V104 Vehicle Power Supply A PC/104 DC to DC Converter Manufactured by TRI-M ENGINEERING Engineered Solutions for Embedded Applications Technical Manual P/N: V104MAN-V7 Revision: 12 September 2006 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.
V104 Manual 12 September 2006 CHAPTER 1 - INTRODUCTION.......................................................................................................................................................................................4 1.1 GENERAL DESCRIPTION.............................................................................................................................................................................4 1.2 FEATURES ............................................................
V104 Manual 12 September 2006 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.
V104 Manual 12 September 2006 CHAPTER 1 - INTRODUCTION 1.1 GENERAL DESCRIPTION The V104 multiple output DC to DC 25 watt converter is a versatile, “bullet-proof” unit that can be supplied with as a +5V, outputs only or can include features such as Power Management, Universal Battery Charger, AC Bus termination, +12V output, -5V output, -12V output and custom output voltages from –42V to +42V.
V104 Manual 12 September 2006 1.2 FEATURES - DC to DC converter for PC/104 bus equipped products. “Load Dump” transient suppression on input power supply. Operates from 8VDC to 30VDC input. “Stacks” onto the PC/104 bus. Passthrough or non-passthrough 8 bit and 16 bit versions. +5V standard, +12V, -12V, -5V and battery charger optional. Highly compact, 100 percent PC/104 conforming. AC bus termination available. Screw terminals blocks for off-board connection to outputs.
V104 Manual 12 September 2006 1.3 SPECIFICATIONS Power Supply Specifications Model V104 5V output* 5A 12V output 1A -5V output 400mA -12V output 160mA Input Voltage Range 8 to 30V Load Regulation ** <30mV Line Regulation ** + 40mV Output temp. drift ** <10mV Switching Freq. 100kHz Output Ripple** <40mV Conducted Susceptibility** >57db Efficiency** Up to 80% Temp Range 0 to 70C Quiescent current*** 22mA Weight 150 grams Size, PC/104 form factor compliant**** 3.55"W. x 3.75"L x 0.
V104 Manual 12 September 2006 CHAPTER 2 – CONFIGURATION AND INSTALLATION 2.1 Introduction This chapter describes the configuration and installation of the V104 power supply. In addition, section 2.2 provides a formula to calculate the available +5VDC. Figure 2-1 shows the V104 connectors, jumper and other options. Figure 2-1, V104 Connector and Jumpers Tri-M Engineering 1407 Kebet Way, Unit 100 Port Coquitlam, BC V3C 6L3 Canada Tel: Fax: E-mail: Web site: 800.665.5600, 604.945.9565 604.945.
V104 Manual 12 September 2006 2.2 Power Considerations The +5V switching regulator is rated at 5A maximum output however, the +5V output supplies power to the +12, -5 and –12VDC regulators. The usable range of the +5V output can be calculated using the following derating formula. Usable +5VDC output = 5A-(I[-5] +I[12]*2.4) /0.80) Where: I[-5] = -5VDC current load I[-12] = -12VDC current load I[12] = 12VDC current load Assuming 80 percent converter efficiency (actual efficiency may vary). 2.3.
V104 Manual 12 September 2006 2.3.3 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 output (optional) Terminal 4: -12VDC output (optional) Terminal 5: -5VDC output (optional) 2.3.4 Battery Power Connector (Optional) The batteries are connected to the screw terminal block, CN3. The V104 accepts DC battery voltages in the range of 8V to 30VDC through the Battery Power Connector.
V104 Manual 12 September 2006 Example: NMH0515S (+15V) can generate the following voltages: - +15V by connecting NMH “0V” to V104 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.
V104 Manual 12 September 2006 2.6.2 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. Figure 2.3, V104 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.
V104 Manual 12 September 2006 2.6.3 PC/104 Bus Interrupts (Optional) Interrupts to the PC/104 bus require the installation of the optional power management mircrocontroller (PM104). The PM104 can be programmed to provide indication of loss of input power, low battery voltage or to provide indication to the PC/104 CPU to begin an orderly shutdown of program operation.
V104 Manual 12 September 2006 2.7 V104 Efficiency and Heat Dissipation Calculation The typical efficiency of the V104 is 80 percent for the +5V output, but efficiency at any specific input voltage, output load and ambient temperature may be higher or lower. Typical efficiency is between 70 and 85 percent. Best efficiency occurs at mid input voltage (16 to 18V), mid output loads (10 to 18 watts) and low heat sink temperature.
V104 Manual 12 September 2006 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 V104, 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 language” called Pbasic.
V104 Manual 12 September 2006 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 seven ampere ‘pico’ fuse F1 limits the current draw from the power source. A series of devices, (toroid coil L3, transorb D4 and filter capacitor C12) filters and clamps the input power.
V104 Manual 12 September 2006 3.4 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. Since the filter capacitors must absorb the “switching ripple” current, capacitors with high ESR values will quickly overheat. For example, a capacitor with a 100mOhm ESR which is absorbing a 5A ripple current, will dissipate 2.5W heat.
V104 Manual 12 September 2006 Note: only the ESR of the output capacitor is used in the formula. It is assumed that the capacitor is purely resistive at frequencies above 20kHz. Worst case output ripple is at highest input voltage and is independent of load. 3.5 Bus Termination (Optional) AC bus termination is provided by 5 “RC” SOIC packages (3 only for 8-bit PC/104 bus), RC1 to RC5 and discrete components C20 and C27.
V104 Manual 12 September 2006 APPENDIX 1 Advantages of Using AC Termination One of the requirements of embedded electronics is for 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 drive current can be as low as 4mA.
V104 Manual 12 September 2006 APPENDIX 2 Installation Hints for the V104 Power Supply 1. To minimize noise induced into the power supply, connect the V104 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 V104 power supply to the vehicle power source (battery). This minimizes any voltage drop caused by the resistance of the wire.
V104 Manual 12 September 2006 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 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.
V104 Manual 12 September 2006 APPENDIX 4 BC104 Battery Charger and PM104 Power Management Units 1) Description When the BC104 and PM104 units are both installed on either the V104 (hereafter referred to as PSU), a 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.
V104 Manual 12 September 2006 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 in the range of 8 to 20VDC through the Battery Power Connector CN3.
V104 Manual 12 September 2006 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 CN4-2 CN4-3 CN4-4 No connection Connect to pin 25 on parallel port Connect to pin 11 parallel port Connect to pin 2 parallel port 4.
V104 Manual 12 September 2006 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.
V104 Manual 12 September 2006 If Chrg_Time > 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
V104 Manual 12 September 2006 Return ‘Return to program. ‘D1 = 1, D0 = 0 channel 2 input, monitors input voltage of battery regulator ‘D1 = 1, D0 =1 channel 3 input, monitors battery charging current ‘Note: channel 0 is usually jumpered to 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.
V104 Manual 12 September 2006 Goto Main_Batt1 Chk_Pwr: Let D1 = 1 Let D0 = 0 Gosub Convert ‘debug AD, Batt_V if AD < Batt_V then No_ Power return No_Power: ‘debug “no_pwr” pause 50 let Bat1_Chrg = 0 PWM Chrg_Limit, 0.50 Goto Main_Batt1 ‘Get battery charging voltage ‘Indicate battery has been discharged ‘turn off charge current Battery Charger Program Batt_Chrg: Let Chrg_Time = 0 Chrg_Lp: Gosub Chk_Pwr For TCnt= 0 to 1 PWM Chrg_Limit,A01_LVL,1000 ‘Initialize charge timer (counts in sec.
V104 Manual 12 September 2006 Distributed By: Tri-M Engineering 1407 Kebet Way, Unit 100 Port Coquitlam, BC V3C 6L3 Canada Tel: Fax: E-mail: Web site: 800.665.5600, 604.945.9565 604.945.9566 info@tri-m.com www.tri-m.
