TRI-M ENGINEERING HE104, Technical Manual

Page 1: ...modules be sent to Tri M directly As always the WinSystems Applications Engineering department is available to assist as needed 2008 WinSystems Inc All rights reserved HE104 TRI M Technical Manual WinSystems Inc 715 Stadium Dr Arlington TX 76011 http www winsystems com Email info winsystems com Phone 817 274 7553 Tri M Systems and Engineering Inc Vancouver Sales Office Unit 100 1407 Kebet Way Port...

Page 2: ...rtor 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 ...

Page 3: ...O PC104 MODULES 10 2 6 JUMPER SELECTION 10 2 6 1 LED Jumper Enable Disable 10 2 6 2 5VDC Low Q Noise Q quiescent 11 2 6 3 12VDC Low Q Noise 11 2 6 4 Mezzanine Expansion Headers 11 2 7 PC 104 BUS INTERRUPTS OPTIONAL 12 2 8 POWER MANAGEMENT CONTROLLER PM104 OPTIONAL 13 2 9 LOW INPUT ALARM 14 2 10 HE104 EFFICIENCY AND HEAT DISSIPATION CALCULATION 15 CHAPTER 3 THEORY OF OPERATION 16 3 1 INPUT POWER PR...

Page 4: ...ineering 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 Engineer...

Page 5: ...C 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 12VDC output is protec...

Page 6: ...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 Highly compact 100 percent PC 104 conforming AC bus termination available Screw terminals provide off board connection to output voltages Figur...

Page 7: ... 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 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 Current rating includes current supplied to 12V 12V 5V...

Page 8: ...3C 6L3 E mail info tri m com Canada Web site www tri m com 7 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: ...2VDC 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 pola...

Page 10: ...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 mod...

Page 11: ...emoved It is important to note that the female sockets are not plugged Although it is highly recommended the female sockets 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 th...

Page 12: ...nnecting 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 ...

Page 13: ...s 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 Two separate interrupt requests can be generated and each interrupt request will remain activ...

Page 14: ...r and generation of interrupts to the PC 104 host CPU The PM104 is programmed in a high level controller basic 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 C...

Page 15: ...ol HE104 On Off control 9 P2 Input Output Pin 2 Connector CN6 8 Analog Digital Chip Select 10 P3 Input Output Pin 3 Int2 Connector CN6 7 Spare Input Output 11 P4 Input Output Pin 4 Connector CN6 6 Data Input Output Line 12 P5 Input Output Pin 5 Connector CN605 Data Clock 13 P6 Input Output Pin 6 Int1 Connector CN6 4 Spare Input Output 14 P7 Input Output Pin 7 Connector CN6 3 Analog Current Limit I...

Page 16: ...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 ...

Page 17: ...ilter 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 capacitor C5 A total of 15 amperes can be supplied to the connected 5VDC load and 12VDC regulator the 5VDC 12...

Page 18: ...rst 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 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 ...

Page 19: ...R 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...

Page 20: ... RC SOIC packages 3 only 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 SD0 LA21 DACK7 DRQ1 IRQ3 6 SD1 LA20 SD11 SA...

Page 21: ...ering 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 20 APPENDIX 1 HE104 5V Regulator Block Diagram 1 1 HE104 12V 12V 5V Regulator Block Diagram ...

Page 22: ...23 June 2005 HE104MAN V8 Manual 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 21 ...

Page 23: ...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 advant...

Page 24: ...ng 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 400...

Page 25: ...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 op...

Page 26: ...nt 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 ...

Page 27: ...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 simultaneou...

Page 28: ...YMBOL Pwrp_Status pin0 Pin number of status of input power SYMBOL PSU_On Off 1 OnOff control of power supply SYMBOL PSUp_OnOff pin1 SYMBOL CS1 2 Chip select A D on Battery Charger 0 active SYMBOL CS1p pin2 SYMBOL Int2 3 PC 104 bus interrupt SYMBOL Int2p pin3 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 o...

Page 29: ...rm 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 applica...

Page 30: ...el 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 SYMBOL AD w1 12 bit ADC conversion result SYMBOL Chrg Time w2 16 bit timer SYMBOL Batt_Peak w3 Peak voltage ...

Page 31: ...tery 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 D0 0 Gosub Convert debug AD Batt_V Get battery charging voltage if AD Batt_V then No_ Power return No_Power debug no_pwr pause 50 let Bat1_Chrg 0 Indicate battery has been discharged PWM Chrg_Limit 0 50 turn off charge current Go...

Page 32: ... 2005 HE104MAN V8 Manual 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 31 Distributed By ...