TRI-M ENGINEERING HPSC104-SER User manual

HPSC104-SER Manual
High Power & Smart Charging
Vehicle Power Supply
DC to DC Converter
Manufactured by
TRI-M ENGINEERING
Engineered Solutions for Embedded Applications
Technical Manual
P/N: HPSC104-SER V1-MAN
Revision: 3-November-2008
TRI-M ENGINEERING
1407 Kebet Way, Unit 100
Port Coquitlam, BC V3C 6L3
Canada
http://www.Tri-M.com
Tel [phone]
North America 800.665.5600
Fax [phone]

3-Novemeber-07 HPSC104-SER Manual
Tri-M Engineering Tel: [phone]
1407 Kebet Way, Unit 100 Fax: [phone]
Port Coquitlam, BC V3C 6L3 E-mail: [email protected]
Canada Web site: www.tri-m.com
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Table of Contents
CHAPTER 1 - INTRODUCTION...........................................................................................................4
1.1 GENERAL DESCRIPTION..........................................................................................................4
1.2 FEATURES.................................................................................................................................5
1.3 SPECIFICATIONS.......................................................................................................................6
CHAPTER 2: CONFIGURATION AND INSTALLATION .....................................................................7
2.1 Introduction..................................................................................................................................7
2.1.1 Main Input Power Connector ................................................................................................8
2.1.2 Output Power Connector ......................................................................................................8
2.1.3 Battery Connector.................................................................................................................8
2.1.4 Aux Battery Connector..........................................................................................................9
2.1.5 RS232 Serial Port Interface..................................................................................................9
2.1.6 Control I/O Connector.........................................................................................................10
2.2 Jumper Selection.......................................................................................................................10
2.2.1 Interrupt Service Request Jumpers.....................................................................................10
2.2.2 PC/104 Memory Mapped Address Jumper.........................................................................10

3-Novemeber-07 HPSC104-SER Manual
Tri-M Engineering Tel: [phone]
1407 Kebet Way, Unit 100 Fax: [phone]
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Canada Web site: www.tri-m.com
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PREFACE
This manual is for integrators of applications of embedded systems. It contains information on
hardware requirements and interconnection to other embedded electronics.
DISCLAIMER
Tri-M Engineering makes no representations or warranties with respect to the contents of this
manual, and specifically disclaims any implied warranties of merchantability or fitness for any
particular purpose. Tri-M Engineering 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 Engineering at the address listed on the title page of this document.
COPYRIGHT © 2006-06-07 TRI-M ENGINEERING
No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or
translated into any language or computer language, in any form or by any means, electronic,
mechanical, magnetic, optical, chemical, manual, or otherwise, without the express written permission
of Tri-M Engineering.

3-Novemeber-07 HPSC104-SER Manual
Tri-M Engineering Tel: [phone]
1407 Kebet Way, Unit 100 Fax: [phone]
Port Coquitlam, BC V3C 6L3 E-mail: [email protected]
Canada Web site: www.tri-m.com
4
CHAPTER 1 - INTRODUCTION
1.1 GENERAL DESCRIPTION
The HPSC104-SER is a high power, high performance DC to DC converter that supplies +5V, -5V,
+12V, -12V and V5Sby (5V standby) outputs. The HPSC104-SER also includes a flash based
microcontroller that supplies advanced power management, smart battery charger, PC/104 I/O
memory mapped interface and an RS232 serial port. The HPSC104-SER is designed for low noise
embedded computer systems, has a wide input range of 6-40V(>6:1) and is ideal for battery or
unregulated input applications. The HPSC104-SER is specifically designed for vehicular applications
and has heavy-duty transient suppressors (9000W) that clamp the input voltage to safe levels, while
maintaining normal power supply operation.
The HPSC104-SER is a state-of-the-art Mosfet based design that provides outstanding line and load
regulation with efficiencies up to 95 percent. Organic Semiconductor Capacitors provide filtering that
reduces ripple noises below 20mV. The low noise design makes the HPSC104-SER ideal for use
aboard aircraft or military applications or wherever EMI or RFI must be minimized.
The HPSC104-SER provides up to four stages of battery charging and can charge Lead-Acid, NiCd,
and NiMh batteries and is also SMBus level 3 compatible. Charge currents are up to 4A, and battery
charging voltages from 10 to 35V.
The HPSC104-SER has advanced power management functions that allows timed on/off control of
the HPSC104-SER, notification of changes to main power and changes in the battery status. For
example, the HPSC104-SER can be programmed to power off the outputs in 60 seconds, and then
turn on again 12 hours later.
The HPSC104-SER size is 3.55 x 3.775 inches, and is a fully PC/104 compliant power supply. All
generated voltages are provided to a removable“pluggable” header. A removable plug allows the
HPSC104-SER to be easily installed. The RS232 serial port is provided on a standard DB9
connector.
The HPSC104-SER can be configured to meet almost any power supply and battery charging need
for embedded applications, whether that be a simple +5V application, or providing power for back
lighted LCD panels, or a full UPS (un-interruptible power supply configuration).

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1.2 FEATURES
•DC to DC converter for embedded applications.
•“Load Dump” transient suppression on input power supply.
•Operates from 6VDC to 40VDC input.
•PC/104 compliant.
•PC/104 memory mapped interface and RS232 serial port for setup, monitoring and control.
•5V, 12V, -12V, -5V, V5SBY and battery charger outputs.
•Temperature range -40 to 85C.
•Monitors up to 8 external temperatures using I2C digital temperature sensors.
•Optocoupled inputs for ignition, and system "shut-down" pushbutton.

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1.3 SPECIFICATIONS
Power Supply Specifications
Model HPSC104-SER
5V output
(Includes current supplied to 12V,-12V & -5V regulators) 25A
12V output 5A
-5V output 400mA
-12V output 500mA
V5SBY 7A
Maximum battery charger current 4A
Battery Charger output voltage range 10 to 35V
Input voltage range 6-40VDC
Load regulation <60mV
Line regulation +40mV
Output temp drift <40mV
Switching frequency
(5V, 12V, -12V & 5VSBY) 310 to 320kHz
Output ripple <20mV
Conducted Susceptibility >57db
Efficiency up to 95%
Temp range** -40 to 85C
Size, PC/104 form factor compliant 3.55”W x 3.775”L x 0.6”H
*Measured on the 5V output.
** Temperature range as measured on the product heat sink.

3-Novemeber-07 HPSC104-SER Manual
Tri-M Engineering Tel: [phone]
1407 Kebet Way, Unit 100 Fax: [phone]
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CHAPTER 2: CONFIGURATION AND INSTALLATION
2.1 Introduction
This chapter describes the configuration and installation of the HPSC104-SER power supply. In
addition, section 2.2 provides a formula to calculate the available +5VDC. Figure 2-1 shows the
HPSC104-SER connectors, jumpers and other options.
Power Considerations.
The +5V switching regulator is rated at 25A maximum output, however the +5V output supplies power
to the +12, -5, and -12VDC regulators. To obtain the usable range of +5V output, “derate” according
to the use of +12, -5, and -12VDC. Use the following formulae to calculate the maximum usable
output.
Where: I[-5] = -5VDC current load
I[-12] = -12VDC current load
I[12] = 12VDC current load
Assuming 90 percent converter efficiency (actual efficiency may vary).
9.0 )4.2*]12[4.2*]12[]5[(
255 III AVoutputUsable
+
−
+
−
−=+

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1407 Kebet Way, Unit 100 Fax: [phone]
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2.1.1 Main Input Power Connector
Input power is connected to the HPSC104-SER by a removable pluggable CN2. The power supply
accepts DC input voltages in the range of 6VDC to 40VDC.
Unregulated vehicle power is connected as follows:
- Terminal 1:“hot” polarity
- Terminal 2: Common (0VDC)
2.1.2 Output Power Connector
Output power is available for use via removable pluggable connector CN5.
-CN5-1: Common
-CN5-2: +5VDC output
-CN5-3: +5VDC output
-CN5-4: +5VDC output
-CN5-5: Common
-CN5-6: V5Sby (5V standby)
-CN5-7: Common
-CN5-8: 12VDC output
-CN5-9: Common
-CN5-10: -12VDC output
-CN5-11: Common
-CN5-12: -5V output
2.1.3 Battery Connector
Batteries are connected via a removable pluggable, CN8. The HPSC104-SER accepts DC battery
voltages in the range 6.5V to 35VDC through the Battery Power Connector.
-CN8-1: Common
-CN8-2: Battery Positive
-CN8-3: Battery Positive
-CN8-4: Common
-CN8-5: TH, thermistor/safety input
-CN8-6: SDA, I2C/SMBus data input/output signal
-CN8-7: SCL, I2C/SMBus clock input/output signal
-CN8-8: Battery Enable output

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2.1.4 Aux Battery Connector
Tri-M Engineering battery packs such as the BAT-NiMh-4500 can be directly plugged into the
HPSC104-SER through connector CN3 and CN7. Connector CN3 is a two row by four pin header
and CN7 is a two row by two pin header, with the BAT104 battery packs having mating female
connectors.
-CN3-1: Battery Positive
-CN3-2: Common
-CN3-3: Battery Positive
-CN3-4: Common
-CN3-5: SDA, I2C/SMBus data input/output signal
-CN3-6: SCL, I2C/SMBus clock input/output signal
-CN3-7: +5V for digital temperature sensor and battery enable
-CN3-8: BE, Battery Enable output
-CN7-1: Battery Positive
-CN7-2: Common
-CN7-3: Battery Positive
-CN7-4: Common
2.1.5 RS232 Serial Port Interface
The HPSC104-SER provides an RS232 serial port for remote control, monitoring and
datalogging. The serial port connector is a standard DB9 connector, CN4.
-CN4-1: BL, Battery Low signal output (TTL level)
-CN4-2: TX-Out, RS232 output signal
-CN4-3: RX-IN, RS232 input signal
-CN4-4: SD-232, Shut Down signal input, RS232 signal levels
-CN4-5: Common
-CN4-6: Not used
-CN4-7: Not used
-CN4-8: Power fail indication
-CN4-9: Fan output power

3-Novemeber-07 HPSC104-SER Manual
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2.1.6 Control I/O Connector
Note: All outputs are active low. The active state of the IGN signal is programmable by using SCU
the utility.
uSig
GND
20K
Vcc5C
Sig-Out
Output Structure for PF, BL & BE
Microprocessor
Output
Field
Connection
2.2 Jumper Selection
This section describes the function of each jumper, and the location of it.
2.2.1 Interrupt Service Request Jumpers
Jumper CN9 sets the interrupt service request to either IRQ5 or IRQ7.
-Pin 1 to 2, IRQ5
-Pin 2 to 3, IRQ7
2.2.2 PC/104 Memory Mapped Address Jumper
Jumper JP2 sets the PC/104 I/O Memory Mapped Address Jumper.
-Pin 1 to 3, Address 0x300 (300 hex)
-Pin 2 to 4, Address 0x310 (310 hex)
-Pin 5 to 3, Address ox320 (320 hex)
-Pin 6 to 4, Address ox360 (360 hex)
SD
IGN 1
3
2
4
8
6
7
5
IC8
OPTOISOLATOR-DUAL
R12 10K
R49 10K
R50 10K
R51 10K
GND GND
C62
0.1uF
C63
0.1uF
GND GND
uMaintained
uMomentary
To Microprocessor
Inputs
Field
Connection
HESC-SER IGN and SD Inputs