Mission Javelin I, Javelin II Operator's 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] [e-mail] 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

Mounting the Javelin Power Supply

 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 Connections

Input Connector (J1)

 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.

A1 A2 A3

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:

J2-8

INHIBIT′

1 X ON
0 0 ON
0 1 OFF

Table 2. Inhibit/Enable Logic Table

J2-7

ENABLE′

POWER SUPPLY

STATE

 Use ITT/Cannon mating connector P/N DE9PK87 with Amp cover

shell P/N 205729-1.

 Use 20-24 AWG stranded wire.

5

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

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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.

1

6 9

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

5

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Javelin I & II Power Supply Operator’s Manual

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, cool­ing fan (Javelin I), customer interface, associated housekeeping circuits, and a selection of Vicor’s DC -DC con­verters.

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

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

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.

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 compli­ance. 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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Figure 1. Javelin Architecture

A1 A2 A3

J1 Pin Out

A1 Line 1
A2 Line 2/Neutral
A3 Ground

Javelin I & II Power Supply Operator’s Manual

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. Exces­sive 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

Positive Return

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, caus­ing 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.

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+5V

AC OK

2.5K

PN2222

J2-6 AC Power OK

J2-4 Signal Return

Figure 2. AC OK Output Circuit

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.

+5V/300mA J2-5 Auxiliary Vcc

78M05

0.1uF

J2-4 Signal Ground

J2-2 Signal Ground

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 ap­pearing 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.

DC OK/DC OK′ (J3-8 and J3-2)

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).

J3-3 +5V Vcc

4.99K
J3-8 DC OK

J3-2 DC OK’

2N7002

J3-7 +5V Return

DC OK

4.99K

49.9K

2N7002

MOC217

Figure 4. DC OK Circuit

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Javelin I & II Power Supply Operator’s Manual

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 ad­justed 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.

Output Cables

Output Bus

Output Return Bus

Twisted Pair Remote Sense Wires

Shielded, Twisted Pair
Paralleling Cable

AC/DC

Input

Power
Supply 1

Power
Supply 2

Power
Supply 3

+

–

J3

+

–

J3

+

–

J3

Figure 5. Paralleling Javelin I and II Power Supplies

Mechanical Considerations

The Javelin can be mounted on either of two surfaces (top or bottom) using standard 8-32 size screws. Maxi­mum 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 re­stricted. 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 high­current outputs, use cable ties to support heavy cables and minimize mechanical stress on connectors. Be care­ful 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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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

Load/Line Regulation

Temperature Regulation

Long Term Drift

Output Ripple – pp:

2V, 3.3V

5V

12-95V

Trim

Total Remote Sense Compensation

OVP Set Point

Current Limit

Over-Temperature Protection

90

0.5

112

102

85>TA<95

0.5 1

0.02 0.2

0.002 0.005

0.02

100

2

1

110 % of V

135 % of V

135 % of I max Automatic restart

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% of V

NOM

% of V

NOM

%C 20 to 100C

%1K hours

mV 20 MHz bandwidth

% 20 MHz bandwidth

% 20 MHz bandwidth

NOM

Volts 0.25V max. each leg

NOM

0% to 100%

Recycle power

Varies according to
power level

Environmental

Maximum Output Pow er 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 Output Pow er

Output Voltages > 10Vdc Output Voltages < 10 Vdc

Maximum Output Power vs. Temperature

0

200

400

600

800

1000

1200

1400

1600

1800

2000

0 20 40 60 80 100

TA max

Pout m ax

400W

600W

800W

1200W

1600W

1800W

Javelin I & II Power Supply Operator’s Manual

MIL-STD

Storage Temperature

C Grade

T Grade

H Grade

M Grade

Operating Temperature

C Grade, Full Power

C Grade, Half Power

T Grade, Full Power

T Grade, Half Power

H Grade, Full Power

H Grade, Half Power

M Grade, Full Power

M Grade, Half Power

Product Weight
Dimensions 4.9 H (124,46mm) x 7.0 W (177,8mm) x 10.75 L (273,1mm)

Warranty

810E

40C to 125C

40C to 125C

55C to 125C

65C to +125C

20C to +55C

20C to +70C

40C to 55C

40C to 70C

40C to 55C

40C to 70C

55C to 55C

55C to 70C

11.50 lbs. (11.0 lbs. Javelin II)

[9.5 L (241,3mm) for Javelin II]

1 Year Limited

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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

0 20 40 60 80 100

Pout max

Temperature, Ambient (C)

Maximum Output Power vs. Temperature

400W

600W

800W

1200W

1600W

1800W

Graph 2. Maximum Output Power vs. Temperature

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Notes

Javelin I & II Power Supply Operator’s Manual

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