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.

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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

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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.

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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.

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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

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External power connections
The illustration 2-2 below indicates the input and output power connections of the
XPWR104HR board mounted in its IDAN enclosure frame. Using IDAN systems the
power devices are directly heat sunk to the frame this will give full rated output
performance over the complete temperature range of -40 to +85 C.
Fig. 2-2 XPWR104HR power supply power connections
8-36v
GND
8 to 36V
GN
D
GND
+12V
GND
-12V
GND
+5V
X1 JUMPER
FOR REMOTE
ON
-
OFF

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Connector descriptions:
Over voltage protected with transient absorber with a working voltage of 36V DC.
Note: The module input power may be up to 100 W (12.5A), this will require a
cable wire diameter of 2 to 3 sq. mm. Make sure this input wire is kept as
short as possible to reduce voltage drops and input inductance.
• TB1 Raw input power to the XPWR104HR. Input voltage range is 8-32V DC (36V maximum).
• TB2: +5V Output of the main DC/DC power supply
• TB4: -12V Output
• TB3: +12V Output
• X1: Remote ON/OFF, close this jumper to disable the XPWR104HR
The output voltages are also indicated on the silk-screen on the solder side of the
module under the terminal blocks. Check these before making any external power
connections. The input of the XPWR104HR is protected against reverse voltages, but
will not withstand long term over voltage. The transient absorbers will clip all fast
disturbance and noise on the input, but may overheat if a continuous over voltage is
present. The transorb is intended to handle transients of 1 millisecond or shorter.

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Chapter 3 - HARDWARE DESCRIPTION
This chapter describes the major features of the XPWR104HR, which are the following:
• The main +5V converter for the computer and PC/104 bus
• The secondary power output converters +12V, -5V and -12V for peripheral devices
• Onboard status LED’s
• Output power calculations

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Fig. 3-1 Block diagram of the XPWR104HR
8
-
36V DC INPUT

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Main +5V converter for computer
The main +5V output is implemented with a synchronous, dual phase switch-mode
DC-DC converter design. The output current of this unit is 15A. This converter has
excellent dynamic and transient response capabilities making it an ideal high-
speed computer power supply.
The input of this converter is protected with a 36V fast transient absorber diode
and low loss forward schottky diodes. These devices are necessary to protect the
input in automotive and industrial installations against fast over voltage spikes and
reverse voltage connections. This converter is equipped with a current foldback
circuit to protect it from short-circuit or overload conditions.
The main +5V converter feeds the PC/104 AT bus +5V pins with power. This
power can also be taken from the board from an external terminal block TB2. (See
previous section for the location of terminal block TB2.). Additionally this supply is
cascaded into the +12V and the –12V circuits.
Remote On/Off control
Header connector X1 near one of the PC/104 mounting holes is the remote
ON/OFF selection switch. Closing this connection will disable the XPWR104HR
and place the converter “OFF”. In this condition the XPWR104HR will consume
minimum power. This signal could be connected to the ignition key of an
automobile or machine.
Secondary +12V, -5, and -12V converters for peripherals
A 5V to +-12V converters with 88%(12V) and 77%(-12V) efficiency generates +-
12V for peripheral devices such as EL- or TFT- panels, hard drives, motors etc.
The +12V output delivers 2.0A of current. +12V power is available from terminal
block TB3. The -12V power is available from terminal block TB4. (See previous
section for location of terminal blocks.) . The +12V and -12V supplies also power
the PC/104 bus.
The +12V converter is a boost converter. Because of this architecture any
sustained short on the +12V will be seen as a short on the 5V converter and the
5V converter will go into current foldback to effectively protect the 12V converter.
Additionally this converter is immune to input line fluctuations because it is
cascaded from the 5V converter.
The –12V converter is a Cuk topology and is known for having continuous
input and output current for an exceptionally clean output voltage. This converter
is also cascaded from the 5 Volts and is current limited so if a short occurs the
output voltage just decays similar to a current foldback.
The –5V converter is a linear supply that is cascaded from the –12V
converter. This converter is limited to 100 milliamps and is 38% efficient.

XPWR104HR 16 RTD Embedded Technologies, Inc
Onboard status LED’s
The XPWR104HR is equipped with 2 indicator LED’s. The function of the LED’s is
described below. These LEDs are near the power connectors and are in the order
of the output and are labeled.
• LED1 - Green. Indicates +5V power converter is alive
• LED2 - Green. Indicates +12V converter is alive
• LED3 - Green. Indicates -12V converter is alive
Overload protection
The +5V converter can regulate to greater than 18 amps. The current limit is higher
that the maximum continuous output current to ensure reliable operation near the
maximum rated output power. Fast current surges are allowed over the rated 15A
continuous current.
The +12V converter is rated to 2A and the -12V converter is rated for 500mA.

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Output power calculations
The maximum available power for the +5V computer system can be estimated
using the following conservative formula:
(The output of the main converter is 15A)
I1 = (+12V output current)
I2 = (-12V output current)
I3 = (+5V output current)
I4 = (-5V output current)
I_bus = +5V to bus
75W = ((I1*12)/0.88 + (I2*12)/0.77 +((I4 *5)/0.038)/0.77)/0.92 + I_bus*5+I3*5
Note: Even though the total output power figure of 15A @5V is not exceeded you
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.

XPWR104HR 18 RTD Embedded Technologies, Inc
Chapter 4 XPWR104HR SPECIFICATIONS
Host interface
16-bit data bus with power pins +5V, +-12V connected to power outputs
Power supply specifications
Input voltage range guaranteed 8-32V DC (36V maximum)
Output Power (75W total) +5V@15A @ 92%
+12V@2.0A@88%
-12V @ 500mA @ 77%
Fully loaded board Efficiency 85.8%
Output load regulation (including transient load) 5% maximum
5 Volt maximum power dissipation 6.52 Watts
-12 Volt maximum power dissipation 1.79 Watts
+12 Volt maximum power dissipation 3.27 Watts
-5 Volt maximum power dissipation 0.82 Watts
Maximum overall power dissipation 12.4 Watts
Connectors
Power connectors Phoenix Contact
CombiconSeries
Host bus AT PC/104 bus
Electromechanical
Operating temperature range -40 to +85 C
Heat sink temperature (Max) +85 C
Internal power dissipation 12.4W (Max)

XPWR104HR 19 RTD Embedded Technologies, Inc
Chapter 5 RETURN POLICY AND WARRANTY
Return Policy
If you wish to return a product to the factory for service, please follow this procedure:
Read the Limited Warranty to familiarize yourself with our warranty policy.
Contact the factory for a Return Merchandise Authorization (RMA) number.
Please have the following available:
• Complete board name
• Board serial number
• A detailed description of the board’s behavior
List the name of a contact person, familiar with technical details of the problem or situation, along with their phone and
fax numbers, address, and e-mail address (if available).
List your shipping address!!
Indicate the shipping method you would like used to return the product to you.
We will not ship by next-day service without your pre-approval.
Carefully package the product, using proper anti-static packaging.
Write the RMA number in large (1") letters on the outside of the package.
Return the package to:
RTD Embedded Technologies, Inc.
103 Innovation Blvd.
State College PA 16803-0906
USA

XPWR104HR 20 RTD Embedded Technologies, Inc