rtd ATX104HR-EXPRESS User manual

ATX104HR-EXPRESS
High Efficiency PCI/104-Express Power
Supply Module
User’s Manual
BDM-610020070
Rev. G

ATX104HR-EXPRESS User’s Manual
ATX104HR-EXPRESS 2 RTD Embedded Technologies, Inc.
ATX104HR-EXPRESS
Power supply module
User’s Manual
RTD Embedded Technologies, Inc.
103 Innovation Blvd.
State College, PA 16803-0906
Phone: [phone]
FAX: [phone]
E-mail
[email protected]
[email protected]
web site
http://www.rtd.com

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ATX104HR-EXPRESS 3 RTD Embedded Technologies, Inc.
Revision History
Rev A Initial Release
Rev B 02/20/2009 Corrected typos (changed PC/104+ to PC/104-Express)
Rev C 10/06/2011 changed name of power output connector, added X2, added surge suppressor, corrected
Graphics
Rev D Corrected explanation of X2 jumper in Connector Descriptions
Rev E 11/12/2014 Corrected X1-X2 operation table
Rev F 11/18/2014 Added information about identifying pin one on X1
Rev G 05/18/2015 Added MTBF
Published by:
RTD Embedded Technologies, Inc.
103 Innovation Blvd.
State College, PA 16803-0906
Copyright 1999, 2002, 2003 2004 by RTD Embedded Technologies, Inc.
All rights reserved
Printed in U.S.A.

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ATX104HR-EXPRESS 4 RTD Embedded Technologies, Inc.
The RTD Logo is a registered trademark of RTD Embedded Technologies. cpuModule and utilityModule are trademarks of RTD
Embedded Technologies. PC/XT, PC/AT and IBM are trademarks of International Business Machines Inc. MS-DOS, Windows,
Windows 95, Windows 98 and Windows NT are trademarks of Microsoft Corp. PC/104 is a registered trademark of PC/104 Consortium.
All other trademarks appearing in this document are the property of their respective owners.

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Table of Contents
CHAPTER 1 INTRODUCTION..................................................................................... 8
Features........................................................................................................................................................................ 8
Power Supply Unit Description.................................................................................................................................. 8
Mechanical description............................................................................................................................................... 9
Connector description................................................................................................................................................. 9
What comes with your board?................................................................................................................................. 10
Using this manual...................................................................................................................................................... 10
When you need help.................................................................................................................................................. 10
CHAPTER 2 BOARD INSTALLATION ...................................................................... 11
Board installation...................................................................................................................................................... 11
General installation guidelines:........................................................................................................................... 11
Installation integrated with a PC/104-EXPRESS module stack:......................................................................... 12
External power connections..................................................................................................................................... 13
Connector Descriptions:........................................................................................................................................... 14
CHAPTER 3 - HARDWARE DESCRIPTION.............................................................. 15
Main +5V and +3.3V converter for the computer.................................................................................................. 17
Current Limit....................................................................................................................................................... 17
Remote On/Off control........................................................................................................................................ 17
Secondary +12V and -12V converters..................................................................................................................... 18
Onboard status LED’s ......................................................................................................................................... 18
Overload protection ............................................................................................................................................ 18
CHAPTER 4 ATX104HR-EXPRESS SPECIFICATIONS........................................... 20
Host interface ............................................................................................................................................................ 20
Power supply specifications...................................................................................................................................... 20
Input voltage range.............................................................................................................................................. 20
Output Power (88W total ).................................................................................................................................. 20
Efficiencies.......................................................................................................................................................... 20
Maximum Board Power dissipation (worst conditions) ...................................................................................... 20
Output voltage regulation.................................................................................................................................... 20
Electromechanical............................................................................................................................................... 21
Electrical Characterization:................................................................................................................................. 22
CHAPTER 5 RETURN POLICY AND WARRANTY................................................... 36
Return Policy............................................................................................................................................................. 36
CHAPTER 6 LIMITED WARRANTY .......................................................................... 38
CHAPTER 7 ATX104HRTX-EXPRESS-88W DIMENSIONED DRAWING ................ 39
CHAPTER 8 IDAN-ATX104HRTX-EXPRESS-88WS DRAWING AND PINOUTS..... 40

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Figure 1: Pheonix Contact 1781043 9
Figure 2: Phoenix Contact 1779987 9
Figure 3: ATX104HR-EXPRESS powering an RTD PC/104-EXPRESS cpuModule stack. PCI bus shown with non-stack through
connector. Standard is press fit stack through. 12
Figure 4: ATX104HR-EXPRESS power supply power connections 13
Figure 5: Block diagram of the ATX104HR-EXPRESS 16
Figure 6: Dimensioned Drawing 39

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Chapter 1 INTRODUCTION
This user’s manual describes the operation of the ATX104HR-EXPRESS power supply
unit for automotive and industrial applications.
Features
Some of the key features of the ATX104HR-EXPRESS include:
Wide input voltage range 8-32 V DC (36V absolute max)
No heat sink required with natural convection cooling up to 45˚C,
83W total output power guaranteed with adequate cooling,
Up to 91 %efficiency at full load
Dual phase construction to minimize input ripple current and improve step
response
Synchronized supplies to reduce switching stresses
Remote ON/OFF operation
ATX104HR-EXPRESS outputs +3.3V, +5V, +12V, -12V, 5V STDBY
Four status LED's
Fully PC/104-EXPRESS compliant
Operating temperature range -40 to +85 C
The following paragraphs briefly describe the major features of the ATX104HR-
EXPRESS. A more detailed discussion is included in Chapter 3 (Hardware description).
The board installation is described in Chapter 2 (Board Installation).
Power Supply Unit Description
The ATX104HR-EXPRESS power supply unit offers a complete reliable power
subsystem for your sophisticated computer and peripherals. To improve reliability in
harsh environments, the ATX104HR-EXPRESS is designed using protection devices
against over voltages, noise spikes and reverse input voltage. The output current of the
+5V and the +3.3V converter is limited to 10A. These features allow reliable system
operation in distributed industrial installations.
A 5V STDBY supply, capable of 1A, is present so ATX compliant systems can be built on
this board. ATX support signals PS_ON# and PWR_ON allow software controlled
shutdown and power monitoring available for your CPU.
The +5V and the +3.3V computer power supplies are designed using high efficiency
switching regulators providing high output current (10A) with efficiency as high as (91 %)
under all conditions. The secondary peripheral power supplies are designed using +12V
and -12V converters that are supplied by the +5V DC/DC converter. Low component
count and extensive use of SMD technology ensures low weight and reliable operation.
Special care has been taken to reduce radiated and conducted emissions. Optimized

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multi-phase circuit layout ensures good EMI immunity over the operating temperature
range under all loads.
The ATX104HR-EXPRESS can be “switched off” from a remote source. If this switch
(jumper X1) is on pins 2-3 the power supply will become inactive while still powered.
Mechanical description
The ATX104HR-EXPRESS is designed on a PC/104-EXPRESS form factor. An easy
mechanical interface to both PC/104-EXPRESS and EBX systems can be achieved.
Stack your ATX104HR-EXPRESS directly on a PC/104-EXPRESS compliant computer
using the onboard mounting holes. Care must be taken to ensure adequate heat
dissipation from the board in high output power installations.
Connector description
The power connections are made using "cable plug" type terminal blocks. This enables
removing connections from the board without removing the cables from the terminal
blocks. The IDAN-ATX104HR-EXPRESS boards always feature screw terminal blocks
for inter-frame wiring.
The mating connector for the standard version is the Pheonix Contact 1781043 (eight
position plug). There is also a Pheonix Contact 1779987 (two position plug).
Figure 1: Pheonix Contact 1781043
Figure 2: Phoenix Contact 1779987

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What comes with your board?
Your ATX104HR-EXPRESS package contains the following items:
ATX104HR-EXPRESS board with mating connectors for power connections
User's manual
If any item is missing or damaged, please call RTD Embedded Technologies, Inc.
customer service department at the following number: [phone].
Using this manual
This manual is intended to help you install your new ATX104HR-EXPRESS module and
get it working quickly, while also providing enough detail about the board and its functions
so that you can enjoy maximum use of its features even in the most demanding
applications.
When you need help
This manual will provide you with enough information to fully utilize all the features on this
board. If you have any problems installing or using this board, contact our Technical
Support Department [phone]. Alternatively, send a FAX to [phone] or
Email to techsupp[email protected]. When sending a FAX or Email request please include the
following information: Your company's name and address, your name, your telephone
number, and a brief description of your questions.

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Chapter 2 BOARD INSTALLATION
The ATX104HR-EXPRESS power supply module is very easy to connect to your
industrial or automotive control system. Direct interface to PC/104-EXPRESS systems
as well as EBX size boards is achieved. This chapter tells you step-by-step how to
install your ATX104HR-EXPRESS into your system.
Board installation
Keep your board in its antistatic bag until you are ready to install it to your system!
When removing it from the bag, hold the board at the edges and do not touch the
components or connectors. Please handle the board in an antistatic environment
and use a grounded workbench for testing and handling of your hardware. Before
installing the board in your computer, check the power cabling. Failure to do so
may cause the power supply unit to malfunction or even cause permanent
damage.
General installation guidelines:
Touch the grounded metal housing of your computer to discharge any antistatic
buildup and then remove the board from its antistatic bag.
Hold the board by the edges and install it in an enclosure or place it on the table
on an antistatic surface.
Install your board in your system, and wire the power supply correctly.
Failure to do so may cause the power supply unit to malfunction or even cause
permanent damage to the device.
Check all wiring connections once and then once more again.
Check the input power to the board is in the range of 8 to 36V DC
Apply power to your ATX104HR-EXPRESS, and make sure the diagnostic LED’s
indicate correct operation.

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Installation integrated with a PC/104-EXPRESS module stack:
Secure the four PC/104-EXPRESS installation holes with standoffs.
Connect the board to the power supply using the power interface connectors.
Figure 3: ATX104HR-EXPRESS powering an RTD PC/104-EXPRESS cpuModule stack. PCI bus shown
with non-stack through connector. Standard is press fit stack through.

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External power connections
Figure 4: ATX104HR-EXPRESS power supply power connections
Pin 1

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Connector Descriptions:
TB1:Raw input power to the ATX104HR-EXPRESS, voltage range is 8-32 V
(36V absolute max) DC. Surge suppressor with 36V clamp voltage followed by
transient absorber with cutoff at 39V DC.
Note: The module input power may be up to 100 W, this will require AWG 16 wire (1.14mm2)(Make
sure this input wire is kept as short as possible to reduce voltage drops (0.005/foot) and
inductive spikes (513 nH/foot). Also wrap the input leads at least once every 2 inches to reduce
loop inductance.
TB2 : +5V Output of the main DC/DC power supply
TB2 : +3.3V Output of the main DC/DC power supply
TB2: -12V Output
TB2 : +12V Output
X1 : Remote ON/OFF , close this jumper in the pin 1 to 2 position to disable the
5V STDBY
X1-X2 operations. (highlighted cells are ATX functionality)
X2=installed
X2=open
X1=1-2
5V=off
12V=off
-12V=off
3.3V=off
5Vstby=off
5V=off
12V=off
-12V=off
3.3V=off
5Vstby=off
X1=2-3
5V=on
12V=on
-12V=on
3.3V=on
5Vstby=on
5V=off
12V=off
-12V=off
3.3V=off
5Vstby=on
X2: PS_ON# signal. Short to enable all voltages except for 5V STDBY
CN1:PCI express bus
CN3: PCI bus
The output voltages are also indicated on the silk-screen on the bottom side of the module under the terminal
blocks. Check these before making any external power connections. The input of the ATX104HR-EXPRESS is
protected against reverse voltages, but will not withstand long term overvoltage. The transient absorbers will clip all
fast disturbance and noise on the input, but may overheat if continuous overvoltage is present.

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Chapter 3 - HARDWARE DESCRIPTION
This chapter describes the major features of the ATX104HR-EXPRESS, which are the
following:
The main +5V and +3.3V converter for the PC/104 and PC/104-EXPRESS busses
The secondary power output converters +12V , –12V, 5V STDBY
Onboard status LED’s
Overload protection
Output power calculations

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Figure 5: Block diagram of the ATX104HR-EXPRESS

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Main +5V and +3.3V converter for the computer
The main +5V and the PCI bus +3.3V output use a synchronous, switch-mode DC-
DC converter design. The output current of both of these independent converters
this limited to 10A. These converters have excellent dynamic and transient
response capabilities making it an ideal high-speed computer power supply. Use
of low loss MOSFET-transistors allows operation without an additional heat-sink.
Internal layers of the PCB are used to distribute heat evenly.
Input circuitry of the ATX104HR-EXPRESS is protected with a 36V fast transient
absorber diode and a low loss forward schottky diode. These devices are
necessary to protect the input in automotive and industrial installations against fast
over-voltage spikes and reverse voltage transients. These situations exist in
vehicle systems with alternators/chargers or in systems with electrically controlled
hydraulic or pneumatic inductive valves and solenoids.
The +5V converter, located closer to the power connectors, feeds the PC/104 AT
bus and the PCI bus +5V pins with power. This power can also be supplied from
the board from an external terminal block TB2. (See previous section for the
location of terminal block TB2.) The +3.3V converter located near the PCI bus
connector only feeds the +3.3V power pins of the PCI bus. A terminal block at the
side of the board next to the +5V output can be used to power other external
+3.3V devices.
Input range is guaranteed from 8 up to 36V under full load and in worst conditions
over the full rated temperature range (with air flow). Note that start up current may
exceed stead-state current consumption.
Current Limit
To protect against fault or short-circuit conditions 5V and 3.3V voltages are
equipped with current fold-back, current limiting circuitry to provide continuous
overload protection. After reaching the current limit point the voltage output will
range between the rated output voltage and zero depending on the amount of
overload Once the short circuit condition is removed, the output will return to the
nominal value without restarting the unit.
Remote On/Off control
X1 controls the 5Vstby and X2 controls all other voltages. See the table in the “Connector
Descriptions:” labeled “X1-X2 operations”. Complete power off is achieved when X1 =1-2 and X2
= open.

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Secondary +12V and -12V converters
+5V to +-12V converters generates power for peripheral devices such as EL- or
TFT- panels, hard drives, motors etc. The +12V output is capable of supplying up
to 2.0A of current. +12V power is available from terminal block TB3. The -12V
power is available from terminal block TB1. (See previous section for location of
TB3). The +12V and -12V supplies also power the PCI104-express and the PCI
bus.
Onboard status LED’s
The ATX104HR-EXPRESS is equipped with 4 indicator LED’s. The function of the
LED’s is described below.
LED1 - Green. Indicates +5V power converter is operational
LED2 - Green. Indicates +3.3V power converter is operational
LED3 - Green. Indicates +12V converter is operational
LED4 - Green. Indicates -12V converter is operational
Overload protection
Both +5V and the +3.3V converter is current limited to 10A. The current limit is
slightly higher that the maximum continuous output current to ensure reliable
operation near the maximum rated output power.
The +12V converter is rated to 2A and the -12V converter is rated for 500mA. The
+12V converter output is limited to 2.0A. The -12V converter output is limited to
500mA. The outputs of the +12V and -12V converters will allow short-term error
conditions, and are not designed to accept long-term over-voltage or reverse
polarity.
Use of Ultra-low ESR tantalum capacitors and stable temperature characteristics
ensure low noise and good transient performance over the complete rated
operating temperature range of –40 to +85C. PCB layout is optimized to provide
lowest radiated and conducted noise.

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Output power calculations
The maximum available power for the +5V computer system can be estimated
using the following method:
5V efficiency 91%
5V STDBY efficiency 82%
3.3V efficiency 89%
12V efficiency 90%
-12V efficiency 88%
All loads are in Watts
L1 = 5V primary load (load on just 5V supply)
L2 = 3.3V load
L3 = 12V load
L4 = -12V primary load (load on just -12V supply)
L7 = 5V total load = L1 + (L3/0.9) + (L6/0.88)
LTOTAL = L2 + L7
LTOTAL < 83 Watts
LSTDBY < 5 Watts
Note: Even though the total output power figure of 88 Watts is not exceeded one
must remember not to overload an individual output! Care must be taken
not to thermally overload the unit. The maximum specified output power
may not be available if the ambient temperature rises, and in this case
additional heat sinking or additional airflow may be necessary. Even though
the unit can stay cooled with natural convection, enclosing the unit in a
container may require heat sinking depending on the load and temperature
in the container.

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Chapter 4 ATX104HR-EXPRESS SPECIFICATIONS
Host interface
PC/104-EXPRESS busses with +5V, +5VSTDBY, +3.3V, +12V, -12V
Power supply specifications
Input voltage range
8-32V DC (36V absolute maximum)
Output voltage ripple at full load (measured peak to peak)
+5V 17.6 mV
+5V STDBY 15.0 mV
+3.3V 20.2 mV
+12V 20.6 mV
-12V 12.6 mV
Output Power (88W total ) +5V@10A for 50W
+5V STDBY@ 1A for 5W
+3.3V@10A for 33W
[email protected]A for 24W
-12V@500mA for 6W
88W available
Efficiencies 5V efficiency 91%
5V STDBY efficiency 82%
3.3V efficiency 87.6%
12V efficiency 93%
-12V efficiency 89.41%
Overall 88%
Maximum Board Power dissipation (worst conditions)
13.69 Watts
Output voltage regulation
+-5% (max)
Host bus PC/104-EXPRESS bus
PC/104-Express stack-through