Crossbow Power Supply

Transcription

1 Crossbow Power Supply Six Output, DC-DC Switching Power Supply Operator s Manual and Installation Instructions MISSION POWER SOLUTIONS Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg.1

2 Crossbow Power Supply DC/DC Switching Power Supply Installation Instructions Mounting the Crossbow Power Supply The power supply can be mounted on any one of four sides: Top, bottom and either side. Use 6 (six) #8-32 mounting screws. Maximum penetration should not exceed 0.13 (3,3 mm) on the side mounts and 0.25 (6,3 mm) on the top or bottom. Use stainless steel screws with lock washers and apply appropriate torque not to exceed 19 in-lbs. Maintain 2 (50,8 mm) clearance at either end for airflow. Positive Return Return Positive Output Connections Installing ring lugs and/or bus bars on output slots: The top and bottom row of screw connections are Positive and the inner screw connections are the Return on all output channels. Remove the screw and place screw through ring lug into the connection. Tighten the screw to a torque of 12 to 19 in/lbs. Do Not Over-Tighten Screws. Use suitable cable sizes for rated current. See Table 1 for appropriate cable sizes. Installing bus bars for paralleled output: Bus bars are factory installed per configuration. Output connections may be made to any and/or all of the output terminals. Make sure that the output cables are appropriate for the output current and that ring lugs are for a #8 screw and are rated to carry sufficient current. See Table 1 for appropriate cable sizes. Insure all screws are tightened (12 to 19 in/lbs) in a bus bar configuration or damage to output terminals will result. Single Slot Configuration Output Voltage Output Current (per slot) Multiple Slot Configuration Figure 1. Typical dual output configuration with one output bussed together and the second a single output. Qty of wires per terminal AWG Wire Gauge Table 1. Suitable wire size and quantity for voltage/ current rating. Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 2

3 Standard Output Voltage Adjustment Slot 1 DCOK/DCOK Slot 1 trimpot access Slot 1 Sense/Trim Each output voltage can be adjusted from 95% to 105% of nominal using the adjustment potentiometer. Access to the adjustment potentiometer is available through a small access hole next to the 3 pin sense and trim connection. Non-standard adjustments to output voltages are available as a factory installed option. Output Sense Connections Output Sense Connections on Driver output slots: The power supply is shipped with Auto Sense installed. For bussed outputs the sense connector on the Driver slot is used. Sense connections are not installed on Booster slots. If Remote Sense is desired, use the 3 pin molex latching connector. See Figure 2 for location. Connector pin 1 is the +Sense and pin 3 is the Sense. See Figure 3. Use Molex mating receptacle P/N with P/N terminals. Attach terminals to AWG stranded twisted pair wire. Attach opposite end of sense lines to the point where regulation is desired. Verify that sense lines are not cross-connected. Output External Trim Connections Trim Connections on Driver output slots: Pin 2 provides Trim access. Onboard trim is optional and when available accessible through an access hole near the 3 pin connector on each slot containing a driver module. See Figure 2. Use Molex mating receptacle P/N with P/N terminals. Attach AWG stranded wire using Molex tool P/N Figure 2. Sense & Trim, DCOK Connections and trimpot access (slot 1 indicated). Note: A Driver slot contains sense, trim, DCOK and regulation capability for any given output. Booster slots are always paralleled to a driver and add power (only) to the driver s output. Any single slot output is populated by a driver. In the example in Figure 2 slots 1 and 6 are drivers and slots 2 through 5 are boosters Pin 1 +Sense 2 Trim 3 Sense Figure 3. Sense and Trim Connections (typical) Note: Bottom row of connectors (slots 4, 5 & 6) are physically inverted Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 3

4 Output DC OK Connections (optional, Driver only) Pin 1 provides External Bias input. Pin 2 provides DCOK indication Pin 1 Ext. Bias 2 DCOK 3 DCOK 4 Ext. Bias Rtn Pin 3 provides DCOK indication. Pin 4 is the return for the External Bias. Use Molex mating receptacle P/N with P/N terminals. Figure 4. DCOK circuit connections (typical) Note: Bottom row of connectors (slots 4, 5 & 6) are physically inverted Attach AWG stranded wire using Molex tool P/N J8 Connector - Input Lug Input/Customer Interface Connections Input Power Connector Lugs (See Figure 5) Input DC power is applied to terminal lugs marked - and + using 5/16 bolts, washers and nuts. (For best performance use a bolt /nut/washer combination that is made of a highly conductive material i.e. Silicon Bronze. Make sure the hardware plating is appropriate for the application and environment). Minimum cable size recommended: Each connection, 4AWG or equivalent. + Input Lug Figure 5. Input Connector Lugs and Customer Interface Connector J8. Customer Interface Connector (J8). (See Figure 6) J8-9, 10, 11, 22, 23, 24 are Disable inputs for output slots 6, 4, 2, 5, 3, 1, respectively. A connection to S_GND will disable the respective slot. J8-1, 2, 15, & 20 are Signal Ground (S_GND). J8-16, 17 are Auxiliary bias +5VS. J8-3 is OTWarn (over-temperature warn). J8-4 is A-Temp (analog temperature reading). J8-5 is GSD (General Shutdown) J8-12 is PR_RTN (Parallel Return) J8-13 is PR_IN (Parallel Input) J8-18 is VOK (Input Voltage within spec.) J8-19 is VOK (Inverse of Input Voltage within spec.) J8-25 is PR_OUT (Parallel Out) Attach terminals to AWG stranded wire. Interface connector: DB-25S or equivalent. Pin 1 J8 Pin Out 1 S_GND 2 S_GND 3 OTWarn 4 A_Temp 5 GSD 6 Spare 7 Spare 8 Spare 9 Disable Slot 6 10 Disable Slot 4 11 Disable Slot 2 12 PR_RTN 13 PR_IN 14 Spare 15 S_GND 16 Pos 5VS 17 Pos 5VS 18 VOK 19 VOK 20 S_GND 21 Spare 22 Disable Slot 5 23 Disable Slot 3 24 Disable Slot 1 25 PR_OUT Figure 6. Customer Interface Connector J8 Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 4

5 Crossbow Power Supply DC-DC Switching Power Supply Overview The Crossbow Power Supply is an environmentally and mechanically ruggedized switching power supply that combines the advantages of high power density and high temperature capability with user-selected isolated outputs. Accepting input voltages from 18 to 36VDC, the power supply can provide up to 1200 watts in a package size of 5 H x 7 W x 12.5 L. The power supply can provide up to 6 isolated outputs and is factory configured to meet user requirements. Its inherent flexibility comes from its use of Vicor 2 nd Generation DC-DC converters. Creating a customized power supply is as easy as choosing the DC/DC converters necessary and having them installed. Slots can be paralleled to increase output current capability by using a Driver/Booster configuration and bus straps. Entire units can also be paralleled to further increase output current capability. Standard Features 28V input per MIL-STD-704E/F and MIL-STD-1275A/B/D, MIL-STD-901D compliance Conducted emissions: MIL-STD-461E: CE101, CE102 Conducted susceptibility: MIL-STD-461E: CS101, CS114, CS115, and CS116 Transient Protection: Consistent with MIL-STD-704E/F and MIL-STD-1275 A/B/D (28VDC). Up to 6 isolated outputs Output voltages: 3.3, 5, 8, 12, 15, 24, 28, 36, and 48 VDC with variable trim of ±5%. Output power per slot: 150W for 3.3VDC, 200W for 5 through 48VDC Forced air cooled with an internal fan, full power to 65 C Input Soft Start for limiting inrush current and input reverse polarity protection Environmental: Low temp: -55, -40, or -20. High temp: Full power to 65C Humidity : 95% non-condensing Input DC Power OK status signal (VOK) Output DC Good for each output voltage General Shutdown and individual slot disable Automatic Remote Sense standard on all outputs. Output over-current protection on all outputs Output over-voltage & over-temperature protection Short circuit protection on all slots Heavy-duty rugged enclosure designed for a high shock and vibration environment Extra cooling provided for higher output with increased altitude capability D shell connector for input control connections. Bus bars provided for high output currents when slots are paralleled. Optional multi-unit parallel capability Optional conformal coating : Allows 100% condensing humidity, salt atmosphere, and fungus environments Analog temperature output (indicating inlet air temperature) Available Auxiliary bias 5 volt output Vicor high frequency ZCS/ZVS DC/DC converter modules Technical Description (See Figure 7) The Crossbow Power Supply consists of an EMI filter, cooling fan, customer interface, associated housekeeping circuits, and a selection of Vicor s DC-DC converters. The DC input voltage is applied to the input bus bars. The input current passes through the EMI filter which is designed to meet military conducted emission specifications. At start-up, inrush current is limited by a thermistor. The thermistor is shorted out after initial power-up by a FET switch controlled by a DC bus voltage sense circuit. The DC voltage is then fed to the backplane. The backplane supplies power to six (6) converter assemblies that provide the desired low voltage, regulated outputs. Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 5

6 Voltage conversion in the output assemblies 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 power supply s outputs are disabled to limit the inrush current and to allow the DC bus potential to charge to the correct operating level. A low-power flyback converter operating with PWM currentmode control converts the input DC bus voltage into regulated low voltage to power the internal housekeeping circuits and DC cooling fan. The internal housekeeping Vcc comes up within 1 second after the application of input power. Once the input bus is within operating limits, the VOK-P signal changes its output to a TTL 1, indicating the input power is good, and allows the output DC/DC converters to turn on after a delay. An auxiliary bias Vcc output of 5VDC capable of sourcing up to 0.1A is provided for peripheral use. An output Disable function is provided by using an optocoupler to control the on/off state of the DC/DC converters. If the Disable control pin is pulled low, the optocoupler turns on and disables the desired output. The delay for an output to come up when measured from release of the Disable pin is 5-10 ms. The General Shutdown function controls all outputs simultaneously and works in a similar manner. There is no ride-through (hold-up) time available with the Crossbow power supply. VDC IN EMI Filter Under, Over & Reverse Voltage Protection Inrush Current Limiting DC/DC Converter Slot #1 DC Fan Fan and Housekeeping Converter DC/DC Converter Slot #2 DC/DC Converter Slot #3 Aux bias +5VDC Customer Inputs Disable General Shutdown etc. Housekeeping Circuits Customer Interface and Opto Isolators DC Bus Sense ON/OFF Control DC/DC Converter Slot #4 DC/DC Converter Slot #5 DC/DC Converter Slot #6 Figure 7. Crossbow Power Supply Architecture Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 6

7 Interface Connections Input Terminal Lugs (See Figure 5) Input DC Power is applied to large lugs + and - on front of unit. A minimum 4AWG or equivalent wires per lug will be necessary to provide ample current capacity. Customer Interface Connector (J8) Individual outputs for slots 1 through 6 can be disabled with a logic 0 at pins 24, 11, 23, 10, 22, and 9 respectively. Signal Ground is available at pins 1, 2, 15 & 20. Auxiliary bias +5V 100 ma is available at pins 16 & 17. The VOK input Power OK signal at pin 18 is a logic 1 whenever DC input power is within tolerance and VOK (pin 19)is a logic 0. All outputs can be disabled by placing GSD (pin 5) at a logic 0. Multiple units can be paralleled by using pins 12 (PR_RTN), 13 (PR_IN), and 25 (PR_OUT). Pins 6, 7, 8, 14 & 21 are not used. See Figure 6 on page 4. Signal Ground (J8-1, 2, 15 & 20) Signal Ground is an isolated secondary ground reference for all J8 interfacing signals. This is not the same as Chassis Ground or the input power lug -. Disable (J8-9, 10, 11, 22, 23, 24) (See Figure 8) The Disable control pins allow outputs to be sequenced either on or off. These pins are the control pins for slots 1 through 6 (see Figure 6, page 4). The Disable pins should be pulled low (less than 0.7V with respect to Signal Ground) to disable the outputs. They will source 4mA maximum. These pins should be open-circuit or allowed to exceed 4.5V when enabled. Do not apply more than 6V to these inputs at any time. CUSTOMER SUPPLIED DB25S +5V (4.5 to 5.5V TYP) J8 16 POWER SUPPLY 475Ω SLOT 1 DISABLE 5V RTN SLOT 1 DISABLE (TYPICAL OF 6) Ω GENERAL SHUT DOWN GSD 5 1 PGND SGND PGND (TYPICAL ENABLE/DISABLE) Figure 8. Enable/Disable and General Shutdown Over-temperature Operation The Power Supply will operate at full output with ambient air temperature up to 65 C. Individual slots will shutdown output if the baseplate of the output module reaches 100 C. If the input air temperature exceeds 70 C the entire unit will shutdown. Operation above an ambient temperature of 65 C but below 70 C will be dependant upon the loading of the individual slots. Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 7

8 General Shutdown (J8-5) The General Shutdown (GSD) control pin on J8-5 allows simultaneous shutdown of all outputs. This pin must be pulled down to less than 0.7V and will source 10mA maximum to shut down all outputs. The GSD pin should be open-circuited or allowed to exceed 4.5V when not in use, or when the outputs are to be enabled. Do not apply more than 6V to this input at any time. Normal open-circuit voltage is 1.5 to 4.5V with respect to Signal Ground. VOK/VOK (J8-18/J8-19) VOK is an active high TTL-compatible signal and provides a status indication of the DC input power. It is on pin J8-18 (VOK) and J8-19 (VOK) and each is capable of sinking 16mA maximum. This signal switches to a TTL 1 when the input voltage is within its specified range. Upon loss of input power, the bus voltage will drop, causing the VOK signal to go low (Logic 0 ). +5V DB25S J8 17 POWER SUPPLY 2.49K 2.49K +12VP VOK VOK K 10.0K 2.49K V RTN 1 VOK-P Figure 9. VOK Output Circuit Auxiliary bias Vcc +5V/0.10A (J8- The Vcc on J8-16, 17 is an auxiliary bias 5V regulated power source. It is +5VDC ±5% with respect to Signal Ground and can supply 100mA maximum. It is short-circuit-proof, but if shorted, all outputs will shut down due to the fact that it is utilized in the Disable circuitry. +5V DB25S J POWER SUPPLY 78M05 +14VS 0.1µF 5V RTN 1 2 SGND Figure 10. Auxiliary bias +5V Vcc Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 8

9 Output/Customer Interface Connections Output Connections 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 Solutions Engineering Department for assistance with applications that use long cable lengths and excessive load capacitance. Sense Connections The Crossbow power supply is shipped from the factory with Auto-Sense capability installed. If Remote Sense is desired, access to the remote sense lines are available at the 3 pin connector of each slot. Pin 1 is +remote sense and pin 3 is remote sense return. Pin 2 is the trim pin. 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 load cables. If it is necessary to compensate for voltage drop along the output load cables, the output can be trimmed up or configured for remote sense. Use stranded twisted pair 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. Reversal of the remote sense lines can destroy the output module. POWER SUPPLY (TYPICAL SLOT) + Out +Sense Load -Sense - Out Use AWG Twisted Pair Wire Figure 11. Remote Sense Connections Trim Options The standard setting for trim is a trim pot installed with 95% to 105% trim adjustability with DCOK. Other options are available: 50% to 105% variable trim (no DCOK available) No variable trim (no trim pot provided, with DCOK) External Trim (no trim pot provided, without DCOK) Non-standard output voltage (NSOV). Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 9

10 External Trim Option The trim pin at pin 2 (driver slot 3 pin connector) is referenced to the sense pin and can be used for external control of the output voltage. A 10% increase to the trim pin voltage will result in a 10% increase in output voltage. Reducing the trim pin voltage by 10% will result in a 10% decrease in output voltage. Note: If a non-standard voltage is requested or when trimming below 5V, consult Mission Power Solutions for assistance. TYPICAL DRIVER SLOT R Ω +OUT +SENSE R2 R8 To error amplifier + V1 - R5 RTH (1K) R3 C1.033µF TRIM -SENSE R6 R7 + V2 - Load VREF (1.23V) R Ω -OUT Use AWG Twisted Pair Wire for Sense Connections Figure 12. External Trim Example: 10% trim adjust on a 12V nominal output. Figure 10 shows a typical variable trim circuit. Using a 1k trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: V 1 =V ref + 10% = 1.353V Given: V ref = 1.23V I R5 = (1.353V - V ref )/R TH = (1.353V 1.23V)/1k = 122 A Given: R TH = 1k Setting the bottom limit: V R6 = 1.23V 10% = 1.107V And since I R5 = I R6 = 122 A, R6 = V R6 /I R6 = 1.107V/122 A = 9.074k V 2 = V 1 + V R6 = 1.353V V =2.46V I R7 = V 2 /R7 = 2.46V/1k = 2.46mA I R8 = I R7 + I R6 = 2.58mA V R8 = (V nom + 10%) V 2 = 13.2V 2.46V = 10.74V Given: V nom = 12V R8 = V R8 /I R8 = 10.74V/2.58mA = 4.162k Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 10

11 Mechanical Considerations The Crossbow power supply can be mounted on any of four surfaces using standard #8-32 size screws. Maximum allowable torque is 19 in/lbs. using stainless steel hardware. The maximum screw penetration for side mounting the power supply is 0.13 in. (3,2 mm) and the maximum screw penetration for top and bottom mounting is 0.25 in (6,3 mm). When selecting a mounting location and orientation, the unit should be positioned so airflow is not restricted. Maintain a 2 (50,8mm) minimum clearance at both ends of the power supply, and route all cables so airflow is not obstructed. The power supply draws air in at the fan/input side and exhausts air out the load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fan moves approximately 100 cubic feet per minute (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 not to short out to neighboring outputs. The maximum torque recommended on output screws is 12 to 19 in/lbs. Crossbow Power Supply Do s and Do not s 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 unit and forces it out at the output power terminals. Placing Multiple Crossbow Power Supplies in Parallel Paralleling signals are available in the J8 connector. The PR_OUT signal (J8-25) is generated in the driver module of the Master power supply and must be connected along with the PR_RTN (J8-12) to the PR_IN (J8-13)/PR_RTN (J8-12) of the Slave power supply. The connecting wires should be twisted pair and as short as reasonably possible. All outputs of both the master and slave power supplies must be connected together with the appropriate size wires/bus bars. It is possible to have as many as 11 booster modules driven by one driver module enabling an output of 2400W (1800W at voltages <5VDC). Consult Mission Power Solutions Engineering department for other output combinations available. Twisted Pair J8 J8 Power Supply #1 25 PR_OUT 12 PR_RTN Master 13 PR_IN 12 PR_RTN Slave +Out -Out Power Supply #2 +Out -Out Figure 13. Parallel Connections Paralleled Output Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 11

12 Specifications Crossbow Power Supply Operator s Manual NOTES: 1.0 PRODUCT DESCRIPTION: THE PRODUCT DESCRIBED HEREIN IS A POWER SUPPLY WHICH IS A 24/28 VOLT DIRECT CURRENT OPERATED DEVICE WITH UP TO SIX DIRECT CURRENT OUTPUTS. THE POWER SUPPLY'S MECHANICAL CONSTRUCTION MAKES IT SUITABLE FOR HARSH ENVIRONMENT APPLICATIONS CONSISTENT WITH EXTREME TEMPERATURE, ALTITUDE, VIBRATION, SHOCK, AND HUMIDITY. THE POWER SUPPLY HAS SIX INDIVIDUAL OUTPUT SLOTS EACH BEING CAPABLE OF HOUSING A 200 WATT OUTPUT VOLTAGE CONVERTER (DEPENDING ON THE OUTPUT VOLTAGE). ADJACENT SLOTS CAN BE PARALLELED FOR OUTPUTS GREATER THAN 200 WATTS OR FOR REDUNDANT OPERATION. STANDARD FEATURES: 28 VOLT INPUT PER MIL-STD-704E/F NORMAL, ABNORMAL, AND EMERGENCY OPERATION, AND 28 VOLT INPUT PER MIL-STD-1275A/B/D. CONDUCTED EMISSIONS: MIL-STD-461E: CE101, AND CE102. CONDUCTED SUSCEPTIBILITY: MIL-STD-461E: CS101, CS114, CS115, AND CS116. REVERSE POLARITY INPUT PROTECTION. INPUT INRUSH PROTECTION. OUTPUT VOLTAGES: 3.3, 5, 8, 12, 15, 24, 28, 36, AND 48 VDC. OUTPUT POWER PER SLOT: 150 WATTS FOR 3.3 VDC, 200W FOR 5 THROUGH 48 VDC DC GOOD EACH OUTPUT OUTPUT VARIABLE TRIM: 95 TO 105% OF NOMINAL OUTPUT VOLTAGE. REMOTE AUTO-SENSE SHORT CIRCUIT PROTECTION. OVER-VOLTAGE PROTECTION. OVER TEMPERATURE PROTECTION. OVER TEMPERATURE WARNING LOGIC SIGNAL LOGIC DISABLE FOR EACH SLOT. GENERAL SHUTDOWN ANALOG TEMPERATURE OUTPUT UNIT TO UNIT PARALLEL CAPABILITY. UNCOMMITTED 5 VOLT STANDBY OUTPUT. VICOR HIGH FREQUENCY ZCS/ZVS DC/DC CONVERTER MODULES FORCED AIR COOLED OPTIONAL FEATURES: NO VARIABLE TRIM/EXTERNAL TRIM OUTPUT VARIABLE TRIM: 50 TO 105% OF NOMINAL OUTPUT VOLTAGE (NO DC GOOD). CONFIGURED FOR REDUNDANT OUTPUT SLOTS CONFORMAL COAT NONSTANDARD OUTPUT VOLTAGES: 2.0<V< 50 VDC. OPERATING AIR TEMPERATURE OPTIONS: C: -20 TO 65 C. H: -40 TO 65 C. M: -55 TO 65 C. STORAGE AIR TEMPERATURE OPTIONS: C: -40 C TO 125 C. H: -55 C TO 125 C. M: -65 C TO 125 C. 2. MECHANICAL REQUIREMENTS: (SEE OUTLINE DRAWING). EXTERIOR SHEET METAL MATERIAL: 0.09 THK AL ALY, 5052-H32 OR EQUIV. FINISH: ALUMINUM: GOLD CHEM-FILM PER MIL-C-5541, CLASS 1A. COPPER: TIN PLATE BRASS: TIN OR NICKEL PRINTED CIRCUIT DESIGN: PER IPC-275 MATERIAL: FR4, 4 0Z ON OUTER LAYERS, 2 OZ ON INNER LAYERS, 94-V-0 MIN. COOLING REQUIREMENTS: FORCED-AIR COOLED WITH INTERNAL FAN, 100 CFM MIN, BRUSHLESS, AND EQUIPPED WITH BALL BEARINGS. 3. MOUNTING LOCATIONS: TOP, BOTTOM, RIGHT AND LEFT SIDES USING 6 #8-32 UNC-2B SCREWS (SEE OUTLINE DRAWING FOR LOCATIONS AND PENETRATION DEPTH). 4. CONNECTIONS: DC INPUT: (SEE FRONT VIEW) TWO 0.33 Ø HOLES TO ACCOMMODATE CUSTOMER SUPPLIED 5/16" HARDWARE. MARKING TERMINATION + INPUT - INPUT RETURN CONTROL CONNECTOR (J8): DB-25 PLUG WITH MALE PINS. PIN NUMBER TERMINATION FUNCTION 1 S_GND SIGNAL GROUND 2 S_GND SIGNAL GROUND 3 OT_WARN OVER-TEMP WARNING 4 A_TEMP ANALOG TEMP OUTPUT 5 GSD GENERAL SHUTDOWN 6 N/C NO CONNECTION 7 N/C NO CONNECTION 8 N/C NO CONNECTION 9 D_6 DISABLE SLOT 6 10 D_4 DISABLE SLOT 4 11 D_2 DISABLE SLOT 2 12 PR_RTN PARALLEL RETURN 13 PR_IN PARALLEL INPUT 14 N/C NO CONNECTION 15 S_GND SIGNAL GROUND 16 +5VS +5V STANDBY 17 +5VS +5V STANDBY 18 VOK INPUT VOLTAGE GOOD 19 VOK' INPUT VOLTAGE NOT GOOD 20 S_GND SIGNAL GROUND 21 N/C NO CONNECTION 22 D_5 DISABLE 5 23 D_3 DISABLE 3 24 D_1 DISABLE 1 25 PR_OUT PARALLEL OUT NOTES CONTINUED: DC OUTPUT: (SEE REAR VIEW) TWO #8-32 UNC-2B SCREWS WITH FLAT AND LOCK WASHERS PER OUTPUT. MAX SCREW PENETRATION DEPTH 0.50". 6 OUTPUTS MAXIMUM. OUTPUTS CAN BE PARALLELED USING VARIOUS COMBINATIONS OF OUTPUT BUS BARS (SEE FIGURE 3.) MARKING TERMINATION + OUTPUT - OUTPUT RETURN OUTPUT REMOTE SENSE CONNECTOR: 1 PER OUTPUT. THREE PIN HEADER MOLEX PIN NUMBER TERMINATION FUNCTION 1 +SENSE + REMOTE SENSE LINE 2 EXT_TRIM EXTERNAL REMOTE PROGRAMMING 3 -SENSE - REMOTE SENSE LINE OUTPUT DCOK CONNECTOR: 1 PER OUTPUT. FOUR PIN HEADER MOLEX PIN NUMBER TERMINATION FUNCTION 1 +EXT_BIAS +BIAS (15V MAX) 2 DC_OK' DC OK NOT 3 DC_OK DC OK 4 +EXT_BIAS_RTN +BIAS RTN 5. ELECTRICAL SPECIFICATIONS (TYPICAL AT 25 C NOMINAL LINE AND 75% LOAD, UNLESS OTHERWISE SPECIFIED). INPUT REQUIREMENTS: NOMINAL INPUT VOLTAGE: 28 VDC PER MIL-STD-704E/F NORMAL, ABNORMAL, AND EMERGENCY OPERATION, AND 28 VOLT INPUT PER MIL-STD-1275A/B/D. INPUT VOLTAGE RANGE: 18 TO 36 VDC CONTINUOUS. MAXIMUM INPUT CURRENT: 95 ADC. MAXIMUM INRUSH CURRENT: 130 APK WITH 6 SLOTS FILLED. LOW LINE MAXIMUM TURN-ON VOLTAGE: 19.0 VDC. LOW LINE MAXIMUM TURN-OFF VOLTAGE: 18.0 VDC. HIGH LINE TURN-OFF VOLTAGE: 51 TO 60 VDC. REVERSE INPUT VOLTAGE PROTECTION: NO DAMAGE, NO FUSES TO REPLACE. TRANSIENT PROTECTION: PER MIL-STD-704E/F FIGURE 9. AND PER MIL-STD-1275A/B/D 100MS TURN-ON TIME: 5 SECONDS MAXIMUM. INPUT CURRENT WITH GENERAL SHUTDOWN ASSERTED: 0.3 ADC MAXIMUM ISOLATION REQUIREMENTS: INPUT TO THE CASE: 100 VDC INPUT TO ANY OUTPUT: >10MEG OHMS INPUT TO CONTROL CONNECTOR PINS: >10MEG OHMS OUTPUT TO THE CASE: 100 VDC OUTPUT TO OUTPUT: 100 VDC OUTPUT TO CONTROL CONNECTOR PINS: 100 VDC CONTROL CONNECTOR TO THE CASE: 100 VDC OUTPUT REQUIREMENTS: (SEE OUTPUT ASSEMBLY TABULATION) STANDARD NOMINAL OUTPUT VOLTAGE (NOPV): 3.3, 5.0, 8.0, 12.0, 15.0, 24.0, 28.0, 36.0, AND 48.0 VDC STANDARD OUTPUT VOLTAGE ADJUSTMENT RANGE: 95 TO 105% OF NOMINAL OUTPUT VOLTAGE. STANDARD OUTPUT POWER PER SLOT: <5.0 = 150 WATTS, >= 5.0 = 200 WATTS. STANDARD OUTPUT SET POINT ACCURACY: ±.02 VDC. LOAD REGULATION: (SEE OUTPUT ASSEMBLY TABULATION). TEMPERATURE REGULATION:.004%/C TYPICAL,.010%/C MAXIMUM. LONG TERM DRIFT:.02%/1000 HRS TYPICAL. REMOTE SENSE COMPENSATION: 0.25 VDC EACH SENSE LINE. AUTOMATIC REMOTE SENSE IS STANDARD. CONNECTIONS: J1-1 (+SENSE) MUST BE CONNECTED TO THE + LOAD CABLE AT LOAD IF USED. J1-3 (-SENSE) MUST BE CONNECTED THE THE - LOAD CABLE AT LOAD IF USED. EXTERNAL TRIM OPTION: ALLOWS REMOTE PROGRAMMING OF OUTPUT VOLTAGE. J1-2 EXT.TRIM INPUT J1-3 EXT.TRIM RTN OVER-VOLTAGE SET POINT: 112% TO 135% OF NOMINAL OUTPUT VOLTAGE, RECYCLE INPUT VOLTAGE TO RESTART (1 MINUTE OFF). OUTPUT POWER OK: STANDARD OUTPUT SIGNAL THAT INDICATES THE STATUS OF THE OUTPUT VOLTAGE. J2-3 DC_OK OUTPUT: ASSERTS A TTL '1' IF OUTPUT IS >95% OF NOPV. ASSERTS A TTL '0' IF OUTPUT IS <85% OF NOPV. J2-2 DC_OK' OUTPUT: INVERTED SIGNAL OF DC_OK. J2-1 +EXT_BIAS: REQUIRES +5VDC FROM THE J8 BIAS OR OTHER SOURCE VCC INPUT CURRENT: <= 3 ma. J2-4 +EXT_BIAS_RTN: RETURN FOR THE DC_OK SIGNALS AND VCC INPUT. OUTPUT ASSEMBLY MARKING REQUIREMENTS: (SEE DETAIL A TYPICAL OUTPUT ASSEMBLY) EACH OUTPUT ASSEMBLY IS IDENTIFIED WITH PRODUCT LABEL WITH THE FOLLOWING INFORMATION: ASSEMBLY MODEL NUMBER AND REV. SERIAL NUMBER. OTHER REQUIREMENTS: DISABLE (SLOT 1-6) J8-9, J8-10, J8-11, J8-22, J8-23, AND J8-24: EACH OUTPUT SLOT IS ENABLED UNLESS DISABLED BY APPLYING A TTL '0' TO THE RESPECTIVE DISABLE SLOT INPUT. DISABLE INPUT VOLTAGE: <0.70 VDC. MAXIMUM INPUT VOLTAGE: 6.0 VDC. NOMINAL INPUT VOLTAGE: 1.5 TO 3 VDC OPEN CIRCUIT OR FLOATING. (NOT DISABLED) DISABLE INPUT CURRENT SINK: 10 ma MAXIMUM. SIGNAL RTN: S_GND GENERAL SHUTDOWN J8-5: THE GSD CONTROL PIN WILL SIMULTANEOUSLY SHUTDOWN ALL OUTPUT ASSEMBLY SLOTS. ALSO TERMINATES THE OPERATION OF THE POWER SUPPLY'S COOLING FAN. SHUTDOWN INPUT VOLTAGE: <0.70 VDC. MAXIMUM INPUT VOLTAGE: 6.0 VDC. NOMINAL INPUT VOLTAGE: 1.5 TO 3 VDC OPEN CIRCUIT OR FLOATING. (NOT DISABLED) SHUTDOWN INPUT CURRENT SINK: 10 ma MAXIMUM. SIGNAL RTN: S_GND NOTES CONTINUED: INPUT POWER OK J8-18: TTL COMPATIBLE OUTPUT SIGNAL PROVIDES A STATUS INDICATION OF THE DC INPUT VOLTAGE. TTL '1' = INPUT VOLTAGE IS BETWEEN 18 AND 51 VDC. LOW LINE CUTOFF: 12 TO 18 VDC. HI-LINE CUTOFF: 51 TO 57 VDC. OUTPUT SINK CAPABILITY: 20 ma MAXIMUM. SIGNAL RTN: S_GND INPUT POWER FAIL J8-19: INVERSE FUNCTION OF INPUT POWER OK. TTL '0' = INPUT VOLTAGE IS BETWEEN 18 AND 51 VDC. LOW LINE CUTOFF: 12 TO 18 VDC. HI-LINE CUTOFF: 51 TO 57 VDC. OUTPUT SINK CAPABILITY: 20 ma MAXIMUM. SIGNAL RTN: S_GND OVER-TEMPERATURE WARNING J8-3: TTL COMPATIBLE OUTPUT THAT ASSERTS A TTL '1' IF THE AIR TEMPERATURE RATING IS EXCEEDED. TTL '1' (OT) = 65 C TO 76 C TYPICAL TTL '0' (OT RECOVERY) = 60 C TO 71 C TYPICAL OUTPUT SINK = 2 ma OUTPUT SOURCE= 1 ma SIGNAL RTN: S_GND OVER-TEMPERATURE SHUTDOWN: ALL OUTPUT SLOTS ARE DISABLED IF THE INTAKE AIR TEMPERATURE IS EXCEEDED. SHUTDOWN TRIP POINT: 70 C TO 81 C RECOVERY: 40 C TO 48 C ANALOG TEMPERATURE MONITOR J8-4: OUTPUT SIGNAL REPRESENTING THE INTAKE AIR TEMPERATURE OF THE POWER SUPPLY. SCALE FACTOR: 0 TO 10 VDC = 0 TO 100 C OUTPUT SOURCE IMPEDANCE: 100 OHMS SIGNAL RTN: S_GND AUXILIARY BIAS +5V/0.10A J8-16 AND J8-17: STANDBY POWER SUPPLY OUTPUT PROVIDED FOR POWER GOOD CIRCUITRY AND PULL-UP VOLTAGE FOR DISABLE INPUTS, GSD, AND INPUT GOOD OUTPUTS. OUTPUT VOLTAGE: 5.0 VDC ±5% OUTPUT CURRENT: 0.10 ADC MAXIMUM PROTECTION: SHORT CIRCUIT PROOF HOWEVER SHORTING OUTPUT WILL CAUSE POWER SUPPLY TO BE DISABLED. OUTPUT RTN: S_GND CASE PARALLEL: PR_IN J8-13, PR_OUT J8-25 AND PR_RTN J8-12 SIGNALS ARE USED FOR PARALLELING POWER SUPPLIES FOR POWER EXPANSION. THE PR_OUT (J8-25) SIGNAL OF THE DRIVER POWER SUPPLY SHOULD BE CONNECTED TO THE PR_IN (J8-13) OF THE BOOSTER POWER SUPPLY. THE TWO POWER SUPPLY'S PR_RTN (J8-12) MUST ALSO BE CONNECTED. 6. COMPLIANCE REQUIREMENTS: CONDUCTED EMISSIONS: MIL-STD-461E CE101 AND CE102 28V CURVE. SUSCEPTIBILITY: MIL-STD-461E CS101, CS114, CS115, AND CS116. ENVIRONMENTAL REQUIREMENTS: OPERATING TEMPERATURE: C: -20 TO 65 C H: -40 TO 65 C M: -55 TO 65 C STORAGE TEMPERATURE: C: -40 TO 125 C H: -55 TO 125 C M: -65 TO 125 C VIBRATION: MIL-STD TYPE 1 SINE 4-50Hz SHOCK: MIL-S-901, LIGHTWEIGHT CLASS (5FT HAMMER BLOW W/57 LB LOAD) ALTITUDE: FT. MAXIMUM OPERATING AND NON-OPERATING. BENCH HANDLING: MIL-STD-810, METHOD PROCEDURE V1. HUMIDITY: 95% NON-CONDENSING, OPERATING AND NON-OPERATING. WITH OPTIONAL CONFORMAL COATING: HUMIDITY: 100% CONDENSING, MIL-STD-810, METHOD 507, OPERATING AND NON-OPERATING SALT ATMOSPHERE: MIL-STD-810, METHOD 509, OPERATING AND NON-OPERATING FUNGUS: MIL-STD-810, METHOD 508, OPERATING AND NON-OPERATING 7. SIZE 5" X 7" X 12.5" NOMINAL 8. WEIGHT 17.5 LBS MAXIMUM 9. ASSEMBLY IDENTIFIED WITH MISSION POWER SOLUTIONS PRODUCT LABEL APPROX. WHERE SHOWN. 10. VENDER: MISSION POWER SOLUTIONS 4168 AVENIDA DE LA PLATA #105 OCEANSIDE, CA SALES@MPWRS.COM TEL: (760) FAX: (760) MPS PART NUMBER: DETERMINED BY PRODUCT STRUCTURE CUSTOMER PART NUMBER: NOT APPLICABLE Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 12

13 Specifications, (continued) Crossbow Power Supply Operator s Manual Figure 14. Enclosure Dimensions Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 13

14 Specifications, (continued) Crossbow Power Supply Operator s Manual Figure 15. Enclosure Dimensions (continued) Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 14

15 Specifications, (continued) Crossbow Power Supply Operator s Manual Figure 16. Model Number / Part Number Tabulation Figure 17. Output Bus Bar Set Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 15

16 Specifications, (continued) Crossbow Power Supply Operator s Manual Figure 18. Output Assembly Tabulation Rev. 04/21/2015 Mission Power Solutions (760) sales@mpwrs.com Pg. 16