Mission Javelin I User manual

Javelin I & II Power Supply Operator’s Manual
I & II Power Supply
Power Factor Corrected AC-DC Switcher
Operator’s Manual
and
“Quick Install” Instructions
www.mpwrs.com
Rev. 05/11/2012 Mission Power Solutions [phone] [email protected] Pg. 1

Javelin I & II Power Supply Operator’s Manual
Javelin I & II Power Supply
Power Factor Corrected AC-DC Switcher
Javelin I & II Power Supply “Quick Install” Instructions
 The Javelin can be mounted at either of two sides (top or bottom).
 Use #8-32 mounting screws. Maximum penetration should not exceed 0.21″ (5,33mm).
 Maintain 2″ (50,8mm) clearance at either end for airflow.
 Input AC or DC power is applied to connector J1 using a 3W3 Power
Connector (Table 1).
 To connect, use ITT/Cannon mating receptacle P/N DAM3W3SA197
with pins, P/N DM53744-6.
 A fault-clearing device, such as a fuse or circuit breaker, with
maximum 15A rating at the power supply input is required for
safety agency compliance.
Single Phase DC
A1 L1 A1 +
A2 L2/N A2 –
A3 Earth Gnd A3 Earth Gnd
Table 1. AC and DC Input Connections
Status/Control Connector (J2)
 J2-1 and J2-9 are spare pins and are not used.
 J2-2 and J2-4 are Signal Return pins.
 J2-3 is +12V fan power.
 J2-5 is VCC +5V @ 300mA.
 J2-6 is AC Power OK (+5V = true).
 J2-7 and J2-8 are used in conjunction according to the following table:
Input Connections
Input Connector (J1)
Mounting the Javelin Power Supply
J2-8
INHIBIT′
J2-7
ENABLE′
POWER SUPPLY
STATE
1 X ON
0 0 ON
0 1 OFF
Table 2. Inhibit/Enable Logic Table
 Use ITT/Cannon mating connector P/N DE9PK87 with Amp cover
shell P/N 205729-1.
 Use 20-24 AWG stranded wire.
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J2 Interface Pin Out
J2-1 Spare
J2-2 Signal Return
J2-3 Fan Power
J2-4 Signal Return
J2-5 VCC +5V @ 300mA
J2-6 AC Power OK
J2-7 PS Enable
J2-8 PS Inhibit
J2-9 Spare
1
5
69
A1 A2 A3

Javelin I & II Power Supply Operator’s Manual
Output Connections
Installing ring lugs on output studs:
 When viewed from the rear, the left stud is Positive and the
right stud is Return.
 Remove the nut and place .312” ID ring lug over output stud.
 Replace and tighten the nut to a torque of 130 in/lbs. Do Not
Over-Tighten Nuts.
DC OK/Sense Connector (J3)
 The Javelin is equipped with Auto-Sense (load sensed at output studs if
remote sense is not connected).
 Connector pin J3-1 is the +Remote Sense and J3-6 is the –Remote
Sense.
 If Remote Sense is desired, connect pin J3-1 to the positive load con-
nection and pin J3-6 to the negative load connection. Attach load end of
sense lines at the point where regulation is desired.
 J3-2 and J3-8 provide DC OK′ and DC OK signals.
 J3-3 and J3-7 provide +5V VCC and +5V Return.
 J3-4 and J3-9 provide paralleling signals PR1 and PR2.
 J3-5 is Chassis Ground.
 Use ITT/Cannon mating receptacle P/N DE9FK87 with Amp cover
shell P/N 205729-1.
 Attach terminals to 20-24 AWG stranded wire.
 Use 20-24 AWG stranded, twisted pair wire for sense connections.
 Verify that sense lines are not cross-connected.
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1
6 9
5
J3 Interface Pin Out
J3-1 +Remote Sense
J3-2 DC OK′
J3-3 +5V VCC
J3-4 PR2
J3-5 Chassis Ground
J3-6 ─Remote Sense
J3-7 +5V Return
J3-8 DC OK
J3-9 PR1

I & II Power Supply
Power Factor Corrected AC-DC Switcher
Overview
The Javelin is a ruggedized, switching power supply that combines the advantages of power factor correction
and power density with user-selectable output voltage and power. Accepting input voltages of 85 to 254 VAC
and 85 to 380 VDC, the Javelin can provide up to 1800 watts in a 4.9H x 7.0W x 10.75L (9.5L for Javelin
II) package. Its inherent flexibility comes from its use of Vicor 2nd Generation DC-DC converters. Javelin I has
a 100 CFM fan installed, while Javelin II utilizes customer-provided forced-air cooling.
Standard Features
 Power Factor Correction: .99 at 115 VAC; .95 at 230 VAC.
 Universal Input: 85-254 VAC, 47-500 Hz, or 85-380 VDC.
 Power Output: 1800W at 230 VAC for selected outputs; 800W at 115 VAC (See Graph 1, Pg 13, for
breakdown of input voltage vs. output power).
 Full power to 55C; half power at 70C . (See Graph 2, Pg 14 for breakdown of output power vs. ambient
temperature.)
 Soft start for limiting inrush current.
 EMI Compliance: FCC Class A; EN 55022 Class A & B; MIL-STD-461E.
 Transient Protection: MIL-STD-704E.
 Environmental: MIL-STD-810E.
 MIL-STD-1399 (300A); 115VAC, 60Hz, single phase; 1KVA5KVA.
 Harmonic Distortion to EN61000-3-2.
 AC Power OK status signal.
 Fan cooled (Javelin I only, Javelin II requires 100 CFM to be provided by customer).
 Equipped with Auto-Sense.
 Output overcurrent, overvoltage and overtemperature protection.
 Ride-through (holdup) time: 20 ms at 1200W load.
 Size: 4.9H x 7.0W x 10.75L (9.5L for Javelin II).
 Heavy-duty “ruggedized” enclosure designed for a high shock and vibration environment.
 Extra cooling provided for higher output with increased altitude capability.
 “D” shell connectors for input and interface connections.
Technical Description
The Javelin consists of a DC or off-line single phase power-factor-corrected front end, with an EMI filter, cool-
ing fan (Javelin I), customer interface, associated housekeeping circuits, and a selection of Vicor’s DC-DC con-
verters.
Input DC or AC mains voltage is applied to a 3-pin power connector. The input current is passed through an
EMI filter designed to meet conducted noise limit specification EN55022, level A and B.
At start-up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after initial power-up
by a DC bus voltage sense circuit driving a thyristor. After rectification, the input voltage is put through a
boost converter that keeps the AC input current sinusoidal and synchronized with the input AC voltage (in
compliance with EN61000-3-2). The boost converter delivers a regulated input to the hold-up capacitors and a
high voltage backplane. The backplane supplies power to the DC-DC converters that provide the desired low
voltage, regulated output.
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Javelin I & II Power Supply Operator’s Manual

Javelin I & II Power Supply Operator’s Manual
Voltage conversion is achieved by Vicor’s family of Zero-Current-Switching (ZCS) DC-DC converters. These
are forward converters in which the main switching element switches at zero current. This patented topology
has a number of unique attributes: low switching losses, high frequency operation (resulting in reduced size for
magnetics and capacitors), excellent line and load regulation, wide output adjustment range, low EMI/RFI
emission, and high efficiency.
At initial power-up, the Javelin output is disabled to limit the inrush current and to allow the DC bus potential
to settle out to the correct operating level. A low-power flyback converter operating with PWM current-mode
control converts the high voltage DC bus into regulated low voltage to power the internal housekeeping circuits
and DC cooling fans.
The internal housekeeping Vcc comes up within 1 second after the application of input power. Once the high
voltage bus is within operating limits, the AC Power OK signal changes its output to a TTL “1,” indicating the
input power is OK, and allows the power output to come up 15-30 ms later. An auxiliary Vcc output of 5 VDC
capable of sourcing up to 300mA is provided for peripheral use.
An output Inhibit/Enable function is provided by using an optocoupler to control Vicor’s DC-DC converters. If
the Inhibit control pin is pulled low and the Enable pin is high or open, the optocoupler will turn on and disable
the output. The delay for an output to come up when measured from release of the Enable pin is 5-10 ms.
Power
Output
Line Filter
Rectifier
Soft Start
Circuit
Boost Converter
Output
PFC Control
Customer
Interface
I/E Control
Fan
Housekeeping
Power
Input
Current
Sample
Waveform
Sample
Inhibit/Enable Control
Inhibit/Enable
Figure 1. Javelin Architecture
Interface Connections
Input Power Terminal (J1)
Input AC (and DC) Power is applied to connector J1 using a 3W3 power
connector. J1-A1 is Line (L1), J1-A2 is Line 2/Neutral (L2/N), and J1-A3 is
Earth Ground (G) for safety.
A fault-clearing device, such as a fuse or circuit breaker, with a maximum
15A rating at the power supply input is required for safety agency compli-
ance. It should be sized to handle the start-up inrush current of 30A at 115
VAC and 60A at 230 VAC.
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J1 Pin Out
A1 Line 1
A2 Line 2/Neutral
A3 Ground
A1 A2 A3

Output Power Connections
The output power terminals available on the Javelin are 5/16–18
studs with flanged nuts. The positive polarity of the output is the
left stud when viewed from the output end. In order to minimize
parasitic cable inductance and reduce EMI, the output power cables
should be routed in close proximity to one another, and large current
loops should be avoided. To avoid excessive voltage drop, do not
undersize power cables, especially for high current outputs. Exces-
sive cable inductance, coupled with large capacitive loading, can
introduce instability in switching power supplies. This problem can
be avoided with proper system design. Consult Mission Power So-
lutions’ Engineering Department for assistance with applications
that use long cable lengths and excessive load capacitance.
Signal Return (J2-4)
Signal Return on J2-4 is an isolated secondary ground reference for all J2 interfacing signals. This is not the
same as Earth Ground on input power connector J1.
Inhibit/Enable (J2-7 to J2-8)
The Inhibit/Enable control pins allow the output to be controlled with either “inhibit” or “enable” logic. Con-
necting Inhibit (J2-8) and Enable (J2-7) to ground causes the Javelin to operate. With Inhibit (J2-8) open the
Javelin will operate, and the Enable pin has no effect. Connecting Inhibit to ground and leaving Enable open
will disable the output of the Javelin. Refer to Table 2 (Pg. 2).
AC OK (J2-6)
AC OK is an active high TTL-compatible signal and provides a status indication of the AC input power. It is
on pin J2-6 and is capable of sinking 16 mA maximum. This signal switches to a TTL “1” when the high volt-
age bus exceeds low-line condition during turn-on. Upon loss of input power, the bus voltage will drop, caus-
ing the AC OK signal to go low. A minimum of 3 ms holdup time is provided for a 1200W load following the
loss of the AC OK signal.
Figure 2. AC OK Output Circuit
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Javelin I & II Power Supply Operator’s Manual
Positive Return
+5V
AC OK 2.5K
J2-6 AC Power OK
J2-4 Signal Return
PN2222

Javelin I & II Power Supply Operator’s Manual
Auxiliary Vcc +5V/0.3A (J2-5)
The Vcc on J2-5 is an auxiliary 5V regulated power source. It is +5VDC 5% with respect to Signal Ground
(J2-4 and J2-2) and can supply 300mA maximum. It is short-circuit proof, but if shorted, all outputs will be
shut down through the Inhibit/Enable circuitry.
Figure 3. Auxiliary Vcc Circuit
Remote Sense Connections
The Javelin is shipped from the factory with Auto-Sense installed. If Remote Sense is desired, sense leads
must be connected from J3-1 (+Remote Sense) and J3-6 (−Remote Sense) to the load point where regulation is
required.
When Auto-Sense is used, the power supply will regulate the output at the output terminals. The voltage ap-
pearing at the load may drop slightly due to voltage drop in the power cables. If it is necessary to compensate
for voltage drop along the output power cables, the output can be trimmed up or configured for Remote Sense.
Use stranded, twisted pair 20-24 AWG wire for the Remote Sense lines. Remote Sense can compensate for a
voltage drop of up to 0.5V, or 0.25V on each leg.
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DC OK and DC OK′ are logic signals provided to indicate with either TTL logic “1” or “0” that the correct
output voltage is available. DC OK (J3-8) is a logic “1” when output voltage is within specification and a logic
“0” when output is out of tolerance. A logic “0” is capable of sinking 16 mA in either circuit. The inverse
signal, DC OK′, is available at J3-2. The circuit is operated with a +5Vcc provided by either the customer or
taken from connector J2-5 (+5V Vcc) and J2-2 (+5V Return).
MOC217
J3-3 +5V Vcc
J3-2 DC OK’
J3-8 DC OK
J3-7 +5V Return
2N7002 2N7002
49.9K
4.99K 4.99K
DC OK
Figure 4. DC OK Circuit
78M05
+5V/300mA J2-5 Auxiliary Vcc
J2-4 Signal Ground
0.1uF
J2-2 Signal Ground
DC OK/DC OK′ (J3-8 and J3-2)

Javelin I & II Power Supply Operator’s Manual
Mechanical Considerations
The Javelin can be mounted on either of two surfaces (top or bottom) using standard 8-32 size screws. Maxi-
mum allowable torque is 20 in/lbs., and the maximum penetration is 0.21(5,33mm).
When selecting a mounting location and orientation, the unit should be positioned so that airflow is not re-
stricted. Maintain a 2(50,8mm) minimum clearance at both ends of the Javelin, and route all cables so airflow
is not obstructed. The power supply draws air in at the front side and exhausts air out the load/input side. If
airflow ducting is used, avoid sharp turns that could create backpressure. The fan moves approximately 100
CFM of air.
Avoid excessive bending of output power cables after they are connected to the output terminals. For high-
current outputs, use cable ties to support heavy cables and minimize mechanical stress on connectors. Be care-
ful to not short out to neighboring outputs. The maximum torque recommended on output nuts is 130 in/lbs.
Javelin Do’s and Don’ts
 Run the output (+/) power cables next to each other to minimize inductance.
 Insert proper fault protection at power supply input terminals (i.e., a fuse).
 Use proper size wires to avoid overheating and excessive voltage drop.
 Do not attempt to repair or modify the power supply in any manner.
 Do not restrict airflow to the unit. The cooling fan draws air into the front of the unit and forces it out at
the input/output terminal (rear) side. It is necessary to provide at least 100 CFM of cooling airflow for the
Javelin II.
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Connecting Javelin I & II Power Supplies in Parallel
To connect up to three Javelin Power Supplies in parallel, connect PR1 (J3-9) to corresponding PR1(s) (J3-9)
and PR2 (J3-4) to corresponding PR2(s) (J3-4). Use 20-24 AWG twisted pair, shielded hook-up cable with the
shield connected to each unit’s chassis ground (J3-9). All units must use equivalent power sources, and all
outputs must be connected to a common bus with equal impedance connections. Output voltage can be ad-
justed on one power supply provided the other unit(s) is/are adjusted completely counterclockwise. If Remote
Sense is used, all units must have a connection to the point of regulation using 20-24 AWG twisted pair wires.
Figure 5. Paralleling Javelin I and II Power Supplies
AC/DC
Input
Twisted Pair Remote Sense Wires
Power
Supply 1
Power
Supply 2
Power
Supply 3 Shielded, Twisted Pair
Paralleling Cable
Output Cables
Output Bus
Output Return Bus
+
+
+
–
–
–
J3
J3
J3

Javelin I & II Power Supply Operator’s Manual
Mechanical Drawing - Javelin I
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Javelin I & II Power Supply Operator’s Manual
Mechanical Drawing - Javelin II (page 1)
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Javelin I & II Power Supply Operator’s Manual
Mechanical Drawing - Javelin II (page 2)
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Javelin I & II Power Supply Operator’s Manual
Specifications
(Typical at 25C, nominal line and 75% load, unless otherwise specified)
General
Number of Outputs 1
Efficiency 75%
Safety Approvals N/A
MIL-STD’s 461E; 704E; 810E; 1399
Maximum Output Power 800W, >104 VAC
1200W, >160 VAC
1800W, >212 VAC (Selected Output Voltages)
Input
Input 85-254 VAC, 47-500Hz
85-380 VDC
Line Regulation 0.2% from 10% load to full load
Inrush Current 30A rms. max. @ 115 VAC
60A rms. max. @ 230 VAC
Ride-Through Time 20 ms at 1200W load
Conducted EMI FCC Class A, EN 55022 Class B
MIL-STD-461E
Power Factor .99 (115 VAC 800W load)
.95 (230 VAC 1200W load)
Transient Surge IEC 801-5 level 3
(Common Mode & Normal Mode)
Dielectric Withstand Primary to Chassis GND = 2121 VDC
Primary to Secondary = 4242 VDC
Secondary to Chassis GND = 500 VDC
Output
Parameter MIN. TYP. MAX. UNITS NOTES
Setpoint Accuracy 0.5 1 % of VNOM
Load/Line Regulation 0.02 0.2 % of VNOM 0% to 100%
Temperature Regulation 0.002 0.005 %C 20 to 100C
Long Term Drift 0.02 %1K hours
Output Ripple –pp:
2V, 3.3V 100 mV 20 MHz bandwidth
5V 2 % 20 MHz bandwidth
12-95V 1 % 20 MHz bandwidth
Trim 90 110 % of VNOM
Total Remote Sense Compensation 0.5 Volts 0.25V max. each leg
OVP Set Point 112 135 % of VNOM Recycle power
Current Limit 102 135 % of I max Automatic restart
Over-Temperature Protection 85>TA<95 Varies according to
power level
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Javelin I & II Power Supply Operator’s Manual
Environmental
MIL-STD 810E
Storage Temperature
C Grade 40C to 125C
T Grade 40C to 125C
H Grade 55C to 125C
M Grade 65C to +125C
Operating Temperature
C Grade, Full Power 20C to +55C
C Grade, Half Power 20C to +70C
T Grade, Full Power 40C to 55C
T Grade, Half Power 40C to 70C
H Grade, Full Power 40C to 55C
H Grade, Half Power 40C to 70C
M Grade, Full Power 55C to 55C
M Grade, Half Power 55C to 70C
Product Weight 11.50 lbs. (11.0 lbs. Javelin II)
Dimensions 4.9H (124,46mm) x 7.0W (177,8mm) x 10.75L (273,1mm)
[9.5L (241,3mm) for Javelin II]
Warranty 1 Year Limited
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INPUT POWER
RATING MAXIMUM INPUTTYPE (#) INPUTVOLTAGE RANGE
(WATTS) Vout >10 / Vout<10
1600 (1) SINGLE PHASE 80 / 85 TO254 VAC
(2) DIRECTCURRENT80 / 85 TO380 VDC
2800 (1) SINGLE PHASE 102 / 108 TO254 VAC
(2) DIRECTCURRENT102 / 108 TO380 VDC
31200 (1) SINGLE PHASE 146 / 158 TO254 VAC
(2) DIRECTCURRENT146 / 158 TO380 VDC
41600 (1) SINGLE PHASE 192 TO254 VAC
(2) DIRECTCURRENT192 TO380 VDC
51800 (1) SINGLE PHASE 215 TO254 VAC
(2) DIRECTCURRENT215 TO380 VDC
Maximum Output Power vs. Input Voltage AC or DC
0
200
400
600
800
1000
1200
1400
1600
1800
2000
50 100 150 200 250
Minimum Input Voltage AC or DC
Maximum O utput Pow er
Output Voltages > 10Vdc Output Voltages <10 Vdc
MaximumOutput Power vs. Temperature
0
200
400
600
800
1000
1200
1400
1600
1800
2000
020 40 60 80 100
TA max
Pout max
400W
600W
800W
1200W
1600W
1800W
Graph 1. Maximum Output Power vs. Input Voltage

Javelin I & II Power Supply Operator’s Manual
0
200
400
600
800
1000
1200
1400
1600
1800
2000
020 40 60 80 100
Pout max
Temperature, Ambient (C)
Maximum Output Power vs. Temperature
400W
600W
800W
1200W
1600W
1800W
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Graph 2. Maximum Output Power vs. Temperature

Javelin I & II Power Supply Operator’s Manual
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Notes