Vicor Javelin II 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

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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

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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.

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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.

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 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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A1 A2 A3

J1 Pin Out

A1 Line 1
A2 Line 2/Neutral
A3 Ground