Badger II Power Supply Operator’s Manual Badger II Power Factor Corrected AC-DC Power Supply Operator’s Manual and ―Quick Install‖ Instructions www.mpwrs.com Rev. 05/11/2012 Mission Power Solutions (760) 631-6846 sales@mpwrs.com Pg.
Badger II Power Supply Operator’s Manual Badger II Power Supply AC-DC Switcher ―Quick Install‖ Instructions Mounting the Badger II Power Supply The Badger can be mounted on either of two sides. Use #8-32 mounting screws. Maximum penetration should not exceed 0.18″ (4,5 mm). Maintain 2″ (50,8 mm) clearance at either end for airflow.
Badger II Power Supply Operator’s Manual Remote Sense Connections Sense Connections on single (Maxi Module) output cards: The Badger II is shipped with Local Sense installed. If Remote Sense is desired, remove jumpers JMP1 and JMP2, located behind the sense connector. (See Fig. 4) Connector pin J3-1 is the +Sense and J3-3 is the –Sense. (See Fig. 6) Use Molex mating receptacle P/N 50-57-9403 with P/N 16-020103 terminals. Attach terminals to 22-24 AWG stranded twisted pair wire.
Badger II Power Supply Operator’s Manual Input/Customer Interface Connections Input Power Connector (J1) - See Fig. 8 Input AC power is applied to connector J1 using 3W3 Power Connector 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 a maximum 15 A rating should be used at the power supply input J1 Pin Out A1 Line A2 Line 2/Neutral A3 Ground Figure 8.
Badger II Power Supply Operator’s Manual Badger II Power Supply Power Factor Corrected AC-DC Switcher Overview The Badger II is a ruggedized, extremely low-profile AC-DC power supply that combines the advantages of power factor correction, high power density, and user-selected isolated outputs. Accepting input voltages of 85 to 254 VAC, and 85 to 380 VDC, the Badger II can provide up to 1,800 watts in a package size of 2.55″H x 7.0″W x 13.75″L.
Badger II Power Supply Operator’s Manual 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. The boost converter delivers a regulated input to the hold-up capacitors and a high voltage backplane.
Badger II Power Supply Operator’s Manual Interface Connections Input Terminal (J1) Input AC 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 (GND) for safety. See Figure 8 (Pg 4). A fault clearing device, such as a fuse or circuit breaker, with a maximum 15 A rating at the power supply input is recommended. It should be sized to handle the start-up inrush of 30 A at 115 VAC and 60 A at 230 VAC.
Badger II Power Supply Operator’s Manual General Shutdown (J2-7) The General Shutdown (GSD) control pin on J2-7 allows simultaneous shutdown of all outputs. This pin must be pulled down to less than 0.7 V and will source 4 mA maximum to shut down all outputs. The GSD pin should be open-circuited or allowed to exceed 4.5 V when not in use, or when the outputs are to be enabled. Do not apply more than 5V to this input at any time. Normal open-circuit voltage is 1.5-3 V with respect to Signal Ground.
Badger II Power Supply Operator’s Manual Output/Customer Interface Connections Output Connections There are three types of output power terminals available in the Badger II. Outputs from Maxi converters (single output cards) are terminated in two 10-32 stainless steel studs (see Fig. 14). The positive polarity of the output is the right stud when viewed from the output end. Outputs from Mini converters (dual output cards) terminate in a 7W2 connector (see Fig.15).
Badger II Power Supply Operator’s Manual Installing Remote Sense requires the Local Sense jumpers to be removed (see Figures 4 and 5, Pg 3). On single output cards, the Local Sense jumpers are located behind the sense connector on JMP1 and JMP2. To remove the jumpers, make certain the power to the supply is off, and pull them off connectors JMP1 and JMP2. On dual output cards, the Local Sense jumpers are on either side of the card at JMP1and JMP2 for Output 1, and at JMP3 and JMP4 for Output 2.
Badger II Power Supply Operator’s Manual Output Module VREF RTH Standard Vicor Maxi, Mini, Micro Special Module 1.23 V 1.23 V 1 kΩ Consult MPwrS Example: 10% trim adjust on a 12 V nominal output. Figure 18 shows a typical variable trim circuit. Using a 1k trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: V1 =Vref + 10% = 1.353V Given: Vref = 1.23V IR5 = (1.353V - Vref)/RTH = (1.353V – 1.23V)/1k = 122A Given: RTH = 1k Setting the bottom limit: VR6 = 1.23V – 10% = 1.
Badger II Power Supply Operator’s Manual Mechanical Considerations The Badger II can be mounted on either of two surfaces using standard 8-32 size screws. Maximum allowable torque is 20 in/lbs., and the maximum penetration is 0.18 in. (4.5 mm). When selecting a mounting location and orientation, the unit should be positioned so airflow is not restricted. Maintain a 2″ (50,8 mm) minimum clearance at both ends of the Badger II, and route all cables so airflow is not obstructed.
Badger II Power Supply Operator’s Manual Mechanical Drawing .19 13.75 AC INPUT CONNECTOR J1 STATUS/CONTROL CONNECTOR J2 OUTPUT SLOT 1 OUTPUT SLOT 2 -OUTPUT PIN OUTPUT SLOT 3 +OUTPUT PIN J1 J2 L1 L2/N WARNING SEE P RODUCT LABEL 7.00 -OUTPUT STUD 2.55 4-40 JACKSCREW J3 PIN A1 2X .50 4-40 JACKSCREW MOUNTING LOCATIONS 8-32 UNC-2B .180 MAX. DEPTH QTY = 2 9.000 2.38 .
Badger II Power Supply Operator’s Manual Specifications (Typical at 25C, nominal line and 75% load, unless otherwise specified) General Number of Outputs Efficiency Safety Approvals Maximum Output Power @ 35°C 1-12 80%, typical (depends on output V & I) None 800 W @ 110 VAC/VDC 1,800 W @ 220 VAC/VDC 10.0 lbs. 2.55"H (64,8mm) x 7.0"W (177,8mm) x 13.75"L (349,3mm) 1 Year Limited Product Weight Dimensions Warranty Input Input 85-254 VAC, 47-500 Hz 85-380 VDC 0.
Badger II Power Supply Operator’s Manual Environmental Storage MIL-STDTemperature C-Grade Storage Temperature T-Grade Industrial H-Grade Grade Military Grade M-Grade Max Operating Temperature Range Commercial Grade C-Grade Operating Temperature T-Grade Industrial H-Grade Grade, Full Power M-GradeGrade, Half Power Industrial Humidity Military Grade, Full Power Altitude Military Grade, Half Power Operational Non-operational Commercial Grade, Full Power Shock Commercial Functional Grade, Half Power CrashWeigh
Badger II Power Supply Operator’s Manual Maximum Output Power vs. Temperature @ 35°C @ 45°C @ 65°C Total Badger Power* 1,800 W 1,500 W 750 W Total Power per Slot 600 W 500 W 250 W ≤5 V 80A 80 A 40 A ≥12 V 600 W 500 W 250 W ≤5 V 40 A 40 A 20 A ≥12 V 250 W 200 W 100 W ≤5 V 20 A 20 A 10 A ≥12 V 150 W 150 W 75 W Total Power per Module Single Output Card (Maxi) Dual Output Card (Mini) Quad Output Card (Micro) *Do not exceed maximum power rating vs. input voltage.
Badger II Power Supply Operator’s Manual Notes Rev. 05/11/2012 Mission Power Solutions (760) 631-6846 sales@mpwrs.com Pg.
