MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications FEATURES 46 Watts for Mobile Access Router to IP/Networks PC/104-Plus compatible/stackable, powering Cisco system cards 9 to 32V input range, supporting both 12V and 24V vehicle batteries Reverse input voltage protection Typical unit Automotive transient protection Efficiency to 92.5% @ full load PRODUCT OVERVIEW No derating to +85°C, 100 lfm Murata Power Solutions’ MAPC-104 non-isolated, triple output DC/DC converter is designed to power the Cisco 3200 Mobile Access Router and is compliant to PC/104-Plus specifications. The equipment ideally suites integration into public safety, defense, homeland security and commercial transportation vehicles, whether on land, in water or air, and is employed for powering secure data, voice and video communications across multiple wireless networks. The MAPC-104 is a high performance, compact and rugged power supply which operates in the harshest conditions, withstanding input transient voltages according to SAE J1455 and J1211. It converts the vehicle’s standard battery voltage of 12V or 24V (VIN range from 9 to 32 Volts) to three fully regulated outputs of 3.3V @ 6A, 5.1V @ 6.3A and 12V @ 100mA up to a total output power of 46 Watts. Taking full advantage of a synchronousrectifier, buck/boost topology, MAPC-104’s boast outstanding efficiency of up to 92.5%, enabling full-power operation to ambient temperatures as high as +85°C with 100 lfm air flow. Independently regulated +3.3V, +5.1V and +12V outputs Power up/down sequencing Low 25mVp-p ripple/noise Power good LED and external signal Compact 3.775” × 3.55” × 0.6” package, standard PC/104-plus pinout Stable no-load condition Thermal shutdown with warning Fully I/O protected UL/IEC/EN60950-1 certification pending The compact 3.775” x 3.55” x 0.60” (95.9 x 90.2 x 15.2mm) open frame, triple output DC/DC power card is mechanically and electrically compliant to PC/104-plus specifications. Operating with the Cisco designed system cards, the MAPC-104 is considered part of the host, which requires the 3.3V (but no –5V/–12V) supply provided. Assembled using fully automated, SMT-on-pcb techniques, MAPC-104s provide stable no-load operation, excellent line and load regulation (±1% max.), quick step response (200μsec), and low output ripple/noise (25mVp-p). All devices feature full I/O fault protection including: input overvoltage and undervoltage shutdown, power up/down sequencing, output overvoltage, output current limiting, short-circuit protection, power good (LED indicator and external signal), overtemperature warning and thermal shutdown. All models are certified to IEC/EN/UL60950-1 safety standards. Selected models include RoHS compliance. Performance Specifications~ Output Model MAPC-104 Output 1 Output 2 Output 3 IOUT(Amps) Input R/N (mVp-p) Regulation (Max.) VIN (Volts) VOUT (Volts) Nom. Max. Typ. Max. Line Load Nom. 3.3 5.1 12 5 5.46 0.07 6 6.3 0.1 25 25 20 35 50 35 ±1% ±1% ±1% ±1% ±1% ±1% ~ Typical at TA = +25°C under nominal line voltage and nominal-load conditions, unless noted. Ripple/Noise (R/N) is tested/specified over a 20MHz bandwidth. All models are specified with an external 0.1μF multi-layer ceramic capacitor installed across each output pin. Efficiency Range IIN (mA/A) Min. Typ. 12 9-32 35/4 91% 92.5% 24 9-32 35/4 89.5% 91% Package/ Pinout C46 See pages 2, 3 for Pinout Devices have no minimum-load requirements and will regulate under no-load conditions. Regulation specifications describe the output-voltage deviation as the line voltage or load is varied from its midpoint value to either extreme. Nominal line voltage, no-load/full-load conditions. For full details go to www.murata-ps.com/rohs www.murata-ps.com Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 1 of 7 MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications MECHANICAL SPECIFICATIONS $)! 0,!#%3 Case C46 " ! ORDERING GUIDE & PART NUMBER STRUCTURE )0( * # $ Model Number Auxiliary Power Connector (P2) MAPC-104 Not installed MAPC-104-5V Installed MAPC-104 - 5V - C * * $#"! 0 490 490 -!8 -!8)-5#/-0/.%.4(%)'(4 PC/104-Triple Output Power Converter Auxiliary Power Connector (P2) Blank = Not installed 5V = P2 is installed RoHS Hazardous Substance Compliance Y = RoHS-5 (with lead) C = RoHS-6 (no lead) -!8)-5#/-0/.%.4(%)'(4 Dimensions are in inches (mm) 0). '2/5.$ 0). 6DC0/7%2/54 315!2%0/343 0/3)4)/.3 5 Volt Auxiliary Power Connector, P2 (Optional) Figure 1. MAPC-104 Input Power Head Pin 1 2 3 4 )0( TOP VIEW www.murata-ps.com IPH Mating connector: Molex 5557 (39-01-4040) Assignment Functional Description OT_Warn Out Overtemperature Warning Pwr_LED_Drive Out External Power Good LED Driver Input Ground VIN– Positive Input VIN+ Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 2 of 7 MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications Figure 2. MAPC-104 (PC/104-plus) Bus Signal Assignments Figure 3. MAPC-104 (PC/104-Reference) Bus Signal Assignments J3/P3 J1/P1 Pin A B C D Pin A B 1 GND Reserved +5.1V AD00 1 IOCHCK* GND 2 VI/O AD02 AD01 +5.1V 2 D7 RSTDRV 3 AD05 GND AD04 AD03 3 D6 +5.1V 4 C/BE0* AD07 GND AD06 4 D5 IRQ9 5 GND AD09 AD08 GND 5 D4 NA (–5V) 6 AD11 VI/O AD10 M66EN 7 AD14 AD13 GND AD12 8 +3.3V C/BE1* AD15 +3.3V Pin D 9 SERR* GND SB0* PAR 0 GND 10 GND PERR* +3.3V SDONE 1 MEMCS16* SBHE* 11 STOP* +3.3V LOCK* GND 2 IOCS16* 12 +3.3V TRDY* GND DEVSEL* 3 IRQ10 13 FRAME* GND IRDY* +3.3V 4 IRQ11 14 GND AD16 +3.3V C/BE2* 5 15 AD18 +3.3V AD17 GND 6 16 AD21 AD20 GND AD19 7 IRQ14 LA18 16 A15 DRQ3 17 +3.3V AD23 AD22 +3.3V 8 DACK0* LA17 17 A14 DACK1* 18 IDSEL0 GND IDSEL1 IDSEL2 9 DRQ0 MEMR* 18 A13 DRQ1 19 AD24 C/BE3* VI/O IDSEL3 10 DACK5* MEMW* 19 A12 REFRESH* 6 D3 DRQ2 7 D2 NA (–12V) C 8 D1 ENDXFR* GND 9 D0 +12V 10 IOCHRDY KEY LA23 11 AEN SMEMW* LA22 12 A19 SMEMR* LS21 13 A18 IOW* IRQ12 LS20 14 A17 IOR* IRQ15 LS19 15 A16 DACK3* J2/P2 20 GND AD26 AD25 GND 11 DRQ5 SD8 20 A11 SYSCLK 21 AD29 +5.1V AD28 AD27 12 DACK6* SD9 21 A10 IRQ7 22 +5.1V AD30 GND AD31 13 DRQ6 SD10 22 A9 IRQ6 23 REQ0* GND REQ1* VI/O 14 DACK7* SD11 23 A8 IRQ5 IRQ4 24 GND REQ2* +5.1V GNT0* 15 DRQ7 SD12 24 A7 25 GNT1* VI/O GNT2* GND 16 +5.1V SD13 25 A6 IRQ3 26 +5.1V CLK0 GND CLK1 17 MASTER* SD14 26 A5 DACK2* 27 CLK2 +5.1V CLK3 GND 18 GND SD15 27 A4 TC 28 GND INTD* +5.1V RST* 19 GND KEY 28 A3 BALE +5.1V 29 +12V INTA* INTB* INTC* 29 A2 30 NA (–12V) Reserved Reserved 3.3V KEY 30 A1 OSC 31 A0 GND 32 GND GND ~ The shaded area denotes power or ground signals. The KEY pins are to guarantee proper module installation: J3/P3, pin A1 is electrically connected to GND for shielding J3/P3, pin D30 is removed and the female side is plugged for 3.3V I/O J2/P2, pin C19 is keyed, pin is removed and the female side is plugged J1/P1, pin B10 is keyed, pin is removed and the female side is plugged J3/P3, pin A30 and J1/P1, pins B5 and B7 are not used. Pin assignments for –5V and –12V are for reference only. Auxiliary 5V Power Connector, P2 Specifications (typical unless noted) +5 Vdc at 1 Amp maximum Power Output~ Power Characteristics See MAPC-104 Specifications P2 Header Type AMP/Tyco Electronics 640455-2 Contact Dimensions Two 0.025" square posts, 0.3" long, 0.10" spacing on centers. See drawings. Contact Material Tin plating over copper alloy Contact Assembly Force 3 lbs. (13N) Single-row, 2-position IDC on 0.10" spacing Mating Connector Environmental Compatible with host MAPC-104 system ~ The contacts are rated at 5 Amps 250Vac. However, whatever current is drawn must be summed with current powering the PC-104 system. A suggested mating connector is AMP/Tyco Electronics MTA-100 Series, part number 647000-2. See also the CST-100 Series. For the MAPC-104-5V model version, spare +5 Vdc power may be taken from the P2 connector which is adjacent to the pin 1 end of the J1 connector (see drawings). Be aware that this power is generated on the MAPC-104 and therefore is in addition to whatever 5V current is used by the host PC-104 system. All power characteristics (regulation, tempco, ripple, etc.) are derived from the MAPC-104. www.murata-ps.com Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 3 of 7 MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications Performance/Functional Specifications Typical @ TA = +25°C under nominal line voltage and full-load conditions unless noted. ~ ~ All models are tested and specified with a single, external, 0.1μF, multi-layer ceramic Input Input Voltage Range Transient Voltage Protection Overvoltage Shutdown Overvoltage Protection Start-Up Threshold Undervoltage Shutdown 9–32 Volts (12V or 24V battery) 125V/100ms (30kVA) 32–36 Volts (34V typical) 48V/5 minutes 9–10 Volts (9.4V typical) 7–9 Volts (8.2V typical) Input Current Input Reflected Ripple Current Internal Filter Type See Performance Specifications 45mVp-p Pi Reverse-Polarity Protection Yes (external fuse mandatory) No load 2000μF (+3.3V) 1000μF (+5.1V) 500μF (+12V) ±3% maximum VOUT Accuracy (50% load) Temperature Coefficient Ripple/Noise (20MHz BW) Line/Load Regulation Efficiency Current Limit Inception (97% VOUT, each other output @ 0 Amps Short Circuit Current (Zener) ±0.02%/°C See Performance Specifications See Performance Specifications See Performance Specifications 7-9 Amps (+3.3V) 8.5-11 Amps (+5.1V) 0.2-0.5 Amps (+12V) 2.65 Amps (+3.3V) 3.24 Amps (+5.1V) 0.12 Amps (+12V) 3.9V (+3.3V) 6V (+5.1V) 13V (+12V) See Tech Notes (LED and external Signal) Overvoltage Protection Power Good within 7-10% of VOUT Dynamic Characteristics Dynamic Load Response (50-100% step to within 1% of VOUT) Power-up Sequencing (5.1V power-down before 3.3V) Power-down Sequencing (5.1V power-down before 3.3V) Switching Frequency 200μsec (+3.3V & +5.1V) 100μsec (+12V) 2-6msec 1-4msec 320 kHz (+3.3V & +5.1V) 1120 kHz (+12V Environmental Calculated MTBF Operating Ambient Temperature With 100 lfm Air Flow, no derating Board Temperature –40 to +85°C –40 to +105°C Thermal Shutdown +112°C to 118°C 3,129,938 hours Thermal Shutdown Warning 27 to 33 seconds 2nd Level Thermal Shutdown +122 to +128°C Storage Temperature Output Minimum Loading Per Output Maximum Capacitive Load –40 to +105°C Physical Dimensions Connector and Pin Material Weight See Mechanical Specifications According to PC/104-plus Spec 3.6 ounces (102 grams) Insulation Level Non-isolated www.murata-ps.com output capacitor on each output and no external input capacitors, unless otherwise noted. All models will effectively regulate under no-load conditions (with perhaps a slight increase in output ripple/noise). See Technical Notes/Performance Curves for additional explanations and details. Input Ripple Current is tested/specified over a 5-20MHz bandwidth with an external 33μF input capacitor and a simulated source impedance of 220μF and 12μH. See I/O Filtering, Input Ripple Current and Output Noise for details. The Current-Limit-Inception point is the output current level at which the converter’s power-limiting circuitry drops the output voltage 3% from its initial value. See Output Current Limiting and Short-Circuit Protection for more details. See Dynamic Load Response for detailed results including switching frequencies. For Start-Up-Time specifications, output settling time is defined as the output voltage having reached ±1% of its final value and the load current having reached at least 80% of its final value. MTBF is calculated using TELCORDIA SR-332 Method 1 Case 3, Issue 1, ground fixed, +30°C ambient air and full-load conditions. All models are fully operational and meet all published specifications, including “cold start,” at –40°C. The highly unlikely, simultaneous failure of several specific on-board components could result in the MAPC-104’s input voltage appearing at its output, despite the unit’s output overvoltage protection mechanisms. In this rare situation, the Power Good signal (IPH pin 2, Pwr_LED_Drive) will be deactivated and systems monitoring Power Good will eventually shut down. If you are using an MAPC-104 to power a load that must be protected against any and all possible overvoltages, no matter how rare, you will have to provide the protection external to the MAPC-104. Please contact MPS for recommendations. Absolute Maximum Ratings Input Voltage: Continuous Up to 5 minutes maximum Transient 36 Volts 48 Volts 125V (30kVA) Input Reverse-Polarity Protection External fuse mandatory Output Current Current limited. Devices can withstand sustained output short circuit. These are stress ratings. Exposure of devices to any of these conditions may adversely affect long-term reliability. Proper operation under conditions other than those listed in the Performance/ Functional Specifications Table is not implied. Connector Designations The official PC/104 bus specification identifies the standard interboard bus connections as paired J1/P1 and J2/P2 on one side and J3/P3 on the other side. However, J1/P1/J2/P2 is physically all one big 4-row connector with J1/J2 bus receptacle sockets (female) on the top side and P1/P2 pins (male) on the bottom. This arrangement provides interboard pass-through connections between PC/104 boards. MPS refers to this single connector as “J1.” MPS’s auxiliary connectors (the IPH and the 5V Auxilliary Power Connector) are internally designated P1 and P2 respectively and this nomenclature may appear on the board silkscreening. This is purely an artifact of automated sequential part numbering in our CAD system and has no relation to the standard PC/104 interboard bus connectors. Don’t get the connectors confused since they are all very different types and locations! Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 4 of 7 MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications Typical Performance Curves 3.3VOUT Efficiency vs. Line Voltage and Load Current (5.1V @ 5.46A and 12V @ 0.07A) Efficiency vs. Line @ 46W 94 94 93 93 92 92 91 91 VIN = 9V Efficiency (%) Efficiency (%) VIN = 12V 90 89 VIN = 24V 90 89 VIN = 32V 88 88 87 87 86 86 9 12 18 24 28 32 0 1.25 Input Voltage (V) 2.5 3.75 5 6.3 0.08 0.1 Load Current (Amps) 5.1VOUT Efficiency vs. Line Voltage and Load Current (3.3V @ 5A and 12V @ 0.07A) 12VOUT Efficiency vs. Line Voltage and Load Current (5.1V @ 5.46A and 3.3V @ 5A) 94 94 VIN = 9V 93 93 VIN = 9V 92 91 Efficiency (%) Efficiency (%) 92 VIN = 12V 90 VIN = 24V 89 91 VIN = 12V 90 VIN = 24V 89 VIN = 32V VIN = 32V 88 88 87 87 86 86 0 1.25 2.5 3.75 5 6.3 Load Current (Amps) www.murata-ps.com 0 0.02 0.04 0.06 Load Current (Amps) Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 5 of 7 MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications Self-Protection Features The MAPC-104 contains two systems for protection of out-of-limit voltages, currents and temperature. These systems control two output lines located on the Input Power Header connector. Both systems operate independently and concurrently. The MAPC-104 will respond to both temperature and voltage/ current simultaneously. The output circuits for both these controls are shown below. Both of them will drive either an external LED lamp and/or a logic circuit. The Overtemperature Warning Circuit assumes that an external pullup resistor is supplied by the user. The Power Good Circuit (“Pwr_LED_Drive Out”) includes an on-board pullup resistor to drive an external LED with about 15mA. /4?7ARN/UT HI (transistor off) = Power is normal. LED lamp is illuminated. LO (transistor on) = Power fault, LED lamp is dark Overtemperature Operation The overtemperature system includes a on-board temperature sensor, a local microcontroller with A/D inputs, a timer and hysteresis so that the user may take steps to prevent inadvertant shut down. Operation proceeds as follows: If the on-board temperature exceeds +115°C, the OT_Warn Output is asserted (LO) by the microcontroller and an internal 30 second software timer is started. The outputs remain powered on. If the 30-second timer has not expired and the on-board temperature cools below +110°C, the OT_Warn Output will be deasserted (HI) and operation will continue unchanged. #/.42/,,%2 --"4 M7 MAXIMUM n6). Pwr_LED_Drive Out (pin 2, pullup to internal +5V): If the 30-second timer has expired and the temperature still exceeds +115°C, the outputs will shut down. As soon as the on-board temperature cools to less than +110°C, the MAPC-104 will automatically restart and power will be restored to the outputs. #/--/. The 5 degree hysteresis between 110 and 115°C prevents rapid cycling of the OT_Warn Output. 8 )NPUT0OWER(EADER)0(PINS Typical External Logic Wiring If the on-board temperature reaches +125°C, the outputs will shut down, regardless of the state of the 30-second timer. The temperature must cool to less than +110°C for auto restart. K7 6DC 6DC /4?7ARN/UT ()4EMPERATURENORMAL ,//VERTEMPERATURE ,/')##/--/. 7 0WR?,%$?$RIVE/UT n6). #/.42/,,%2 "33 Typical OT Warning External LED Lamp Wiring n6). 6DC #/--/. /4?7ARN/UT 8 )NPUT0OWER(EADER)0(PINS 7 Typical Power Good External LED Lamp Wiring ,/')##/--/. n6). Figure 1. Overtemperature Warnimg Circuit M! The transistors in these outputs are either on (typically less than 0.4 Volts out) or off (high impedance state). Depending on how the user wires the external circuit, these indicators have the following sense: ()0OWERISNORMAL ,/&AULT Figure 2. Overtemperature Warnimg Circuit OT_Warn Out (pin 1): HI (transistor off) = Temperature is normal LO (transistor on) = Over temperature condition www.murata-ps.com Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 6 of 7 MAPC-104 PC/104-Plus Series Non-Isolated, DC/DC Converters 3.3, 5.1 & 12.4, 46W Mobile Applications Power Good Operation Local power is measured by several circuits shared with the overtemperature system. The Pwr_LED_Drive Output is indirectly controlled by the on-board microcontroller. The on-board PWM switching controller measures +3.3V and +5V output voltages and all output currents. The microcontroller measures input voltage and the +12V output voltage. The system requires that the input voltage is within normal tolerances at all times. If the input voltage is too high very briefly at startup (but not exceeding the absolute input voltage), the system will start normally if the input voltage reaches acceptable limits quickly (under half a second). This typically occurs as a load is applied. When the system first starts, the Power Good LED (if installed) remains dark briefly until all on-board startup conditions are met (less than half a second) at which point the LED is illuminated. The operation proceeds as follows: If the fault condition remains, the system will attempt to restart two more times, spaced about half a second apart. If the fault remains for the third time, the system will shut down and will not retest the fault. The system must now be restored by fully cycling the input power. The 3-fault countdown only occurs if the fault does not recover continuously throughout the attempted restart interval. An occasional random shutdown and successful restart will not trigger the 3-fault counter. However, external logic should record the frequency and quantity of such shutdowns. RoHS-5 compliance refers to the exclusion of the six hazardous substances in the RoHS specification with the exception of lead. MPS’s RoHS-5 products use all the conforming RoHS materials, however our solders are Sn63/Pb37. If the outputs on any lines deviate from approximately ±7% of nominal and/or the output current is excessive, the outputs are all shut down and the Pwr_LED_Drive Output is desasserted (LO, lamp dark). The system will attempt to restart in about half a second by briefly turning on all outputs. If successful and the fault is eliminated, the Pwr_LED_Drive Output will be asserted (HI, lamp lit) and operation continues. USA: Mansfield (MA), Tel: (508) 339-3000, email: [email protected] Canada: Toronto, Tel: (866) 740-1232, email: [email protected] Murata Power Solutions, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 U.S.A. Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356 UK: Milton Keynes, Tel: +44 (0)1908 615232, email: [email protected] France: Montigny Le Bretonneux, Tel: +33 (0)1 34 60 01 01, email: [email protected] Germany: München, Tel: +49 (0)89-544334-0, email: [email protected] www.murata-ps.com email: [email protected] ISO 9001 REGISTERED Murata Power Solutions, Inc. makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without notice. © 2008 Murata Power Solutions, Inc. Japan: Tokyo, Tel: 3-3779-1031, email: [email protected] Osaka, Tel: 6-6354-2025, email: [email protected] Website: www.murata-ps.jp China: Shanghai, Tel: +86 215 027 3678, email: [email protected] Guangzhou, Tel: +86 208 221 8066, email: [email protected] 06/12/08 www.murata-ps.com Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_MAPC-104.A06 Page 7 of 7