VICOR 4kW MegaPAC-EL Specifications
Contents
1. ModuPAC REMOTE SENSE JuniorPAC VOUT J2 MATING HDWR RAMPAC 1 TRIM PIN ACCESS HOUSING MOLEX P N 50 57 9403 L 2 1 2 SENSE TERMINALS MOLEX PIN 16 02 0103 L OUTPUTADJUST 3 sense CRIMP TOOL MOLEX P N 11 01 0208 VOUT J3 DC OK POWER GOOD MATING HDWR Geis HOUSING MOLEX PIN 39 01 0043 J3 PIN1 2 TERMINALS MOLEX P N 30 00 0031 2 POWER GBON CRIMP TOOL MOLEX P N 57005 5000 2 POWER GOOD INVERTED 1 SIGNAL GROUND DualPAC BPN J1 OUTPUT CONNECTORS MATING HDWR 27111 4AND4 V QUT HOUSING MOLEX P N 39 01 2060 212 AANDE OU TERMINALS MOLEX P N 39 00 0039 amp E CRIMP TOOL MOLEX P N 11 01 0197 p OUTPUT ADJ 1 3 R SENSE 6 RISENSE 92 JCAPINI gog A J2 REMOTE SENSE MATINE HDWR 215 J2 A c 1 TRIMPIN ACCESS HOUSING MOLEX P N 50 57 9403 2 SENSE TERMINALS MOLEX P N 16 02 0103 i 3 41 01 nc ed te SENSE CRIMP TOOL MOLEX P N 11 01 0208 DUALPAC COMPONENT SIDE VIEW 2 1 J1 B M1 o M 1 Ja s B 50 QutputA OutputB 48V 21A 12V 83A i ol lo M22. 10 V 132V 5V 82V Given 12V R8 8 2V 5254A 15 62 Using the above resistor combination 12V output can be trimmed externally up to 13 2V and down to 10 8V For further information on external trimming refer to Chapter 5 of the Applications Design Guide or consult the factory for assistance CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS BELOW 5V Pg 20 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 Specifications PFC MegaPAC Design Guide Input Characteristics Input Voltage Power Factor Inrush Current Ride Through Time Power Fail Conducted EMI Surge Immunity Dielectric Withstand Overvoltage and Transients Output Characteristics Line Load Regulation Line Regulation Load Regulation VI 200 V1 J00 Setpoint Accuracy Maxi Setpoint Accuracy Ripple and Noise External Output Trim Range Using Trim Sc pin Overcurrent Trip Point Overvoltage Protection Efficiency Output Power 85 264 Vac 47 500 Hz 100 380 Vdc 0 99 115 Vac 0 95 230 Vac 25A pk 115 Vrms and 230 Vrms gt 20 ms at nominal line full load gt 3 ms warning FCC Class A EN55022 Class A Certain configurations meet B Contact Factory Mil STD 461 CE 101 and 102 require external filtering EN 61000 4 5 Installation Class 3 Performance Criteria B Temporary loss of output power may occur which is self recoverable Primary to Ch
3. 6 89452 I lovselzee 19 31 G3NDIS3Q 3 NMOGLNHS N35 Lg eieloezt 90 HMOd OV TYNDIS VEO AG 601 8 01r cour 90 871159 zo 2210 10 11 N d XTIOW 1001 4 28 4 i OL i H 6 00 00 6 N d X3T1OW S TVNIWH3L Ee ou OZLC L0 6 N d 5 i WMH ONLLWW SD VAUSLNI OLE 267 MM U f I fees ic 10670616611 15 Applications Engineering 800 927 9474 o c N 2 Westcor Division 408 Vicor 800 735 6200 Rev 4 2010 PFC MegaPAC Design Guide Interface Connections Chassis Input Power Terminals J9 Input AC power is applied to terminal block J9 using a pressure screw terminal that accepts a maximum wire size of 14 AWG The insulation should be stripped 35 inches and the maximum torque applied to the screws should not exceed 4 4 Ib in The connector manufacturer recommends the wires not be tinned A ferrule Phoenix P N 32 00 58 0 purchased from other sources can be used to prevent fraying J9 1 GND is Earth Ground for safety J9 2 L2 and J9 3 L1 the other Hot connections For Input DC power L2 is and L1 is gt A fault clearing device such as a fuse or circuit breaker with a maximum 15 rating at the power supply
4. Use Molex mating receptacle 39 01 0073 with 39 00 0031 terminals provided SENGE Attach terminals to 22 28 AWG stranded wire using Molex tool 57005 5000 A W 3 POWERGOOD 2 POWER GOOD INVERTED 1 SIGNAL GROUND Sense Connections on DualPACs Sense connections do not have to be made either if the Local Sense option has been ordered or Autosense is present refer to note on Autosense Sense connections are available on the J2 connector P2 for the FinPAC or the and connectors If using J2 or P2 connector see instructions on page 10 DualPAC Output Connector T On and J1B Pin 3 is the Sense and Pin 6 is the Sense Use Molex mating receptacle 39 01 2060 with 39 00 0039 terminals 6 5 4 6 5 4 provided RI R Attach terminals to 18 24 AWG twisted pair wire using Molex S R47 tool 11 01 0197 3 2 1 3 21 T Verify that Sense lines are not cross connected before applying PIN input power 1 and 4 V OUT 2 and 5 V OUT 3 REMOTE SENSE 6 REMOTE SENSE Trim Pin Connection J2 and P2 for FinPAC The Trim J2 connection should only be made if the Trim option has not been J2 Trim Pin Connector installed A or an in the ConverterPAC part number means the Trim J2 option is installed e g M5V 40AT s Use Molex mating receptacle 50 57 9403 with 16 02 0103 terminals 13 3 Sene provided Attach terminals to 22 24 AWG stranded wire using Molex tool 11
5. PFC Mini and PFC MegaPAC Information furnished by Vicor is believed to be accurate and reliable However no responsibility is assumed by Vicor for its use No license is grant ed by implication or otherwise under any patent or patent rights of Vicor Vicor components are not designed to be used in applications such as life sup port systems wherein a failure malfunction could result in injury or death sales are subject to Vicor s Terms and Conditions of Sale which available upon request Specifications are subject to change without notice The latest data is available on the Vicor website at vicorpower com VICOR VVestcor Division www vicorpower com Pg 30 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010
6. Vcc IN POWER GOOD POWER GOOD INVERTED SIGNAL GROUND 1 All ConverterPACs except the FinPAC occupy one slot The FinPAC occupies two slots 2 New output studs were installed on the ConverterPACs and are 1 8th inch longer Refer to pages 12 and 19 for more information Rev 4 2010 Vicor 800 735 6200 4 Westcor Division 408 522 5280 MATING HDWR HOUSING MOLEX P N 39 01 0073 TERMINALS MOLEX P N 39 00 0031 CRIMP TOOL MOLEX P N 57005 5000 MATING HDWR HOUSING MOLEX P N 39 01 2120 TERMINALS MOLEX P N 39 00 0039 CRIMP TOOL MOLEX P N 11 01 0197 Applications Engineering 800 927 9474 Pg 11 PFC MegaPAC Design Guide Pg 12 PFC MegaPAC Quick Install Instructions For Mechanical Drawing see page 15 Mounting the PFC MegaPAC and PFC MegaPAC High Power Mount the power supply on any of its four sides Use 8 32 or 4mm mounting screws Do not exceed a maximum penetration of 0 15 3 8mm The maximum allowable torque is 5 5 Ib in Maintain 2 5 1cm clearance at either end for airflow Input Connections Input Power J9 Input Panel Connectors Apply input AC power to terminal block J9 using a pressure screw terminal Moo Strip length of AC power conductors to be 0 35 inches Maximum torque is 4 4 Ib in 4 gt INPUTS DO NOT Place a fuse or circuit breaker in the input line for safety reasons fS C OPERATE Use a maximum wire size
7. 01 0118 ITEMS FOR REF ONLY NOT INCLUDED IN KIT Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 23 Pg 24 PFC MegaPAC Design Guide Current Share Boards Optional Feature Current sharing also known as Load Sharing is the ability to divide the output current evenly across all active power supplies This greatly reduces stresses on each power supply and allows them to run cooler resulting in higher reliability Standard current sharing tech niques typically utilize shunt resistors or Hall Power Supply 1 24V 1kW TRIM 5 OUT Effect devices to measure the current from each power supply Power shunt resistors continually dissipate power and require cooling especially when dealing with high output currents of gt 100Amps Hall Effect devices measure mag netic fields generated by current flowing through a conductor and although they dissipate no power they tend to be large and expensive Power Supply 2 24V 1kW 5 TRIM 5 OUT First developed by Westcor Engineering for par alleling MegaPAC supplies the Box to Box Current Share Board or CSB allows two or more Vicor power supplies to current share by utiliz ing the inherent voltage drop produced in the negative output return cable This eliminates the need for addi tional shunt resistors or expensive Ha
8. 0800 419 419 Fax 33 1 3452 2830 Email vicorfr vicr com Vicor Italy Tel 39 02 2247 2326 Free Phone taly Only 800 899 677 Fax 39 02 2247 3166 Email vicorit vicr com Vicor Germany Tel 49 89 962439 0 Free Phone Germany Only 0800 018 29 18 Fax 49 89 962439 39 Email vicorde vicr com Vicor U K Tel 44 1276 678 222 Free Phone UK Only 0800 980 8427 Fax 44 1276 68 1 269 Email vicoruk vicr com ASIA PACIFIC Vicor Hong Kong Tel 852 2956 1782 Fax 852 2956 0782 Vicor Japan Co Ltd Tel 81 3 5487 3880 Fax 81 3 5487 3885 For more information about this or other Vicor products or for assistance with component based power system design contact the Vicor office nearest you Vicor s comprehensive line of power solutions includes modular high density DC DC converters and accessory components configurable power supplies and custom power systems Westcor a division of Vicor designs and builds configurable power supplies incorporating Vicor s high density DC DC converters and accessory components Westcor s product line includes LOPAC FAMILY PFC MicroS PFC Micro PFC Mini MEGAPAC FAMILY PFC MegaPAC PFC MegaPAC EL Low Noise PFC MegaPAC High Power PFC MegaPAC Low Noise High Power Mini MegaPAC Autoranging MegaPAC 4kW MegaPAC 4kW MegaPAC EL Low Noise ConverterPACs OTHERS FlatPAC EN Rugged COTS versions MI are available for the PFC Micro PFC MicroS
9. 85 Altitude Derate 2 6 total output power for each 1 000 ft to a maximum operating altitude of 15 000 ft Non operating storage maximum altitude is 40K Operating Temperature 209 to 40 C full power 20 C to 60 C half power 40 C optional with rugged chassis MI or MC suffix Shock and Vibration Mil STD 810 MI rugged chassis ONLY Humidity 0 to 95 non condensing Safety Agency Approvals cURus UL 60950 1 CSA 60950 1 cTUVus EN 60950 1 UL 60950 1 CSA 60950 1 CE Mark Low Voltage Directive 73 23 EEC amended by 93 68 EEC Note some MI chassis will not carry all safety approvals Product Weights fully configured MP Chassis MX Chassis 9 75 lbs 4 42 kgs 10 Ibs 4 54 kgs Warranty 2 years limited warranty See vicorpower com for complete warranty statement See Vicor module specifications A preload may be necessary for modules trimmed down below 90 of normal output voltage The maximum operating temperature is 40 C If using a VI 200 with output voltage less than 12V and more than 150 Watts the operating temperature decreases to 35 C This also applies when using a FinPAC with output voltage less than 24 V and more than 500 Watts Output Studs New more robust output studs with a 3 to 1 safety margin 45 in lbs were installed in ConverterPACs the slide in assemblies used in the MegaPAC Family These new outputs studs 1 8 longer to allow for multiple lugs They are fully compatible w
10. a PC Tron DC rated fast acting fuse The BatPAC is a 200 Watts programmable current source that can be con figured as a battery charger Maximum current and voltage settings are controlled using poten tiometers that come as a standard feature or through Trim pin access as an option BatPACs are available for 12V 24V and 48V battery systems FINPAC The FinPAC output assembly consists of a Maxi DC to DC converter that converts the unregulat ed high voltage bus to the desired regulated output voltage Each Maxi module can provide up to 600 Watts of output power Each FinPAC occupies 2 slots because it has an extra large heatsink attached to dissipate the heat generated by this more powerful Maxi converter Currently the FinPAC is ONLY used in the high power MX chassis It cannot be used in any other member of the MegaPAC Family Contact Westcor for future updates Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 7 PFC MegaPAC Design Guide ConverterPAC Functional Description See ConverterPAC Datasheet and or Design Guide for complete information on all ConverterPACs Continued FlexPAC The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the high voltage bus to the desired output voltage Each FlexPAC output can be manually trimmed from 2V to 25V and supports up to 5 amps with a maximum output power of 50W per output All outputs maintain less than 5
11. a driver and booster s should never be disconnected For help in identifying boosters and drivers refer to the Part Numbering section on page 8 Please note that total output voltage should not exceed the converter baseplate output isolation rating of 400V For detailed guideline on how outputs should be placed in series please refer to the Applications note Creating high voltage outputs available on the website at www vicorpower com O L210 O ZO Bus Bars for Paralleling o o o o OL lt lt Loosen screw to e remove ConverterPAC i a H D H D Z NM Boosters Driver Figure 2 Paralleling ConverterPACs Pg 6 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide ConverterPAC Functional Description See ConverterPAC Datasheet and or Design Guide for complete information on all ConverterPACs ConverterPACs are the family of slide in output assemblies used in MegaPAC power supplies Most ConverterPACs of the same length are interchangeable within a MegaPAC and between different AC input MegaPAC chassis Ex
12. department for assistance The DC OK option monitors the output voltage of a given ConverterPAC and provides a TTL logic signal depending on its output voltage Figure 2 J3 DC OK Connector Figure 1 ModuPAC Pinout ee 3 3V Output 5V with D option DC OK Figure 3 Output Sequencing Wire Interconnect Figure 3 shows the correct wiring connections between the Power Good Connector J3 of a 5 ModuPAC and the Input Interface Connector J10 of a typical PFC MegaPAC configuration In this example the 3 3V ModuPAC is located in the slot 7 and the 5V ModuPAC with the DC OK option is located in slot 8 In order for the Power Good option to properly function it requires a 5V source to provide the necessary Vcc pull up This 5V source is conveniently available using the 5V aux source from the Input Interface Connector J10 9 and J10 10 With a voltage properly applied to the 5V ModuPAC s Power Good Connector J3 1 and J3 4 the Power Good signal J3 3 can now be connected to the Enable Disable control pin for slot 7 J10 7 The 5 ModuPAC s Power Good sig nal will remain low until its output has reached approximately 95 of its nominal output voltage This will keep the 3 3V output in disabled mode allowing the 5V output to reach regulation first In addition should the 5V output drop below 85 the Power Good signal will drop low and disable the 3 3V output Figure 4 and
13. input 18 required for safety agency compliance It should be sized to handle the start up inrush current of 25A pk at 115 Vrms and 230 Vrms ul 12 INPUTS DONOT INPUT CONNECTIONS OPERATE oe lt OT 39 2 L NEUTRAL 3931 GROUND NOTE SET SCREW MAXIMUM TORQUE 44 INCH POUNDS LABEL NO 94 0046 REV Figure 3 Input Panel Connectors Output Power Connections P P for Single Output or J1A J1B for Dual Outputs For single output ConverterPACs these terminals are two 1 4 20 plated steel studs The upper stud is positive with respect to the lower stud For dual output ConverterPACs there is a 6 pin Molex connector for each output pins and 4 are the Output and pins 2 and 5 are the Output Pins 3 and 6 are duplicates of the Remote Sense terminals present on J2A and J2B Use appropriate wire size rated to handle the full output current including short circuit levels Avoid large current loops in output cables run power and return cables next to one another to minimize inductive effects All outputs are isolated and can provide positive or negative outputs Output Sense Connections J2 for Single Output or for Dual Outputs Newer power supplies may have some outputs configured with the Autosense feature that automatically locally senses the output if remote sense is not used To check if an output has the Autosense feature measure the i
14. js o O o i i Example D12V 8 3A 48V 2 1A Note 1 All ConverterPACs except the FinPAC occupy one slot The FinPAC occupies two slots 2 New output studs were installed on the ConverterPACs and are 1 8th inch longer Refer to pages 12 and 19 for more information Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC BatPAC CURRENT LIMIT ADJUST L VOLTAGE LIMIT ADJUST ai VOUT a J3 PIN1 FinPAC QUT OUTPUT ADJUST OUT P2 PIN1 FlexPAC __M 1 STATUS I M 2 STATUS M 1 VOLTAGE ADJUSTMENT M 2 VOLTAGE ADJUSTMENT Dj mW 6 6 CONNECTOR nooo VOLTAGE ADJUSTMENT M 4 VOLTAGE ADJUSTMENT I 3 STATUS M STATUS Note J2 BATPAC REMOTE INTERFACE CURRENT LIMIT ADJUST CURRENT MONITOR 4 3 VOLTAGE LIMIT ADJUST 2 1 VOUT MATING HDWR HOUSING MOLEX P N 39 01 0043 TERMINALS MOLEX P N 30 00 0031 CRIMP TOOL MOLEX P N 57005 5000 P2 REMOTE SENSE TRIM SC amp POWER GOOD SENSE SENSE TRIM
15. 01 0208 J2 1 provides Trim access For the FinPAC refer to P2 Connector P2 5 provides Trim Access Use Molex mating receptacle 39 01 0073 with 39 00 0031 terminals provided Attach terminals to 22 28 AWG stranded wire using Molex tool 57005 5000 P2 Trim Pin Connector SENSE SENSE TRIM VccIN POWER GOOD POWER GOOD INVERTED SIGNAL GROUND Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 13 PFC MegaPAC Design Guide PS OK Power Good Connection J3 and P2 for FinPAC DC OK is only available as an option and is not always present J3 4 is Vcc In J3 3 is Power Good J3 2 is Power Good inverted and J3 1 is Signal Ground Use Molex mating receptacle 39 01 0043 with 39 00 0031 terminals provided Attach terminals to 22 28 AWG stranded wire using Molex tool 57005 5000 For the FinPAC refer to the P2 Connector P2 3 is Power Good Use Molex mating receptacle 39 01 0073 with 39 00 0031 terminals provided Attach terminals to 22 28 AWG stranded wire using Molex tool 57005 5000 Interface Connections J10 Use Molex mating receptacle 39 01 2120 with 39 00 0039 terminals DC OK Power Good 73 4 Vee 13 3 Power Good 13 2 Power Good Inverted J3 1 Signal Ground Ble A P2 DC OK Connector SENSE SENSE TRIM VccIN POWER GOOD POWER GOOD INVERTED
16. 0mV noise over the entire output range outputs support local sense only For electrical trim options and specific output sequencing contact the factory LIST OF CONVERTERPACS USED IN THE PFC MEGAPAC AND PFC MEGAPAC HIGH POWER AND THEIR FEATURES ConverterPAC OVP OCP OTL RS AS LS AS PG TrimPot ModuPAC Std Std Std AS AS Opt Opt JuniorPAC N A Std N A AS AS Opt Opt DualPAC N A Std N A AS AS N A Opt RAMPAC N A Std N A AS AS Opt Opt BatPAC N A Std N A N A N A N A Std FinPAC Std Std AS 8 Opt FlexPAC Std Std Std LS LS N A Std OVP Overvoltage Protection latching RS Remote Sense OCP Overcurrent Protection auto recovery LS Local Sense OTL Overtemperature Limiting latching AS Autosense PG Power Good DC OK TTL Signal See page 12 and 14 for more information on Autosense All the above mentioned ConverterPACs can be used in both the MegaPAC and MegaPAC High Power except the FinPAC which currently can only be used in the PFC MegaPAC High Power The UniPAC not listed above cannot be used either in the PFC MegaPAC or the PFC MegaPAC High Power Currently the UniPAC is only used in the 4KW MegaPAC Note All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC JuniorPAC and RamPAC Pg 8 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide Part Numbering MegaPAC Mp
17. 5 show the startup and shutdown waveforms for the circuit shown in Figure 3 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 27 PFC MegaPAC Design Guide Output Sequencing contd Channel 1 5V Output Channel 22 3 3V Output Channel 3 5V DC OK signal Tek Single Seq 2 50kS s E Figure 4 Startup Waveforms Tek Single Seq 50 0kS s 222 Source Coupling Slope Level Edge Chi DC 2 56 V Figure 5 Shutdown Waveforms Pg 28 Vicor 800 735 6200 Westcor Division 408 522 5280 Edge Source Applications Engineering 800 927 9474 a 2 00 V amp M20 0ms Chi 760mVj more E T I 1of2 Coupling Slop Level v 806 DC 760mV chi Ch2 Ch3 Ch4 Rev 4 2010 PFC MegaPAC Design Guide Notes Rev 4 2010 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 29 PFC MegaPAC Design Guide VICOR GLOBAL OFFICES USA Vicor Corporation Corporate Headquarters 25 Frontage Road Andover MA 01810 Tel 800 735 6200 Tel 978 470 2900 Fax 978 475 6715 Vicor Corporation 377 E Butterfield Road Suite 201 Lombard IL 60148 Tel 630 769 8780 Fax 630 769 8782 Vicor Westcor Division 560 Oakmead Parkway Sunnyvale CA 94085 Tel 408 522 5280 Fax 408 774 5555 EUROPE Vicor France Tel 33 1 3452 1830 Free Phone France Only
18. 55022 class At start up inrush current is limited by PTC thermistor PTC is shunted out shortly after initial power up by a DC bus voltage Sense circuit driving a relay After rectification the input voltage 1s put through a boost converter that keeps the AC input current sinu soidal and synchronized with the AC input voltage in compliance with EN61000 The boost converter delivers regulated high voltage DC to the hold up capacitors and backplane The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired regulated outputs Voltage conversion in the output assemblies is achieved by Vicor s family of Zero Current Switching ZCS DC to 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 adjustment range for output low EMI RFI emissions and high efficiencies At initial power up the PFC MegaPAC outputs are 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 cir cuits and DC cooling fan The internal housekeeping Vcc comes up wi
19. 6 0 6 J10 12 GEN SHUTDOWN Figure 4 Interface Connector Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide Enable Disable J10 1 to J10 8 The Enable Disable control pins allow ConverterPAC outputs to be sequenced either on or off J10 1 through J10 8 are the control pins for output positions 1 through 8 respectively see Figure 5 and Connector Pin Identification on page 9 For DualPACs and FlexPACs both outputs are sequenced In parallel array using VI VE modules only the driver ConverterPAC need be controlled The Enable Disable pins should be pulled low to less than 0 7V with respect to Signal Ground to disable the outputs They will sink 10 mA maximum These pins should be open cir cuited or allowed to exceed 4 5V when enabled Do not apply more than 6V to these inputs at any time If driven from an electromechanical switch or relay a capacitor should be connected to eliminate the effects of switch bounce A TTL 1 applied to the base of the transistor turns output OFF Pin 1 or Pin 12 for GSD is pulled Low with respect to Signal Ground Enable Disable Output 1 General Shutdown TTL 1 OFF 1 TTL 0 ON IL 0 Signal Ground Figure 5 Enable Disable and General Shutdown Enable Disable control of Maxi Mini Micro Module Arrays When using the Enable Disable function on an output that consists of two or more Maxi modules it
20. 6 70 110 output adjustment T5 98 105 output adjustment F7 80 110 output adjustment T6 100 110 output adjustment F8 90 110 output adjustment VI VXI low noise 150 mV or less 15V Vout 24V 5 F9 100 110 output adjustment V2 VXI low noise 50 mV or less Vout 15 Vdc I Industrial Grade module V3 VXI low noise 1 ripple or less Vout gt 24V K Custom SRF module used P Preload lp option Optional for all ConverterPACs EXCEPT the DualPAC BatPAC and RamPAC lg options Optional for all ConverterPACs EXCEPT the BatPAC DualQPAC and FlexPAC Trim range dependent on module type and voltage 3 Ram When using an external RAM components such as autosense resistors and local sense jumpers must be removed before turning on the supply In addition in order to insure proper operation sense pins must be connected either locally or remotely after the RAM s output For further information contact Applications Engineering 47 options Optional for all ConverterPACs EXCEPT the BatPAC DualQPAC and FlexPAC Trim Range dependent on mod ule type and voltage Sv options Optional ONLY on the ModuPAC DualPAC and JuniorPAC N A on all other ConverterPACs Requires 15 minimum load Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 9 PFC MegaPAC Design Guide ConverterPAC Output and Connector Pin Identification for the MegaPAC
21. AC J UniPAC XU DualPAC D QPAC XQ RamPAC R FinQPAC PZL BatPAC B L DualQPAC LD Junior QPAC LJ Please note that the MegaPACs including Low Leakage versions are not UL 2601 compliant Pg 26 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 PFC MegaPAC Design Guide Output Sequencin Using the MegaPAC s standard Input Interface Connector J10 along with the ConverterPAC s optional DC OK Option it is possible to implement unique output voltage power up and power down sequences Below is an exam ple showing how this may be done DC OK Option is not available for VI 200 VI J00 dual output DualPACs Requirement 5V must start before the 3 3V output If the 5V output is lost the 3 3V output must turn off The first step in meeting this require ment is to configure the 5V ModuPAC Vout with the DC OK Option which is indi om cated by a D designator in the P DC OK Power Good ModuPAC s part number located on the Vtrim Pot Adjust Option J3 Pi top surface of each ModuPAC above the 2 4 134 Vee Vout Any ModuPAC that has the DC Vout o 3 J3 3 Power Good i o J3 2 Power Good Inverted OK option will also have the 4 pin J3 Cy DC OK connector installed To order ModuPAC with the DC OK option J3 pin 1 DC OK Option please contact Westcor s customer serv ice
22. HO LAN G39NV13 SGNLS ANY TANVd LAdLNO 0102 Suva 5518 IVNOLL4O HLIM BALS LON os selov t Q35NV 14 Q31VU3S 02 v L 61147 25811 ez Ww S81 WW sezi ors eozelov t ereglgce 6 ES TANWd GALS CHNDIS3Q 3H 32v4ufs 3015100 WIN 00v 061 NOLLVH L3N3d MHDS WNWIXVW QV38H L 8 HO HNVd ANY 0015 TVNIDIHO seoul t X91 S310H YIWOLSNI zx lee s ir 1 mi 4 7 NI e 267 NU 6 H r 8 9r000 t6 ON 138V1 187121549 H NI t y 3NDYOL WAWIXYW MYDS 135 3LON ONNO HINV3 ET 6 AROHIIM pen WULNAN 217 6F NISL 1 6 1000 SUMI SNOLLD3NNOO HIDN31 01 9 zt 6305 401 ETE 6140549 58 691522 SMIYDS NINYO p Ire lu zv FEL c d H EL it E 3 8 2 i i 621015 zres 09 81 vNOLLdO L uly dO NOILO3HIQ gt AN ILL D L i T
23. MegaPAC High Power PFC MegaPAC EL Low Noise Mini MegaPAC Autoranging MegaPAC 4kW MegaPAC 4kW MegaPAC EL Low Noise The advantage of the Low Leakage MegaPAC power supply is in multiple power supply systems that have one AC input This option will lower the input leakage current for these products to 1001LA or less An additional external EMI filter is typically required How Low Leakage is obtained Low Leakage for the MegaPAC Family of power supplies is obtained with the removal of the Y capacitors from within the EMI filter of the MegaPAC as well as the Y capacitors on the input of the ConverterPACs This reduces the leakage current from the AC input to AC ground chassis to below 100uA leakage value may differ with use of Maxi modules Consult Factory for more information At the same time since the Y capacitors are a vital com ponent of the EMI filter without them the EMI will go up When this happens the unit will no longer meet Westcor s published specifications for conducted EMI In order to reduce the EMI to within an acceptable limit an additional external EMI filter is required All safety agency certifications for the MegaPAC Power Supplies remain intact Contact Applications Engineering for more information Westcor currently has the following ConverterPACs See ConverterPAC information sheet and or Design Guide for more infor mation VI 200 V1 J00 Maxi Mini Micro ModuPAC M FinPAC PZ JuniorP
24. PFC MegaPAC Design Guide MegaPAC Power Factor Corrected AC DC Switchers Design Guide and Quick Install Instructions Nia VICOR www vicorpower com Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 PFC MegaPAC Design Guide TABLE OF CONTENT Overview of Product ine upah deti eer eei cep nae ee 3 Mechanical Considet atiotis occae tete testet CE depen e eR eco 4 MepaPAC Do s aiid noe te ege ete du ahs ute Lopes abe 4 Technical prono diets 5 Configuring Reconfiguring MegaPACS sss entente ennemi eren ene 6 ConverterPAC Eo EVER 7 Part Num berit ssc 9 ConverterPAC Output and Connector Pin Identification esee 10 Quick Install Instruct Ons uu hr eet e es t De Ed cir v e ar ee Dor end 12 Mechanical Dra wimg EE 15 Interface Connecti OM si 26 cases sts uu tie eee ae 16 sc E 21 Power Deta tim ge RENE M 23 Connector Kit MEDI 23 Current Share Boards ec
25. Power Circuit Output Waveform Sample gt Power y ConverterPAC 2 Output Sample PFC Control IL ConverterPAC 3 Power Output Customer Interface Enable Disable Control E D Control Housekeeping ConverterPAC 8 _ Power Fan L Current Power Output Monitor L Figure 1 PFC MegaPAC and PFC MegaPAC High Power Architecture Rev 4 2010 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 5 PFC MegaPAC Design Guide Configuring and Reconfiguring MegaPACs Most ConverterPACs of the same length can be inserted into any available slot of MegaPAC chassis They also be easily added replaced or moved by sliding the assemblies in or out of a MegaPAC chassis Currently two exceptions are the FinPACs which can only be used in the high power chassis and the UniPACs which can only be used in the 4KW MegaPAC For outputs greater than 200 Watts a driver ModuPAC and one or more booster ConverterPACs will be used For outputs greater than 600 Watts a driver FinPAC and one or more booster ConverterPACs will be used Arrays of drivers and boosters should be configured so all boosters are placed in the slots to the immediate right of the driver when looking at the output end of the MegaPAC Prior to removing or installing ConverterPACs you must remove power fro
26. SIGNAL GROUND provided J10 1 to 8 are Enable Disable for slots 1 8 J10 9 is J10 10 is Signal Ground J10 11 is AC Power OK and 10 101 12 is General Shutdown Attach terminals to 18 24 AWG stranded wire using Molex tool 11 01 0197 104 110 5 110 6 FlexPAC Connections J1 Use Molex mating receptacle 39 01 2120 with 39 00 0039 terminals provided Attach terminals to 18 24 AWG stranded wire using Molex tool 11 01 0197 pins 11 5 12 and 6 are for special trim options Contact factory for use Local Sense only 1 t z 0 VOUTMA 4 VOUTM4 E D 1 7 0 ED7 E D 2 108 E D8 E D 3 J10 9 Vcc 5V 0 3A 0 4 10 0 SIGNAL GROUND E D 5 10 1 AC POWER OK E D 6 J10 12 GEN SHUTDOWN VOUTMI 1 VOUTMI VOUTM2 2 VOUTM2 VOUTM3 3 VOUTM3 DONOTUSE 3 DONOTUSE DONOTUSE 6 DONOT USE Pg 14 Vicor 800 735 6200 Westcor Division Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide n amp E S a e Q gt 2 gt s Q Q c 1 0 TVNOISN3WIO 133HS 335 HONI 8 1 SI GALS 3HL ONY 183SNI 55 88 V SVH T3NVd 114110 MAN 3HL LN3S3Hd 38 AVW NOILVNISWOD TANVd ONY GALS 114110 Q3N9IS3Q 3H YO TVNIDIHO JHL YJH1 ALON 99153 39 TIVNISI
27. aa 7bcccc v xx p P for standard chassis p Xforhigh power chassis number of outputs b number of DC DC modules and FlexPACs customer specific configuration code v optional revision code and may be blank note v G for RoHS compatible product xx additional option codes note xx MI for rugged chassis MC for rugged chassis with conformal coating ConverterPAC Xxp V xgAxp X type For RoHS add G to current prefix eg MISV I0A M ModuPAC RoHS GM R RAMPAC RoHS GR M15V 10ADFI D DualPAC RoHS GD B BatPAC RoHS GB D15V 6 7A 12V 8 3AT J JuniorPAC RoHS GJ PZ FinPAC RoHS GPZ Xp Voltage out XE Current out rounded to 1 decimal point XF Options See below Can be multiple options FlexPAC Fxxaaa bbb ccc ddd F FlexPAC xx pack chassis variations eg FSS100 050 100 050 voltage se or output 1 with implicit factor of 10 103 10 bbb output 2 ccc output 3 ddd output 4 ConverterPAC Options B Booster module M Military Grade nodule D DC OK or Power Good R RAM external F Full 50 110 output adjustment S Trimpot removed for externgl BatPAC adjustment Fl 50 107 5 output adjustment T 90 110 output adjustment F2 50 105 output adjustment Tl 90 107 5 output adjustment F3 50 102 5 output adjustment T2 90 105 output adjustment F4 50 100 output adjustment T3 90 102 5 output adjustment F5 60 110 output adjustment T4 90 100 output adjustment F
28. al Input 85 264 Vac 47 500 Hz or 100 380 Vdc Power Outputs Standard Chassis 1 600W at 230 Vac High Power Chassis 2 400W at 230 Vac 1 200W at 115 Vac 1 200W at 115 Vac Outputs Standard Chassis Up to 32 outputs High Power Chassis Up to 25 outputs Fan Cooled Full power to 40 half power to 60 Soft start for limiting inrush current Conducted EMI meets FCC class A and EN 55022 class Some configurations meet Class B Consult Factory Harmonic Distortion to EN61000 3 2 RoHS compliant available Output Sequencing and General Shutdown Refer pg 25 Consult Applications Engineering for automatic sequencing circuitry Overcurrent protection on all outputs Overvoltage protection and Overtemperature limiting on all ConverterPAC outputs not applicable with VI J00 Size 3 4 H x 6 0 W x 12 4 L 313 9mm 152 4mm x 309 mm Safety Agency Approvals cURus cTUVus CE Mark Optional Features e DC OK status signal Current Share Boards see page 24 and 25 Output voltage adjustment range with built in potentiometer Low Leakage Version available upon request see page 26 40C operation Conformal Coating contact factory Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 3 PFC MegaPAC Design Guide Mechanical Considerations The PFC MegaPAC can be mounted on any of four surfaces using standard 8 32 or 4mm screws The chassis comes with four mounting points on each surface maxim
29. assis GND 2 121 Vdc Primary to Secondary 4 242 Vdc Secondary to Chassis GND 750 Vdc Per Mil STD 704 and 1399 MI rugged chassis only Ist Gen 0 2 max 10 to full load 0 5 max No load to 10 load Maxi 0 20 max to 0 3 max LL to HL Full Load Maxi 0 1 No load to full load 1 for standard voltages 2 for special or adjustable voltages 1 for standard voltages 2 for special adjustable voltages and 48 Vdc outputs Std outputs 2 or 100 mV p p whichever is greater 75 min load VXI options Vi 150 mVp p or less 15V lt Vout 24V outputs V2 50 mVp p or less Vout 15 Vdc V3 1 ripple or less Vout gt 24V VXI options require 15 minimum load RAMPAC 10mVp p or 0 15 whichever is greater FlexPAC 50mV p p 10 110 of nominal voltage Maxi modules 50 110 of nominal voltage VI 200 VI J00 modules 90 110 of nominal voltage VI 200 VI J00 modules 10 15V 2 25V FlexPAC 105 125 of full load capability of VI 200 VI J00 modules 115 typical of full load capability of Maxi modules 135 FlexPAC 115 135 on 200 and Maxi modules only 80 typical MP Prefix MX Prefix 1 600 W at 230 Vac 2 400 W at 230 Vac 1 200 W at 115 1 200 W at 115 Vac T Note Not to exceed an input current of 15A Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 PFC MegaPAC Design Guide Environmental Characteristics Storage Temperature 409 to
30. ce nce Ped rende Best Eo ceder 24 Low Leakage Versioni sy uu 26 Output Sequencing u uu et akin i i v ete i Ae 27 Pg2 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide MegaPAC Power Factor Corrected AC DC Switchers Overview The PFC MegaPAC family of supplies combine power factor correction PFC with the inherent configurability of all Westcor MegaPAC products This design guide covers 4 model variations 1 MegaPAC 1600W max standard chassis 2 PFC MegaPAC MI 1600W max rugged COTS chassis 3 PFC MegaPAC High Power 2400W max standard chassis 4 MegaPAC High Power MI 2400W max rugged COTS chassis All PFC MegaPACs have the same input and output connections mounting points and the same dimensions The extended length EL chassis 1s covered in a different design guide A complete power supply is configured at the factory by selecting and inserting up to eight same length slide in output assemblies called ConverterPACs ConverterPACs incorporate one or more VI 200 VI J00 Maxi Vicor DC to DC converters and or FlexPACs and are available in a wide selection of output voltage and power levels The net result is a power supply that offers the advantages of a custom supply but is assembled from standard and modular building blocks Curren
31. ceptions are the FinPAC and UniPAC They can be added moved or changed as necessary The following ConverterPACs be used in the MegaPAC and or MegaPAC High Power Spec sheets for ConverterPACS are available at http www vicorpower com ModuPAC JuniorPAC DualPAC VI J00 RAM _ RamPAC VI 200 BatMOD BatPAC FinPAC ModuPAC The ModuPAC output assembly consists of a VI 200 DC to DC converter that converts the high voltage bus to the desired regulated output voltage Each ModuPAC can provide up to 200 Watts of power Multiple ModuPACs can be paralleled in a driver booster configuration to provide more power ModuPACs are fused with a PC Tron DC rated fast acting fuse A passive LC filter is used to reduce output ripple noise down to 1 typical and 2 maximum peak to peak from 10 to 100 of rated load An optional DC Power Good signal or output voltage Trim potentiometer can be specified The ModuPAC contains overvoltage protection OVP overcurrent protection OCP and overtemperature limiting OTL The OCP has automatic recovery when the overcurrent con dition is removed The OVP and OTL are latching functions and require recycling of the AC input power to restart J
32. ctions are not made or needed no Local Sense selection is necessary sim ply connect the output to the load and the unit will automatically operate in Local Sense If Remote Sense connections are made the unit will operate in a Remote Sense mode Remote Sense terminals should be terminated to their respective output i e RS to Output and RS to Output See page 13 for more information on Autosense For units without Autosense sense connections must ALWAYS be made Not connecting sense lines to their respective output can cause failure to the unit Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide Sense Connector J2 and P2 for the FinPAC Sense connections do not have to be made if the Local Sense option was ordered or 1f Autosense is present see above note on Autosense J2 Sense Connector J2 Pin J2 1 Trim Pin Acces 1 Use Molex mating receptacle 50 57 9403 with 16 02 0103 terminals provided 5 5 4 12 2 is the Sense and J2 3 is the Sense Attach terminals to 22 24 AWG twisted pair wire using Molex tool 11 01 0208 Attach opposite ends of Sense lines to point where regulation is desired P2 Sense Connector Verify that Sense lines are not cross connected before applying input power For the FinPAC P2 7 is the Sense and P2 6 is the Sense 7 SENSE
33. dard voltages include 2V 3 3V 5V 10V 12V 15V 24V 28V and 48V If using a nonstandard voltage or if a ConverterPAC is ordered with a Trim option the resistor calculations will differ from those on page 17 Please consult the factory for assistance Rev 4 2010 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 19 PFC MegaPAC Design Guide OUTPUT MODULE Viet 1 200 1 700 gt 3 3 2 50V 10 0 1 200 1 00 3 3V 0 97V 3 88kO Maxi Mini Micro Pre Defined 1 23V 1 0 Use 22 24 AWG Twisted Pair Wires Remote Sense P Out J2 2 Sense 2 Load mplifier R 26 RTH R5 2 R7 V2 12 3 Sense I V Ref P Out Use 22 24 AWG Twisted Pair Wires Figure 11 External Trim Maxi Mini Micro User Defined 1 23V Consult Factory Table 1 Module Internal Reference Voltages and Thevenin Resistances Example 10 Trim adjust on a 12V nominal output Figure 11 shows a typical variable Trim circuit Using a 10k trimpot R7 the resistor values for R6 and R8 can be calculat ed as follows Ve Veep 10 2 75V Given Vef 2 5V see Table 1 Ips 2 75V V g Rqg 2 75V 2 5 10 25 Setting the bottom limit 2 5V 10 2 25V And since Ig5 Ig 254A R6 2 25V 254A 90 V V Veg 2 75 2 25V 5V In V R7 5V 10kO 500A Ing In Ing 525A Vas
34. from an electromechanical switch or relay a capacitor should be connected to eliminate the effects of switch bounce Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 17 PFC MegaPAC Design Guide AC OK Power Fail J10 11 This is an active high TTL compatible signal and provides a status indication of the AC input power see Figure 7 and Connector Pin Identification on page 9 It is capable of sourcing 0 5mA at gt 3 2V and sink 16mA at 0 5V This signal switches to a TTL 1 when the high voltage bus exceeds low line condition during turn on and switches to a TTL 0 3 ms minimum before loss of output regulation due to the loss of input AC power This signal can be used to warn external control circuits of an impending loss of power 11 AC Power OK PN2222 10 Signal Ground Figure 7 AC OK Power Fail Auxiliary 5V 0 3A J10 9 The on J10 9 is an auxiliary 5V regulated power source see Figure 8 and Connector Pin Identification on page 9 It is 5 5 with respect to Signal Ground and can supply 300 mA maximum It is short circuit proof but if shorted all outputs will shut down through the Enable Disable circuitry The Auxiliary Vcc typically powers user circuitry or is used with the Power Good circuitry to provide a pull up reference for the outputs of the DC Power Good circuit on a ConverterPAC If used for this purpose the Signal Gr
35. hould be enabled at the same time 2 Out conductors must be of equal length and wire gauge Separate Out conductors must be used from each supply to the load or the use of a Y connection to a common point must be used as shown in figure 1 Each leg of the Y must have a minimum of a few millivolts of drop in order for proper operation 50mV to 100mV of drop will pro vide from 5 to 1 accuracy 3 V1 and V2 for all Box to Box circuits must be con nected directly at the negative output power studs or ter minals to achieve accurate current sharing 4 D can be added if redundancy is needed If redun dancy is not required D can be replaced with direct wire connections 5 When using D the Power input should be connected on the cathode side of the paralleling diodes as shown above 6 Terminate Sense Leads either locally or remotely as shown in figure 1 7 For paralleling more than 2 supplies consult factory for assistance Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide Current Share Boards Optional Feature contd 0 13 3 3mm Dia Non Plated thru hole 4 places Molex CT43045F surface mountable 1 74 1 500 connector 390 height above board 44 2mm 38 1mm J1 Pinout Pin Descripti
36. is necessary to connect the E D pins of the corresponding module locations together such that both modules are commanded to turn ON or OFF simultaneously Example Slots 2 4 and 6 have been configured as a single output parallel array see Fig 6 In order to disable the 48V output E D 2 E D 4 and E D 6 should be shorted together as shown in Fig 6 With E Ds connected together a single switch can then be used to remotely enable and disable the output Note For single output power supply configurations the simplest method of remotely enabling and disabling the output is to use the General Shutdown GSD function J10 Slot 8 M3 3V 40A Slot 7 M5V 40A Slot 6 PZ48V 12 5AJS1 Slot 5 Slot 4 PZ48V 12 5AJS1 Slot 3 Slot 2 PZ48V 12 5AN Slot 1 Figure 6 Enable Disable Control of Maxi Arrays General Shutdown GSD J10 12 The GSD control pin on J10 12 allows simultaneous shutdown of all ConverterPAC outputs see Connector Pin Identification on page 9 This pin must be pulled down to less than 0 7V and will sink 13 mA 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 3V with respect to Signal Ground If driven
37. ith the original flanged nut ConverterPACs for use in parallel arrays Other advan tages include Inner nut that might become loose replaced by a brass insert Stronger connection to the PCB Improved conductivity less voltage drop and heating Both the stud and panel are less likely to break due to over torqueing Shown below are the original and re designed studs Original Redesigned Refer to page 12 for dimensional data Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide PFC MegaPAC Output Power Derating Output Power vs Input Voltage Vac 47 500 HZ 2 400W 200 Vac Power Exceeded Output Power Watts 85 95 105 125 145 165 185 200 215 235 255 265 Input Voltage Vac or Vdc For VDC 100V min applies PFC MegaPAC Connector Kit 19 130040 Listing ITEM QTY DESCRIPTION VENDOR 1 PART NO 1 1 HOUSING 12 POS 165 W LATCH MOLEX 38 01 2120 2 12 TERMINAL FEM CRIMP 18 24 AWG TIN MOLEX 39 00 0039 CRIMP TOOL FOR ITEM 2 MOLEX 11 01 0197 3 8 HOUSING 7 POS 098 CTR L PROFILE MOLEX 39 01 0073 4 8 HOUSING 4 POS 098 CTR L PROFILE MOLEX 39 01 0043 5 94 TERM FEM CRIMP 22 18 AWG PH BRNZ MOLEX 39 01 0031 CRIMP TOOL FOR ITEMS 3 AND 4 MOLEX 00 01 0197 6 8 HOUSING 3 POS 1 CTRS W LATCH MOLEX 50 57 9403 7 27 TERM FEM CRIMP 22 24 AWG SEL GLD MOLEX 16 02 0103 of CRIMP TOOL FOR ITEM 7 MOLEX 11
38. ll Effect devices and provides a simple 5 wire connection method to achieve a 1mV accuracy between the Negative Output power rails This accuracy translates to a 1 current sharing if there is a total of 100mV conductional voltage drop in the negative return path Constructed as a current source to drive the Trim pin of a Vicor module the design uses an accurate comparator circuit to monitor the power returns In addition the cir cuit is unidirectional and can only trim an output voltage up The benefit is that only the supply that is supporting less current is adjusted up This action balances the cur rents to the load by matching the output voltages of the supplies In the case of one supply failing the circuit will attempt to trim the failed supply only This will leave the remaining functional supply alone to provide power to the load at its nominal voltage Thus the circuit also offers simple redundancy In addition because CSB functions as a current source the Trim outputs T1 and T2 of the CSB can be placed in parallel to create a sum ming node This allows current sharing between more than two supplies by paralleling the T2 output of one CSB circuit with the output of the next CSB Please note The CSB is not intended for use in Hotswap Applications Vicor 800 735 6200 Westcor Division 408 522 5280 Figure 1 CSB Interconnect Example Requirements 1 For proper operation the power supplies being paral leled s
39. m the MegaPAC and wait 5 minutes Failure to do so can result in personal injury or damage to the supply Take standard ESD precautions when handling ConverterPACs Removing ConverterPACs ConverterPACs can be removed by loosening the captive screw at the base Once this screw has been loosened the ConverterPAC will slide out of the chassis Once a ConverterPAC has been removed the empty slot MUST be filled with either another ConverterPAC or an airblock If the slot is left empty it will provide an airflow escape and cause failure to the power supply Installing ConverterPACs as Drivers ConverterPACs can be installed in empty slots by simply sliding in the new ConverterPAC and securing the screw at the base Power and interface connections can be made after the ConverterPAC has been installed Installing Booster ConverterPACs to Increase Output Power ConverterPACs be paralleled for more power Additional power to an output is obtained by connecting one or more boosters in parallel with a single driver The driver can be placed in any open slot boosters should be inserted in the slots to the immediate right of the driver as viewed from the output end of the MegaPAC Figure 2 shows a driver placed in slots 1 and 3 boosters placed in slots 2 to 4 After inserting the driver and boosters they are paralleled using bus bars across the positive and negative output studs Drivers should not be paralleled with each other Bus bars between
40. mped ance from the Out to Sense and Out to Sense pins If the impedance is 5 ohms then the output has Autosense and does not require local sense jumpers FlexPAC is local sense only If units do not have Autosense sense connections must be made When making sense connections keep in mind that although all outputs are open Sense protected the Sense terminals MUST be connected to their respective outputs before the PFC MegaPAC and PFC MegaPAC High Power are powered up Regardless of the output polar ity configured the Sense should always connect to the Power output The Sense connects to the Power output Sense connections are not required on booster ConverterPACs BatPACs or if the Local Sense option is specified Local Sense mode means that the Remote Sense lines are not connected Sense pins can be accessed on or J2A J2B on dual output units Signal Ground J10 10 Signal Ground see Figure 4 and Connector Pin Identification on page 9 is an isolated ground reference for all J10 interfacing signals and can be used for ConverterPAC output status signals such as Power Good This is not the same as Earth Ground on input power connector J9 J10 J10 1 0 1 J10 7 E D 7 J10 2 E D 2 08 E D 8 0112 13 415 16 ED3 109 5 0 7 8 9 10 11 12 104 0 4 J10 10 SIGNAL GROUND 210 5 E D 5 J10 11 AC POWER OK 10
41. ning input and output wiring in close proximity as this may cause noise related problems e PFC MegaPACs NOT user serviceable Please contact our customer service department at 1 800 735 6200 for repair assistance Please be advised that attempts to repair or modify the power supply will void the warranty A proper fault protection device fuse or breaker should be used in series with the input terminals Use proper size wires to avoid overheating and excessive voltage drop Never loosen the inner nut on a ConverterPAC FinPAC ConverterPACs can only be used with a high power chassis A high power chassis is identified by an MX prefix code in the specific model number Output voltages over 60Vdc whether from individual modules or series arrays are considered as hazardous sec ondary outputs under UL 60950 Appropriate care must be taken in design implementation of the supply Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 PFC MegaPAC Design Guide Technical Description The PFC MegaPAC chassis consists of an off line single phase power factor corrected front end EMI filter cool ing fan customer interface and associated housekeeping circuits Input AC mains voltage L1 L2 and GND is applied to a terminal block The input current is passed through an EMI filter designed to meet conducted noise limit specifications of FCC Part 15 VDE 0871 and
42. not have the autosense feature NEVER connect the remote sense wires in reverse To avoid failures always terminate the Sense to the and the Sense to the Out f needed compatible connector kits can be ordered separately Refer to page 23 for additional information regarding connector kits To avoid overheating NEVER operate the supply with an open output slot Open slots should always be filled with a ConverterPAC or a plastic airblock designed for the PFC MegaPAC Always turn the power supply OFF before disconnecting any input or output wires Failure to do so may lead to an electrical shock hazard and or damage to the power supply e Do not insert or remove a ConverterPAC while the power supply is running They not designed for hot inser tion or extraction Wait 5 minutes after shutting off the power supply before inserting or removing a ConverterPAC Do Not restrict airflow to or from the supply as this can cause overheating damage Booster ConverterPACs are available for power expansion Refer to page 6 for additional information Do Not use boosters as independent outputs Operating boosters with disconnected bus bars will cause failures Before turning on the unit ensure all input and output wire are properly connected and all hex nuts properly tight ened Keep output wires as short as possible and run the output power cables next to each other Use twisted pair wiring whenever possible Avoid run
43. of 14 AWG with soldered terminals PONDE a The connector manufacturer recommends the wires not be tinned A ferrule Phoenix Nate SET SCREW MAXIMUM TORQUE 4 4 INCH POUNDS P N 32 00 58 0 purchased from other sources can be used to prevent fraying LABEL NO 900046 REV B Output Connections Single Output ModuPAC Power Connections Installing ring lugs and or bus bars on output studs upper stud is Positive and the lower stud is the Return Ge oe Vout Newer outputs studs are 1 8th inch longer See pgs 12 and 19 for more information L Vtrim Pot Adjust Option Remove nut EN Place ring lug over output stud Replace and tighten outer nut to a maximum torque of 45 Ib in Do Not Over pin 1 DC OK Option FP Tighten Nuts Verify all output nuts are properly installed before turning on supply Installing power connectors on DualPACs and DualPAC Output Connector Use Molex mating receptacle 39 01 2060 with 39 00 0039 terminals provided J1A J1B Pins and 4 are Positive while pins 2 and 5 are the Return 6 5 4 6 5 4 Attach terminals to 18 24 AWG stranded wire using Molex tool 11 01 0197 Rot 1 RS RSI 3 2 4 3 2 1 Sense Connections Note Newer power supplies have the Autosense feature For these units if Remote Sense conne
44. on 1 Power 2 Tl Y O 3 V1 Y 4 2 0 12 3 0 5 v2 012 0 900 6 No Connection 3 0mm 22 9mm 1 14 4 29 0mm gt Figure 2 Mechanical Drawing ma 24 0 1 0 gt Red 22 AWG CO Power Yellow 22 AWG Ti P1 Brown 22 AWG V1 White 22 AWG T2 Black 22 AWG O V2 Figure 3 Cable Drawing Specifications 1 Power 2 50Vdc at 5mA maximum 2 Accuracy ImV between Vout connections 3 Output current when not trimming up 1uA VI 200 J00 SuA Maxi Mini Micro 4 Use 4 non plated through holes with standoffs for mounting 5 CSB01 MUST be used for current sharing VI 200 VI J00 converters VI 200 J00 6 CSB02 MUST be used for current sharing Maxi Mini Micro converters Maxi Mini and Micros PLEASE NOTE THE CSB IS NOT INTENDED FOR HOTSWAP APPLICATIONS Contact your Regional Applications Engineer at 1 800 927 9474 for additional information Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 25 PFC MegaPAC Design Guide Low Leakage Version If Low Leakage is required the MegaPAC Family of Power Supplies has a model variant must be requested This model enables the user to meet various additional specifications Presently the MegaPAC Mini MegaPAC and Autoranging MegaPAC are available in Low Leakage versions Other models can be made available The MegaPAC Family of Power Supplies consist of PFC MegaPAC PFC
45. or Remote terminated to their respective output for the unit to operate properly Local Sense P Out Remote Sense Use 22 24 AWG Twisted Pair Wires Figure 10 Sense Leads External Trim J2 1 Output voltage can be trimmed using an optional factory installed Trim potentiometer or with the Trim pin see Figure 11 The Trim potentiometer is located on the ConverterPAC If the Trim potentiometer has not been ordered the Trim pin must be used When using the Trim pin the Trim limits are determined by the DC DC con verter used on the ConverterPAC Maximum Trim ranges are 10 above the nominal converter voltage and 50 below the nominal converter voltage except 10V 12V and 15V outputs which are 10 below nominal as meas ured from the output studs or output connector of the power supply Note The combined effects of module trim up remote sense and dynamic load step may cause the module to trip OVP See page 7 for information on restart The Trim pin on J2 can be used to control the output voltage It is referenced to the Sense pin on J2 and can be controlled by either a resistor network or an external voltage source To increase an output voltage above its nomi nal it is necessary to increase the voltage at the Trim pin above the internal reference voltage Vref The reverse is true to decrease an output voltage Note Converters are sometimes pre trimmed at the factory if a nonstandard output voltage is requested Stan
46. ound on J10 10 must also be connected to the J3 1 Signal Ground pin of the ConverterPAC J10 9 Auxiliary Vcc 5V 300 mA 10 Signal Ground Figure 8 Auxiliary Vcc Power Good J3 3 The optional Power Good signal J3 3 18 referenced to Signal Ground on J3 1 and indicates the status of the out put voltage This signal is asserted TTL 1 when the output voltage is above 95 of nominal It is a TTL 0 when the output voltage is below 8596 of nominal If the Trim option 15 also used the Power Good trip points DO NOT track with the trimmed voltage It is possible to trim the output below the fixed setpoints of the Power Good circuit and cause a negative Power Good signal ConverterPAC In 2 49K 2N2222 10K Figure 9 Power Good and Vcc Power Good 2 49K Power Good Inverted mE Signal Ground Power Good Inverted J3 2 This is the inverse of the Power Good signal and is referenced to Signal Ground on J3 1 Signal Ground J3 1 Signal Ground on J3 1 is an isolated secondary ground reference for J3 status signals It is used to provide a refer ence point for the Power Good circuitry and is not the same as Earth Ground on input power connector 19 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 4 2010 Pg 18 PFC MegaPAC Design Guide In J3 4 The Vcc In on J3 4 is an input that requires 5V either from
47. the J10 Auxiliary Vcc or from another source Input current to this pin is limited by an internal resistor to 3 mA If the J10 Auxiliary Vcc is connected to Vcc In on J3 4 then the J10 Signal Ground must be connected to Signal Ground on J3 1 tSense Sense J2 2 and J2 3 See page 10 and 13 for information on Autosense The Sense on J2 2 should be connected to the Power Out and the Sense on 72 3 to the Power Out terminal Do not reverse or leave the Sense pins open Sense pins can be terminated locally at the output of the power supply in which case the power supply will provide regulation 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 this termination should be made close to the output load Compensation of up to 0 5V 0 25V per lead can be obtained Use twisted pair 22 24 AWG wire for this purpose For DualPACs the Sense pins are available on connectors designated as J2A 2 and J2B 2 for outputs A and B respectively Sense pins on J2A 3 and J2B 3 respectively These pins are also duplicated on the power con nectors and Reminder Only units with Autosense will automatically operate in Local Sense mode if no sense connections are made It will operate in remote sense mode if remote sense connections are made Units without Autosense MUST have sense connections Local
48. thin 2 s after the application of input power Once the high voltage bus is within its limits the AC OK signal asserts to TTL 17 indicating the input power 18 OK and enables the power outputs An auxiliary Vcc output of 5 Vdc sourcing up to 0 3A is provided for periph eral use An output Enable Disable function is provided by using an optocoupler to control the Gate In pins of the ConverterPAC assemblies If the Enable Disable control pin is pulled low the optocoupler turns on pulling the Gate In pin low and disabling the ConverterPAC output The nominal delay for an output to come up when meas ured from release of the Enable Disable pin is 10 15 ms The General Shutdown function controls all outputs simultaneously and works in a similar manner The ride through holdup time is the amount of time the load can be supported before loss of output regulation after the loss of input power Detecting the loss of input power takes a finite time period after which the AC Power signal goes from TTL 1 to 0 This signal is available for use within 1 2 seconds after initial power up and can be used to indicate an impending loss of power At least 3 ms of warning time is given Following the loss of input power the outputs are disabled when the bus voltage drops below its operating threshold High Voltage Input x E Line Filter Rectifier Soft Start Boost Converter DE B s ConverterPAC 41
49. tly the standard power chassis uses only FlexPACs and ConverterPACs with VI 200 V1 J00 Vicor DC to DC converters while the high power chassis accepts FlexPACs and ConverterPACs with both VI 200 VI J00 and or Maxi module Refer to page 7 for a brief overview of the ConverterPACs used Using the PowerBench configurator tool available on vicorpower com anybody can now configure a PFC MegaPAC and other Westcor power supplies online Manufactured at Westcor a division of Vicor the entire family of MegaPAC power supplies is completely user configurable If output requirements change i e more power or a different output voltage 1s needed upgrading is easy simply unlock a single screw and replace the slide in ConverterPAC assembly with one that is of the same length and has the desired voltage power rating For additional flexibility ConverterPACs can be connected in par allel to increase output power booster ConverterPACs or in series for higher voltages total output voltage should not exceed 400V The driver is to the left of the boosters when looking at the output end of the supply A user friendly interface provides control and output sequencing capability see page 27 for more information about this capability in addition to useful status indicators Please consult our Applications Engineering Department if you have other special requirements Standard Features Power Factor Correction 0 99 at 115 Vac 0 95 at 230 Vac Univers
50. um allowable torque is 5 5 Ib in The maximum penetration is 0 15 in 3 8mm When selecting a mounting location and orientation the unit should be positioned so air flow is not restricted Maintain a 2 minimum clearance at both ends of the PFC MegaPAC and route all cables so airflow is not obstructed The standard unit draws air in at the fan side AC input side and exhausts air out the load side If airflow ducting 18 used use caution as sharp turns could present back pressure to the PFC MegaPAC The fan moves approximately 30 CFM of air Avoid excessive bending of output power cables after they are connected to the PFC MegaPAC For high current out puts use cable ties to support heavy cables in order to minimize mechanical stress on output studs Be careful not to short out to neighboring output studs The PFC MegaPAC units are supplied with serrated flanged hex nuts on all output studs Therefore thread locking compounds or lock washers are not required The maximum torque recom mended on flanged nuts is 45 Ib in Never loosen the inner nut on a ConverterPAC This nut supports the hardware inside the ConverterPAC and 15 factory torqued Avoid applications in which the unit is exposed to excessive shock or vibration levels In such applications a shock absorption mounting design 15 required MegaPAC Do s and Don ts Pg4 Remote sense should be used a To improve poor output regulation b When using older ConverterPACs that do
51. uniorPAC The JuniorPAC consists of a VI J00 DC to DC converter that converts the high voltage bus to the desired regulated output voltage JuniorPACs can provide up to 100 Watts of output power and are fused with a single PC Tron DC rated fast acting fuse A passive LC filter is used to reduce out put ripple noise down to 1 typical and 2 maximum peak to peak from 10 to 100 of rated load An optional DC Power Good signal or output voltage Trim potentiometer can be specified The JuniorPAC contains output overcurrent protection which recovers automatically when the overcurrent condition is removed Overvoltage protection and overtemperature limiting are not available DualPAC This output assembly consists of two VI J00 DC to DC converters that convert the high voltage bus to the desired regulated output voltages as noted above The outputs are electrically isolated For detailed pin out description refer to pg 9 RAMPAC This output assembly consists of a VI J00 DC to DC converter with a Ripple Attenuator Module RAM and is designed for applications requiring low output ripple noise The RAMPAC can attenuate the ripple noise down to 10 mV peak to peak over 20 MHz bandwidth from 10 to 10096 of rated load of the converter Outputs from 5V to 50V are available BatPAC The BatPAC output assembly consists of a VI 200 BatMod current source that converts the high voltage bus to the desired regulated output voltage The converter is fused with
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