Opus Solutions DCX 4 User manual

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 1
Technical support: Email: [e-mail] Tel:[phone] x225
Package Contents
1 - DCX 4. Automotive ATX intelligent DC-DC 500W Power Supply
1 - 24 pin ATX power cable with ATX12V power and Drive connectors
1 - 4 Pin Drive power cable for HDD/SSD power
1 - 2 pin power switch cable for DC-DC to Soft Power Switch connector pins on MB.
1 - 2 pin IGN pigtail cable for Vehicle ACC or ON/OFF to J2 of DC-DC
1 - 8 pin EPX 12V cable for MB Power
1 - 6 pin PCI-e 12V cable for GPU Power
1 - User guide (the one you are reading)
General Information
DCX4 is an intelligent DC-DC power supply. It monitors and protects the battery from deep discharge. It is designed to
power ATX, BTX, ITX motherboards and single board computer systems. DCX4 can also be used to power any Single
board computer. System power up and down can be controlled by the vehicle ignition switch output. System shut
down can be delayed (from 5 min to 2 hr) after Ignition (ON/OFF) input is turned off. Start up and shutdown voltage
can be set or changed using JU1 jumper position 4 & 5 (refer figure JU1 jumper block setting)
Remote output can be used to turn on/off peripherals such as Radio, head units, LCD Monitor, etc.
Remote output can be turned off before or after the shut down dely. This is controlled by JU2 jumper position 7.
Remote output can be delayed to prevent thumps in Audio installation. Contact OPUS for proper SW loading.
DCX4 is Compatible with 12 or 24 Volt battery system operation. To operate in 24V mode load JU2- position 8 jumper.
This will ensure proper low voltage start-up and shut-down sequence in the event of low voltage in 24V mode.
Operating Modes
DCX4 is designed to operate in 4 different modes. The mode settings are determined by the by your specific
application and/or by the mother board/ Single board computer. Operating modes are setup using JU2 jumper block
positions 9 & 10 Jumpers.
Refer to fig: JU2 jumper setting.
ATX mode with ON / OFF state input: Mother board: ATX power compliant.
Requires 5VSB, uses soft power switch pins of mother board to power up the system and PS_ON signal to
control state of main power.
System power-up & power down is controlled by ON/OFF input pin of DCX4 (J2 –pin 2).
DCX4 PWR-SW (J7) output connected to mother board soft power switch pins (observe correct polarity).
PS_ON input (PS_ON signal is part of ATX power connector).
ATX mode with PB (momentary ON/OFF push-button switch) for ON/OFF: Mother board: ATX power compliant.
Requires 5VSB, uses soft power switch pins of mother board to power up the system and PS_ON signal to
control state of main power.
System power-up & power down is controlled by front panel soft ON/OFF Push-Button switch (Front panel
push button switch is connected to Mother board Soft power switch pins).
DCX4 PWR-SW (J7) output: no connection.
PS_ON input (PS_ON signal is part of ATX power connector).
Sub ATX mode:Mother board: Partially ATX power compliant.
May Require 5VSB or 12V SB, uses soft power switch pins of mother board to power up the system and
PS_ON signal is NOT used.
System power-up & power down is controlled by ON/OFF input pin of DCX4 (J2 –pin 2).
DCX4 PWR-SW (J7) output connected to mother board soft power switch pins (observe correct polarity).
PS_ON signal is not used
AT mode: Mother board: AT power compliant.
System power-up & power down is controlled by ON/OFF input pin of DCX4 (J2 –pin 2).
DCX4 applies power to the system/ load when ON/OFF input is connected to battery voltage. Turns off the
power to the load when ON/OFF input is disconnected from the battery voltage.

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 2
General wiring guidelines
Use a dedicated #10 AWG wire or thicker wire to connect the unit to the battery. If Battery wire length is more than 10
feet then use next thicker wire gauge.
Note: Do not share power cable with other equipment. It is highly recommended to run a separate pair of fused power
cable to the PC. This eliminates the noise injection from other equipments that share power.
Use minimum of #18 AWG wire for on/off input.
Testing the PC with DC-DC Power supply installed for proper operation
Power-up the computer by Turning the Ignition switch on (starting the vehicle) or toggling the switch on. The Green
Status LED should light up constantly and the computer should power up normally.
(Note: After connecting the power connecter to the power supply, wait for DC-DC to blink twice before
turning on the IGN/ ON-OFF switch input. This procedure is required every time the power is applied
to the DC-DC main power (yellow) leads.)
1. Open any application and test for normal operation then close the application.
2. Turn off the computer by turning the ignition switch off. Within 5-10 Sec. the PC should start to go into
Standby or shut down mode and the Green status light should go back to the idle/standby blink rate.
4. Wait about 10 seconds and Turn on the Ignition switch again. The computer should power up normally.
5. Open an application for Standby mode testing. Use the application as you would normally.
6. Turn off the computer by turning the ignition switch off. The computer should go into Standby, Hibernate or
Shut down mode, as configured in the operating system.
7. Repeat steps 4 to 6 for all applications that are used in your computer.
Note: All applications software must be checked for proper Standby mode operation.
If any application has problem going into Standby mode then the operating system must be configured for Shutdown

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 3
DC-DC power supply Connectors
J1 –Power Input Terminals
J1 Power Input Terminals
Pin# Function Description
J1-B BATT Battery Positive (FromVehicleBattery thru aFuse)
J1-G GND Ground (Battery Return) BATT
GND # 6 Screw
Terminals
J2 –Ignition or ON/OFF Input connector
Pin# Function Description
1 RMT Remote On/OFF (Output - Blue)
2 IGN Ignition or ON/OFF (Input - RED) 1
2Connectorused: Molex: 39-30-0020
Mating connector: Molex: 39-01-2025
RMT- This output can be used to turn ON/OFF the remote devices such as Data Acq, Camera, monitor, etc. Remote
turn ON delay is set by JU2jumper positions.
J3 –External / Remote LED connector
Pin# Function Description
1 LED+ ToExternal LEDAnode - output
2 LED- ToLED Cathode - output
3 OB LED- On Board LEDCathode - input Factory Default Setting: Pin 2 andPin 3 are
shorted withshorting jumper foron boardLED or
Trace shorted on PCB on Bottomside of PCB
Toconnect External LED: Remove shorting jumper and Connect Anode of external LEDto pin 1 and cathode to pin 2
1
2
3
Connector type used: JST: B/S 3B-PH-K-S
Mating connector type: JST: PHR-3
J7 –Power-Switch Output connector
Pin# Function Description
1PWR-SW+ Power-Switch + (Output - GRN)2 PWR-SW- Power-Switch - (Output - WHT)
Connect to Motherboard or SBC power switch pins. OBSERVE pin polarity for proper operation
1 -
2 + Connector type used: JST: B/S 2B-PH-K-S
Mating connector type: JST: PHR-2
J9 –ATX / BTX Motherboard Power connector
Pin# Function Description
1 +3.3V +3.3V (Output - ORN)
2 +3.3V +3.3V (Output - ORN)
3 GND Power Ground (Return - BLK)
4 +5V +5V (Output - RED)
Pin# Function Description
13 +3.3V
14 -12V
No connection
15 GND PowerGround (Return - BLK)
16 PS-ON*
24
9
101112
212223
678
181920
345
151617
12
1314
5 GND
+12V (Output - YEL)
6 +5V Power Ground (Return - BLK)
7 GND Power Ground (Return - BLK)
8 PWR-GD
+5V (Output - RED) 17 GND 18 GND PowerGround (Return - BLK)
19 GND PowerGround (Return - BLK)
20 nc
9 +5V STBY +12V (Output- YEL)10 +12V
Power-Good (Output - GRY)
11 +12V
12 +3.3VS
+5V Stand-by (Output - PUR) 21 +5V
-12V (Output - BLU)
22 +5V
PowerGround (Return - BLK)
23 +5V Power Ground (Return - BLK)24 GND
Power supply -ON (Input - GRN)
+3.3VS (Input - ORN)
+3.3V (Output - ORN)
+5V (Output - RED)
+5V (Output - RED)
+5V (Output - RED)
Connectorused Vertical: Molex: 39-28-1243
Connector used Horizontal: Molex 39-30-0240
Mating connector: Molex: 39-01-2245

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 4
J12 –EPS 12V –Motherboard Power connector
Pin# Function Description
1 GND
2 GND PowerGround (BLK)
3 GND PowerGround (BLK)
4 GND
Pin# Function Description
512V
612V
712V
812V
8
1234
5
6
7Connectortype used: Molex: 39-30-0080
Mating connector type: Molex: 39-01-2085
PowerGround (BLK)
PowerGround (BLK)
+12V Output (YEL)
+12V Output (YEL)
+12V Output (YEL)
+12V Output (YEL)
J13 –PCI-e 12V –Motherboard/ GPU Power connector
Pin# Function Description
112V +12V Output to MB orGPU (YEL)
212V +12V Output to MB orGPU (YEL)
312V +12V Output to MB orGPU (YEL)
Pin# Function Description
4 GND Power Ground ( BLK)
5 GND Power Ground ( BLK)
6 GND Power Ground ( BLK)
123
4
5
6Connectortype used: Molex: 39-30-0060
Mating connector type: Molex: 39-01-2065
J10 & J14 –Drive Power connector
Connectorused: JST: B 4B-PH-K-S
Mating connector: JST: PHR-4
1
2
3
Pin# Function Description
112V +12V Output (YEL)
2 GND PowerGround (BLK)
3 GND PowerGround (BLK)
4 +5V +5V Output (RED)
4

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 5
JU1 –Shut down delay, Start-up & Shut-Dn Voltages, and Stby-On Jumpers
12 3 4 5
Shut Down Delay (SD) Jumpers
Psn # - SD Dely
1 2 3 Time
0 0 0 - (10 Sec)
1 0 0 - 5 Min
0 1 0 - 10 Min
1 1 0 - 15 Min
0 0 1 - 30 Min
1 0 1 - 45 Min
0 1 1 - 1 Hr
1 1 1 - 2 Hrs
Start-UP & Shut-Down Voltage Jumpers
Psn # - Start-UP Shut-Down Psn#
4 5 Voltage Voltage 8
0 0 - 10.5V - 7.0V 0
1 0 - 11.0V - 9.0V 0
0 1 - (12.5V) - (10.5V) 0
1 1 - 13.5V - 12.0V 0
0 0 - 20.0V - 15.0V 1
1 0 - 22.0V - 18.0V 1
0 1 - (24.0V) - (21.0V) 1
1 1 - 25.0V - 22.0V 1
When STBY-ON Jumper is
installed, Stand-by voltage is
maintained after Power down.
Required for Stand-by mode
operationonly.
0 = Jumper not Installed
1 = Jumper Installed .
2mm Shorting
Jumper installed
Psn # Standy -By Power state
6__
Stand-by Power ON/OFF Jumper
6
0 - Stand-by Pwr OFF
1 - Stnd-by Pwr ON
JU-1 JumperBlock
JU2 –Remote-Off State, Operating Voltage Mode and Operating Mode Jumpers
78910
Psn # - Operating
9 10 Mode
0 0 - ATX
1 0 - PB
0 1 - Sub ATX
1 1 - AT
0 = Jumper not Installed
1 = Jumper Installed .
JU-2 Jumper Block
Psn # 12V / 24V mode operation
8__
0 - 12V operation
1 - 24V operation
Psn # Remote off state
7__
0 - After SD Delay
1 - Before SD Delay
Recommended Installation Steps
Step 1. Configure DC-DC JU1 and JU2 jumpers. . Install OPUS DC-DC in the system.
Step 2. Configure ATX/ ITX motherboard BIOS: Turn off AC power loss auto restart, ACPI: S1 or S3 mode, Push btn: Instant off.
Step 3. Configure operating system: Power-down, hibernate or Stand-by mode.
Step 4. Test the PC for proper operation. If all passes then, configure the DC-DC shut down delay jumpers if required.
Suggestion: Configure and test system with a standard AC- DC ATX power supply first. Then switch over to OPUS DC-DC power supply.

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 6
DC-DC Typical Application Example
c
Battery
1
2
20/
24
Pin
20/24 pin ATX Power
Conn.
1, 2,3
4
6,7,8
J7 -
PWR SW
J9 -
ATX/
BTX
Power
out
+ BATT
GND
IGN
To Drives
Power
Connector
Front Panel
Connector
To ATX soft power
switch pins
YEL
BLK
Ignition Switch
ACC OPUS DCX6
DC-DC Power supply ATX, uATX or ITX
Compatible
motherboard
J1 -
Power input,ON/
off & RMT Conn. White
Fuse
RED
ON/OFF Switch
optional
4p 4pin 12VATX
Power connector
9BLU/WHT RMT1
APM /uC
controlled
switch
LCD, Amplifer, etc.
Fuse BLK
YEL
+ - ON/OFF
Fuse .35A
9
9
8
Pin
J8 -
Drive
Power
out
Fuse .35A
RMT2
Turn ON
delay
controlled
BLU
ORN Fuse 3.5A +12V
To power external devices that
require regulated 12V Power
External OD, GPS, etc
+ -
Green
-
+
+ -
DCX4 DC-DC PCB Dimensions

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 7
Trouble shooting guide
Computer does not turn on?
Check to make sure that battery and ON-OFF pins are connected to DC-DC Power Supply connector.
Computer does not turn off when the ignition is turned off!
Check the Green LED state
Interpreting the Green Status LED light flashing
0.1 sec ON and 5 Sec OFF Approx.: DC-DC power supply is in Idle or stand-by state.
On constantly The PC is powered and the PC should be operating.
Error Flashes Reason
1 Flash Battery voltage is below normal operating range.
(every 10 Sec.) Voltage set by JU1 4, 5
2 Flashes The computer power up sequence failed. Reasons:
Check the wiring of the two pin power-switch cable from power supply connector J9 to power switch pins on the ATX
motherboard. If connected properly check the polarity of the power switch pins, may be reversed.
Check ATX mother board bios settings.
Locked up motherboard or software crash.
Faulty DC-DC power supply.
3 Flashes Power supply output voltages are out of normal voltage range. Reasons:
Power supply output is over loaded or shorted.
Faulty DC-DC power supply.
4 Flashes Power down, stand-by or hibernate sequence failed. Reasons:
Check the wiring of two wire power-switch cable from power supply connector J9 to power switch pins on the ATX
motherboard. If connected properly check the polarity of the power switch pins, may be reversed.
Check ATX motherboard bios settings.
Check if ACPI function is enabled in the power management BIOS setup. Make sure ACPI drivers are installed in the operating
system.
Check if application is compatible with ACPI mode of operation.
Locked up motherboard or software crash
Faulty DC-DC power supply

Vehicle DC-DC 500W+ User Guide DCX 4
www.opussolutions.com OPUS Solutions, Inc. 2019 UG-DCX4 -Rev x1 24-MAY-2019 8
Technical Specifications
DC Input
12V version
24V version
Normal Operating Range:
9V to 36V DC
18V to 36V DC
Peak Range Less than 10 Sec:
6V to 38V DC
14V to 38V DC
Input protection:
Under voltage, Over voltage, Over current, Transients and Load dump.
EMI / Noise Filtering:
Common & normal mode filters,
Input Connectors:
Mfg
Mfg PN
Mating Conn.
Main Power:
#6 Screw Trm
Ignition/ ON-OFF:
Molex:
39-30-0020
39-01-3025
MiniFit-Jr
DC
Output
Base Module: DCX 4.0
Voltage
Max. Current
Tolarance
Ripple
Power
5V Stby
2.5A
1%
50mV P-P
12.5W
3.3V
15A
1%
50mV P-P
50W
5V
15A
1%
50mV P-P
75W
12V
30A
5%
100mV P-P
360W
-12V
.1A
15%
250mV P-P
1W
Total output Power
500W
Optional DCX 4.1 module (12V2)
12V
36A
5%
100mV p-p
430W
Total Combined Power of DCX 4.0 & DCX 4.1 must be limited to 750W or lower.
Output Connectors:
Mfg
Mfg PN
Mating Conn
ATX
Molex:
39-30-0240
39-01-2245
Mini Fit-Jr
EPS12
Molex:
39-30-0080
39-01-2085
Mini Fit-Jr
PCI-E 12V
Molex:
39-30-0060
39-01-2065
Mini Fit-Jr
Per-SW
JST:
2B-PH-K-S
PHR-2
PH
General
Compatibility:
ATX, uATX & ITX Mother boards
Modes of operation:
ON/OFF switch or Momentary push button modes
Switching Frequency:
300Khz Spread spectrum
Operating Topology:
Boost- Buck for 12V version & Buck for 24V version
Efficiency:
TBD
> 90%
MTBF:
TBD
On/OFF input :
Ignition or Switched battery feed
Delayed Shut down:
1Sec to 2Hrs
Startup and shut down voltages:
4 ranges
Automatic Low voltage OS shut down
Over temperature monitoring
Environmental
Operating Ambient Temp:
-25°C to +70°C
Storage Temp:
-55°C to 125°C
Humidity:
5% to 95% non-condensing
Vibration:
Designed to meet Mil 810 Ground vehicles specifications
Transients & Load dumps:
Designed to meet ISO-16750-2,
Physical
Dimensions:
216m L x 96mm W x 25mm H
Weight:
375 Grams