smart charging vehicle power supply dc to dc convertor
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WinSystems
is pleased to be partnered with the Tri-M
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power supplies. With Tri-M
we recommend all technical and RoHS inquiries regarding their
modules be sent to Tri-M
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HE104 TRI-M
Tri-M Systems and Engineering, Inc.
Vancouver Sales Office
Unit 100
1407 Kebet Way
Port Coquitlam, BC V3C 6L3
http://www.tri-m.com
Canada Telephone: 604.945.9565
Toll free: 800.665.5600
is a leader in industrial PC/104 DC/DC
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  • Page 1 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.

  • Page 2: June

    PC/104 Vehicle Power Supply High Efficiency & 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...

  • Page 3: Table Of Contents

    HE104MAN-V8 Manual 23 June 2005 CHAPTER 1: INTRODUCTION............................4 1.1 GENERAL DESCRIPTION .............................4 1.2 F ................................5 EATURES 1.3 S ...............................6 PECIFICATIONS 2.1 I .................................7 NTRODUCTION 2.2 P ............................8 OWER ONSIDERATIONS 2.3 HE104 C ...............................8 ONNECTORS 2.3.1 Main Input Power Connector ...........................8 2.3.2 Output Power Connector..........................9 2.3.3 Battery Power Connector (Optional) ........................9 2.3.4 Onboard PC “Boost”...
  • Page 4 HE104MAN-V8 Manual 23 June 2005 PREFACE This manual is for integrators of applications of embedded systems. 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.

  • Page 5: Chapter 1: Introduction

    HE104MAN-V8 Manual 23 June 2005 CHAPTER 1: INTRODUCTION 1.1 GENERAL DESCRIPTION The HE104 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.

  • Page 6: Features

    HE104MAN-V8 Manual 23 June 2005 1.2 Features DC to DC convertor for PC/104 bus equipped products. “Load Dump” transient suppression on input power supply. Operates from 6VDC to 40VDC input. “Stacks” onto the PC/104 bus. Passthrough or non-passthrough 8 bit and 16 bit versions. 5V, 12V standard, -12V, -5V and battery charger optional.

  • Page 7: Specifications

    HE104MAN-V8 Manual 23 June 2005 1.3 Specifications Power Supply Specifications Model HE104 5V output* 12V output -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.

  • Page 8: Introduction

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 9: Power Considerations

    HE104MAN-V8 Manual 23 June 2005 2.2 Power Considerations Usable +5V output =10A – (I [-5] + I [-12] 2.4 + I [12] 2.4) 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”...

  • Page 10: Output Power Connector

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 11: Bus Termination (Optional)

    HE104MAN-V8 Manual 23 June 2005 Examples of NMH0515S can generate the following voltages: 15V by connecting NMH “0V” 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.

  • Page 12: 5Vdc Low Q/ Noise (Q=Quiescent)

    HE104MAN-V8 Manual 23 June 2005 2.6.2 +5VDC Low Q/ Noise (Q=quiescent) This jumper allows the +5VDC regulator IC1 to be changed from the 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.

  • Page 13: Pc/104 Bus Interrupts (Optional)

    HE104MAN-V8 Manual 23 June 2005 Figure 2.3, HE104 Mezzanine Connectors Connector CN5 Pinout Connector CN6 Pinout 1. +5V 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.

  • Page 14: Power Management Controller Pm104 (Optional)

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 15: Low Input Alarm

    HE104MAN-V8 Manual 23 June 2005 Table 2.1 PM104 Pin Number and I/O Functions IC3 PIN# PM104 Microcontroller Description (IC3) HE104 Function or Connection Battery Charger Function PM104 Supply Voltage HE104 Supply Voltage Common Common PC0 (PC out) Connector CN4-3 PCI (Pc in) Connector CN4-4 plus5V input/output No connection...

  • Page 16: He104 Efficiency And Heat Dissipation Calculation

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 17: Chapter 3: Theory Of Operation

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 18: Switching Regulator, +12Vdc

    HE104MAN-V8 Manual 23 June 2005 3.3 Switching regulator, +12VDC A switching regulator IC2, generates 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.

  • Page 19: Filter Capacitors

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 20: Bus Termination (Optional)

    HE104MAN-V8 Manual 23 June 2005 Note: that only the ESR of the output capacitor is used in the formula. It is assumed that the capacitor is purely resistive at the frequencies about 20kHz. Worst case output ripple is at highest input voltage.

  • Page 21: Appendix 1: He104, +5V Regulator Block Diagram

    HE104MAN-V8 Manual 23 June 2005 APPENDIX 1: HE104, +5V Regulator Block Diagram: 1.1 HE104, +12V, -12V, &-5V Regulator Block Diagram 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 Canada Web site: www.tri-m.com...
  • Page 22 HE104MAN-V8 Manual 23 June 2005 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 Canada Web site: www.tri-m.com...

  • Page 23: Appendix 2: Advantages Of Using Ac Termination

    HE104MAN-V8 Manual 23 June 2005 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.

  • Page 24: Appendix 3: Installation Hints For The He104 Power Supply

    HE104MAN-V8 Manual 23 June 2005 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.
  • Page 25 HE104MAN-V8 Manual 23 June 2005 (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.
  • Page 26 HE104MAN-V8 Manual 23 June 2005 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.
  • Page 27 HE104MAN-V8 Manual 23 June 2005 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.
  • Page 28 HE104MAN-V8 Manual 23 June 2005 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.
  • Page 29 HE104MAN-V8 Manual 23 June 2005 ‘D1 = 0, D0 = 0 channel 0 input, pin3 of connector CN3 ‘D1 = 0, D0 = 1 channel 1 input, pin4 of connector CN3 ‘1. on max cell voltage ‘2. on time ‘3. –ve delta V ‘4.
  • Page 30 HE104MAN-V8 Manual 23 June 2005 Let DIOp =D0 ‘next bit of command Pulsout CLK.2 ‘Activate the LTC1594 Low CS1 ‘Get ready for input from LTC 1594 Input DIO Pulsout CLK.2 ‘Dummy statement for delay Input DIO ‘Sampling requires two clocks Pulsout CLK.2 Let AD = 0 ‘Clear old ADC result.
  • Page 31 HE104MAN-V8 Manual 23 June 2005 Let Bat1_chrg = 0 Main_Batt1: 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 D0 =0 gosub Convert ‘Get battery charging voltage let Batt_V =AD...
  • Page 32 HE104MAN-V8 Manual 23 June 2005 Distributed By: 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 Canada Web site: www.tri-m.com...

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