rtd XPWR104HR User manual

XPWR104HR
High efficiency PC/104 power
supply module
User’s Manual
BDM-610020045
Rev. A
I
IS SO O9 90 00 01 1 a an nd d A AS S9 91 10 00 0 C Ce er rt ti if fi ie ed d

XPWR104HR 2 RTD Embedded Technologies, Inc
XPWR104HR
Power supply module
User’s Manual
RTD Embedded Technologies, INC.
103 Innovation Blvd.
State College, PA 16803-0906
Phone: [phone]
FAX: [phone]
E-mail
[e-mail]
techsu[email protected]
web site
http://www.rtd.com

XPWR104HR 3 RTD Embedded Technologies, Inc
Revision History
Rev. A New manual naming method
Published by:
RTD Embedded Technologies, Inc.
103 Innovation Blvd.
State College, PA 16803-0906
Copyright 1999, 2002, 2003 2004 2005 by RTD Embedded Technologies, Inc.
All rights reserved
Printed in U.S.A.
The RTD Logo is a registered trademark of RTD Embedded Technologies. cpuModule and utilityModule are trademarks of RTD
Embedded Technologies. PhoenixPICO and PheonixPICO BIOS are trademarks of Phoenix Technologies Ltd. PS/2, 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.

XPWR104HR 4 RTD Embedded Technologies, Inc
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION.................................................................................. 6
Features........................................................................................................................................................................6
Some of the key features of the XPWR104HR include:........................................................................................ 6
Power supply units......................................................................................................................................................6
Connector description.................................................................................................................................................7
What comes with your board.....................................................................................................................................7
Using this manual........................................................................................................................................................7
CHAPTER 2 BOARD INSTALLATION..................................................................... 9
Board installation........................................................................................................................................................9
General installation guidelines:............................................................................................................................. 9
Installation integrated with a PC/104 module stack: ...........................................................................................10
Connector descriptions:.......................................................................................................................................12
CHAPTER 3 - HARDWARE DESCRIPTION .......................................................... 13
Remote On/Off control........................................................................................................................................ 15
Secondary +12V, -5, and -12V converters for peripherals ....................................................................................15
Overload protection..................................................................................................................................................16
Output power calculations........................................................................................................................................17
CHAPTER 4 XPWR104HR SPECIFICATIONS...................................................... 18
Host interface.............................................................................................................................................................18
Power supply specifications......................................................................................................................................18
Connectors................................................................................................................................................................. 18
Electromechanical.....................................................................................................................................................18
CHAPTER 5 RETURN POLICY AND WARRANTY................................................ 19
Return Policy.............................................................................................................................................................19
CHAPTER 6 LIMITED WARRANTY....................................................................... 21

XPWR104HR 5 RTD Embedded Technologies, Inc
List of Illustrations
.............................................................................................................................................................. Illustrations
Fig. 2-1: XPWR104HR powering an RTD PC/104 cpuModule stack
Fig. 2-2: XPWR104HR power supply power connections
Fig. 3-1: XPWR104HR Block diagram

XPWR104HR 6 RTD Embedded Technologies, Inc
Chapter 1 INTRODUCTION
This user’s manual describes the operation of the XPWR104HR power supply unit for
automotive and industrial applications.
Features
Some of the key features of the XPWR104HR include:
• Wide input voltage range 8-32V DC (36V maximum)
• 75W output power guaranteed with adequate cooling, 92% 5V efficiency
• Remote ON/OFF operation
• Power output options include: XPWR104HR +5V, -5V, +12V, -12V
• Two status LED's
• Fully PC/104 compliant
• Operating temperature -40 to +85 C
• No electrolytic capacitors to increase the operating altitude
The following paragraphs briefly describe the major features of the XPWR104HR. A
more detailed discussion is included in Chapter 3 (Hardware description). The board
installation is described in Chapter 2 (Board Installation).
Power supply units
The XPWR104HR power supply unit offers a complete reliable power subsystem
for your sophisticated computer and peripherals. To improve reliability in noisy
environments, the XPWR104HR is designed using protection devices against over
voltages, noise spikes and reverse input voltage. The output current of the +5V
converter is limited to 15A. This enables reliable system operation in distributed
industrial installations.
The main +5V computer power supply is designed using a high efficiency, dual
phase switching regulator module providing high output current (15A) with a high
efficiency (92% maximum) under all conditions. The secondary peripheral power
supplies are designed using +12V (boost) and -12V (Cuk) converters. Low
component count and extensive use of SMD technology ensures low weight and
reliable operation. This combination creates low input current ripple to minimize
stress on the unregulated input supply. The output creates a very low ripple
voltage signature.
The XPWR104HR can be “switched off” from a remote source. If this switch (X1
jumper) is closed the power supply will become inactive while still powered.

XPWR104HR 7 RTD Embedded Technologies, Inc
Mechanical description
The XPWR104HR is designed on a PC/104 form factor. An easy mechanical
interface to both PC/104 and EBX systems can be achieved. Stack your
XPWR104HR directly on a PC/104 compliant computer using the onboard
mounting holes. Care must be taken to ensure adequate heat dissipation from the
onboard heat sink in high output power installations. See the following link for a
description of the PC104 specification. http://www.rtd.com/pdf/PC104-246.pdf
Connector description
The power connections are made using "cable plug" type terminal blocks. This
enables removing connections from the board without opening the cables from the
terminal blocks. The IDAN-XPWR104HR boards always feature screw terminal
blocks for inter-frame wiring.
What comes with your board
Your XPWR104HR package contains the following items:
• XPWR104HR board with mating connectors for the power connections
• User's manual
If any item is missing or damaged, please call RTD Embedded Technologies
customer service department at the following number: (814)-234-8087.
Using this manual
This manual is intended to help you install your new XPWR104HR module and get
it working quickly, while also providing enough detail about the board and it's
functions so that you can enjoy maximum use of it's features even in the most
demanding applications.

XPWR104HR 8 RTD Embedded Technologies, Inc
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] during American east coast
business hours. Alternatively, send a FAX to [phone] or Email to
[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 the problem.

XPWR104HR 9 RTD Embedded Technologies, Inc
Chapter 2 BOARD INSTALLATION
The XPWR104HR power supply module is very easy to connect to your industrial or
automotive control system. Direct interface to PC/104 systems as well as EBX size
boards is achieved. This chapter tells you step-by-step how to install your XPWR104HR
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.
• Make sure to use 16 AWG wire.
• Twist power and ground wires to minimize input inductance
• Keep input wires less than one foot in length
• If you must use longer wires, you may want to attach a large value, high ESR capacitor to the input (i.e. 220uF 50V
electrolytic)
• Check all wiring connections once and then once more again.
• Check the input power to the board is in the range of 8 to 32V DC (36V maximum)
• Do not hot plug the input or loads. This causes inductive spikes that can damage the board
• Apply power to your XPWR104HR, and make sure the diagnostic LED’s indicate correct operation.

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Installation integrated with a PC/104 module stack:
• Secure the four PC/104 installation holes with standoffs.
• Connect the board to the power supply using the power interface connectors.
Fig. 2-1: XPWR104HR powering an RTD PC/104 cpuModule stack
Note: For full output power performance, install your XPWR104HR at the top of
your PC/104 system and make sure adequate cooling is provided. You may
increase airflow with the EFAN104 fan module available from Real Time
Devices. If used inside an enclosure make sure the internal temperature of
the enclosure does not exceed 85°C.
RTD cpuModule
XPWR
104HR
RTD dataModule