VICOR 4kW MegaPAC-EL Specifications

PF MegaPAC-EL and PFC MegaPAC-High Power Low Noise Design Guide
PFC MegaPAC-EL™
PFC MegaPAC-HPEL™
Power Factor Corrected AC-DC Switchers
Design Guide
and
“Quick Install” Instructions
www.vicorpower.com
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
TABLE OF CONTENT
Overview of Product...........................................................................................................................3
Mechanical Considerations.................................................................................................................4
MegaPAC Do’s and Don’ts.................................................................................................................4
Technical Description..........................................................................................................................5
Configuring and Reconfiguring MegaPACs......................................................................................6
ConverterPAC Description..................................................................................................................7
Part Numbering...................................................................................................................................8
ConverterPAC Output and Connector Pin Identification.................................................................. 9
Quick Install Instructions....................................................................................................................10
Mechanical Drawings........................................................................................................................ 12
Interface Connections...................................................................................................................... ..13
Specifications......................................................................................................................................18
Power Derating...................................................................................................................................20
Connector Kit Listing.........................................................................................................................20
Current Share Boards..........................................................................................................................21
Output Sequencing..............................................................................................................................23
Pg 2
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™
Power Factor Corrected AC-DC Switchers
Overview
The PFC MegaPAC-EL and PFC MegaPAC- High Power Low Noise (HPEL) combine power factor correction
(PFC) with the configurability of the MegaPAC family of power supplies. The PFC MegaPAC-EL and PFC
MegaPAC-HPEL provide up to 1,600 Watts and 2,400 Watts of output powers respectively and have power densities of 4.3W per cubic inch and 6.5W per cubic inch respectively. The chassis has 8 slots and can provide as many
as 16 outputs for the PFC MegaPAC-EL and 13 outputs for the PFC MegaPAC-HPEL. The PFC MegaPAC-EL
and PFC MegaPAC-HPEL have the same input and output connections, mounting points, and the same dimensions:
3.4”H x 6.0”W x 15.6”L (85,6mm x 152,4mm x 396,8mm). Note that length of older units were 15.5” L
(393,6mm)
A complete power supply is configured at the factory by selecting and inserting up to eight (four to six for the PFC
MegaPAC-HPEL depending on ConverterPACs used) same length slide-in output assemblies called
ConverterPACs. ConverterPACs incorporate one or two 1st and/or 2nd Generation Vicor DC to DC converters 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. The PFC MegaPACEL ONLY uses ConverterPACs with 1st Generation Vicor DC to DC converters (VI-200 and VI-J00 modules)
while the PFC MegaPAC-HPEL accepts ConverterPACs with both 1st Generation (VI-200 and VI-J00) and/or 2nd
Generation module (Maxi). Refer to page 7 for a brief overview of the ConverterPACs used.
Manufactured at Westcor, a division of Vicor, the entire family of MegaPAC power supplies is completely userconfigurable. If output requirements change, i.e., more power or a different output voltage is 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 parallel to increase output power (booster ConverterPACs), or in series for higher voltages (total output voltage should
not exceed 500V). The driver is to the left of the boosters when looking at the output end of the supply. A userfriendly interface provides control and output sequencing capability (see page 23 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
• Universal Input: 85-264 Vac, 47-500 Hz, or 100-380 Vdc
• Power Outputs: PFC MegaPAC-EL: 1,600W at 230 Vac PFC MegaPAC-HPEL: 2,400W at 230 Vac
1,200W at 115 Vac
1,200W at 115 Vac
• Outputs:
PFC MegaPAC-EL: Up to 16 outputs
PFC MegaPAC-HPEL: Up to 13 outputs
• Output ripple: <10mVp-p or 0.15% whichever is greater
• Fan Cooled
• Full power to 40°C; half power to 60°C
• Soft start for limiting inrush current
• Conducted EMI meets FCC class “B” and EN 55022 class B specifications
• Harmonic Distortion to EN61000-3-2
• AC Power OK status signal
• Output Sequencing and General Shutdown (Refer pg. 23. Consult Applications Engineering for automatic sequencing circuitry.)
• Autosense (Refer to page 10 and 13 for more information on Autosense)
• Overcurrent protection on all outputs
• Overvoltage protection on all ConverterPAC outputs (not applicable with VI-J00 modules)
• Overtemperature limiting on all ConverterPAC outputs (not applicable with VI-J00 modules)
• Size: 3.4”H x 6.0”W x 15.5”L (85,6mm x 152,4mm x 393,7mm)
• Safety Agency Approvals: CE Mark, CTÜVUS
Optional Features
• DC OK status signal
• Current Share Boards - see page 21 and page 22
• Output voltage adjustment range with built-in potentiometer
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 3
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Mechanical Considerations
The PFC MegaPAC-EL and PFC MegaPAC-HPEL 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; maximum allowable torque is 20 lb-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-EL and PFC MegaPAC-HPEL 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 is used, use caution, as sharp turns could present back pressure to the PFC
MegaPAC-EL and PFC MegaPAC-HPEL. The fan moves approximately 30 CFM of air.
Avoid excessive bending of output power cables after they are connected to the PFC MegaPAC-EL and PFC
MegaPAC-HPEL. For high-current outputs, 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-EL and PFC
MegaPAC-HPEL 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 recommended on flanged nuts is 45 lb-in.
Never loosen the inner nut on a ConverterPAC. This nut supports the hardware inside the ConverterPAC and is factory torqued.
Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such applications, a shock
absorption mounting design is required.
MegaPAC Do’s and Don’ts
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Pg 4
For units without Autosense, do not leave ConverterPAC Sense lines open. Always terminate them to their
respective output locally or at the load. Use twisted pair 22-24 AWG wire. If ConverterPAC has Autosense, no
local sense connection is required. See page 10 and 13 for more information on Autosense.
If needed, use Connector Kit # 19-130040 for the PFC MegaPAC-EL and PFC MegaPAC-HPEL.
Always fill all output slots of the MegaPAC. If a slot is not filled with a ConverterPAC, it should be filled with
an airblock. Airblocks are plastic assemblies whose main function is to fill up an empty slot. Any airflow
escape from an empty slot significantly degrades thermal performance, and can result in overheating and damage to the power supply.
Always turn the power supply off, before disconnecting input or output wires.
When using the remote sense feature, the +Out and -Out load wires should never be disconnected while the
supply is operating. Failing to do so could damage the power supply.
Do not unplug ConverterPACs while input power is applied. They are not designed for hot-plug applications.
Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the output power
terminals.
For power expansion, use booster ConverterPACs. Viewing the unit from the output terminal side, always
insert boosters to the right side of the driver.
Do not use boosters as independent outputs. Disconnecting bus bars will damage booster ConverterPACs.
For booster arrays, do not remove busbars.
Always ensure that output hex-nuts are properly torqued before applying power to supply.
Run the output (+/–) power cables next to each other to minimize inductance.
Wait 5 minutes after shutting off power before inserting or removing ConverterPACs.
The MegaPACs does not have user serviceable components. They must be returned to the factory for repairs.
Contact Customer Service for a RMA number before returning the unit. Do not attempt to repair or modify
the power supply in any manner other than the exchange of ConverterPACs as described in this Design Guide.
Insert proper fault protection at power supply input terminals (i.e., a fuse).
Use proper size wires to avoid overheating and excessive voltage drop.
Never loosen the inner nut on a ConverterPAC.
Verify output nuts are tight before powering up.
FinQPACs require 2 slots each because of the larger heatsink attached to dissipate the extra heat generated by
the higher power 2nd Gen module Refer to page 7 for more information on which ConverterPACs can be
used.
Older PFC MegaPAC-ELs cannot use the 2nd Gen FinQPAC ConverterPAC because of chassis differences.
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Technical Description
The PFC MegaPAC-EL and PFC MegaPAC-HPEL chassis consists of an off-line single phase, power-factor-corrected front end, EMI filter, cooling fan, low noise filters, 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 “B” specifications of FCC Part 15, VDE 0871, and EN55022
class "B." At start-up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after initial
power-up by a DC bus voltage Sense circuit driving a relay. After rectification, the input voltage is put through a
boost converter that keeps the AC input current sinusoidal 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-EL and PFC MegaPAC-HPEL 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 circuits and DC cooling fan. The internal housekeeping Vcc comes up within 2 s after
the application of input power. Once the high voltage bus is within its limits, the AC OK signal asserts to a TTL
“1” indicating the input power is OK, and enables the power outputs. An auxiliary Vcc output of 5 Vdc sourcing
up to 0.3A is provided for peripheral 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 measured 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
OK signal goes from a 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.
Input
Line Filter
Soft Start
Circuit
Rectifier
Boost Converter
High Voltage
DC Bus
Waveform
Sample
Current
Sample
QPAC #1
Power
Output
QPAC #2
Power
Output
QPAC #3
Power
Output
QPAC #8
Power
Output
PFC Control
Customer
Interface
E/D Control
Fan
Current
Monitor
Enable/Disable Control
Housekeeping
Power
Figure 1. PFC MegaPAC-EL and PFC MegaPAC-HPEL Low Noise Architecture
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 5
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Configuring and Reconfiguring MegaPACs
Most ConverterPACs of the same length can be inserted into any available slot of a MegaPAC chassis. They can
also be easily added, replaced, or moved by sliding the assemblies in or out of a MegaPAC chassis. For outputs
greater than 200 Watts, a driver QPAC and one or more booster ConverterPACs will be used. For outputs greater
than 600 Watts, a driver FinQPAC 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 from 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 can 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. All 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 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 500V. 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.
Bus Bars for Paralleling
Loosen screw to
remove ConverterPAC
1
2
3
4
5
6
7
8
Driver
Boosters
Figure 2. Paralleling ConverterPACs
Pg 6
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
ConverterPAC Functional Description
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 or between different AC input
MegaPAC chassis. They can be added, moved, or changed as necessary. A key feature of the Extended Length
ConverterPAC is the low ripple and noise output to 10 mV p-p or 0.15%, whichever is greater. The following Extended Length ConverterPACs can be used in the PFC MegaPAC/EL - Low Noise.
QPAC (L)
The QPAC output assembly consists of a 1st Generation VI-200 DC to DC
converter that converts the unregulated high voltage bus to the desired regulated output voltage. Each QPAC (L) can provide up to 200 Watts of output
power, and booster QPACs can be added in parallel for more power. Power
and slave QPACs can be added in parallel for more power. QPACs are fused
with a PC-Tron, DC-rated, fast-acting fuse. An active preload ensures the DC
to DC converter operates in its highest noise performance range. As the load
on the module increases, the preload removes itself from the circuit. QPACs
using the VI-200 module have an optional DC OK TTL signal. All QPACs have
overcurrent protection with automatic recovery when the overcurrent condition
is removed. Over Voltage Protection (OVP) and Over Temperature Limiting
(OTL) are available. Please note that for the QPAC (L) the output voltage
from either output terminal to chassis should not exceed 500 Vdc, or peak.
DualQPAC (LD)
The DualQPAC output assembly consists of two 1st Generation VI-J00 DC to
DC converters that provide two isolated output voltages. DualQPACs can provide up to 100 Watts of output power from each output. The DualQPACs are
fused with a PC-Tron, DC-rated, fast-acting fuse. An active preload ensures the
DC to DC converter operates in its highest noise performance range. OVP and
OTL is not available. Please note that for the QPAC (L) the output voltage
from either output terminal to chassis should not exceed 100 Vdc, or peak.
JuniorQPAC (LJ)
The Junior QPAC output assembly consists of a 1st Generation VI-J00 Vicor
DC to DC converter that converts the unregulated high voltage bus to the
desired regulated output voltage. OVP and OTL is not available. Please note
that for the QPAC (L) the output voltage from either output terminal to
chassis should not exceed 500 Vdc, or peak.
FinQPAC (PFL)
The FinQPAC output assembly consists of a 2nd Gen Maxi DC to DC converter that converts the unregulated high voltage bus to the desired regulated output voltage. Each Maxi module can provide up to 600 Watts of output power.
Each FinQPAC occupies 2 slots because it has an extra large heatsink attached
to dissipate the heat generated by this more powerful 2nd Gen onverter. It cannot be used in any other member of the MegaPAC Family. PACs using the VI200 module have an optional DC OK TTL signal. FinQPACs have overcurrent
protection with automatic recovery when the overcurrent condition is removed.
Over Voltage Protection (OVP) and Over Temperature Limiting (OTL) are
available.Please note that for the FinQPAC (PFL) the output voltage from
either output terminal to chassis should not exceed 500 Vdc, or peak.
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
+
VI-200
_
QPAC
VI-J00
VI-J00
DUALQPAC
VI-J00
JUNIORQPAC
+
Maxi
VI-200
_
FINQPAC
Applications Engineering 800-927-9474
Pg. 7
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
LIST OF CONVERTERPACS USED IN THE PFC MEGAPAC-EL AND PFC
MegaPAC-HPEL LOW NOISE AND THEIR FEATURES
ConverterPAC
QPAC (L)
DualQPAC (LD)
JuniorQPAC(LJ)
FinQPAC(PFL)+
OVP
Std
N/A
N/A
Std
OCP
Std
Std
Std
Std
OTL
Std
N/A
N/A
Std
RS/AS* LS/AS*
AS*
AS*
AS*
AS*
AS*
AS*
AS*
AS*
PG
Opt
Opt
Opt
Opt
TrimPot
Opt
N/A
Opt
Opt
OVP
Overvoltage Protection (latching)
RS
Remote Sense
OCP
Overcurrent Protection (auto-recovery)
LS
Local Sense
OTL
Overtemperature Limiting
AS
Autosense
PG
Power Good (DC OK TTL Signal)
+ 2nd Gen OTL is non-latching
* See page 10 and 13 for more information on Autosense.
Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualQPAC and JuniorQPAC.
Part Numbering
PFC MegaPAC-EL
eg. MP5-78256-EL
MPx A -7x B xxx-EL
PFC MegaPAC-HPEL
eg. MX4-74143-EL
MXx A -7x B xxx-EL
MP
MegaPAC Chassis (only 1st Gen)
xA
7
Number of outputs
Power Factor Corrected
ConverterPAC
Xx D V/x E Ax F
eg. L15V/10A
X
xD
xE
xF
*ConverterPAC Options
B
Booster module
D
DC OK or Power Good1
F
Full 50-110% output adjustment2
F1
50-107.5% output adjustment
F2
50-105% output adjustment
F3
50-102.5% output adjustment
F4
50-100% output adjustment
F5
60-110% output adjustment
F6
70-110% output adjustment
F7
80-110% output adjustment
F8
90-110% output adjustment
F9
100-110% output adjustment
I
Industrial Grade module
K
Custom SRF module used
P
Preload
MX
X
xB
xxx
MegaPAC chassis with 2nd Gen (or with both Gens)
Represents the use of a 2nd Gen Module.
Number of modules
Assigned by Westcor
ConverterPAC type
L - QPAC
LD - DualQPAC
LJ - JuniorQPAC
PFL - FinQPAC
Voltage out
Current out (rounded to 1 decimal point)
Options (See below*). Can be multiple options.
M
R
S
T
T1
T2
T3
T4
T5
T6
V1
V2
V3
Military Grade module
RAM external 3
Trimpot removed for external BatPAC adjustment
90-110% output adjustment4
90-107.5% output adjustment
90-105% output adjustment
90-102.5% output adjustment
90-100% output adjustment
98-105% output adjustment
100-110% output adjustment
"VXI" low noise (150 mV or less) 15V < Vout < 24V outputs5
"VXI" low noise (50 mV or less) Vout < 15 Vdc
“VXI” low noise (1% ripple or less) Vout > 24V
1 D option: Optional for all ConverterPACs EXCEPT the DualQPAC, BatPAC
2 F options: Optional for all ConverterPACs EXCEPT the BatPAC and DualQPAC
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.
4 T options: Optional for all ConverterPACs EXCEPT the BatPAC and DualQPAC
5 V options: Optional ONLY on the QPAC, DualQPAC and JuniorQPAC. N/A on all other ConverterPACs.
Pg 8
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
ConverterPAC Output and Connector Pin Identification
QPAC
JuniorQPAC
+ V0UT
J2 REMOTE SENSE TRIM/SC & POWER GOOD
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0073
OUTPUT ADJUST
- VOUT
J2-PIN1
DualQPAC
J1-B-PIN1
J2-PIN1
7
6
5
TRIM TOP
TRIM BOT
N/C
TERMINALS- MOLEX P/N: 39-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
+SENSE
7
6
5
4
3
2
1
-SENSE
TRIM
Vcc IN
POWER GOOD
POWER GOOD INVERTED
SIGNAL GROUND
J1-B
(OUTPUT CONNECTORS)
MATING HDWR:
1 AND 4 +V OUT
4
5
1
2
2 AND 5 -V OUT
6
3
3 +R/SENSE 6 -R/SENSE
4 Vcc IN
3 POWER GOOD
2 POWER GOOD INVERTED
J1-A
1 SIGNAL GROUND
(OUTPUT CONNECTORS)
HOUSING- MOLEX P/N: 39-01-2060
TERMINALS- MOLEX P/N: 39-00-0039
CRIMP TOOL MOLEX P/N: 11-01-0197
MATING HDWR:
4
5
1
2
1 AND 4 +V OUT
HOUSING- MOLEX P/N: 39-01-2060
2 AND 5 -V OUT
6
3
3 +R/SENSE 6 -R/SENSE
TERMINALS- MOLEX P/N: 39-00-0039
CRIMP TOOL MOLEX P/N: 11-01-0197
J1-A-PIN1
FinQPAC
+ 0UT
P2 REMOTE SENSE TRIM/SC & POWER GOOD
7
6
5
OUTPUT ADJUST
- OUT
4
3
2
1
+SENSE
-SENSE
TRIM
Vcc IN
POWER GOOD
POWER GOOD INVERTED
SIGNAL GROUND
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0073
P2-PIN1
TERMINALS- MOLEX P/N: 39-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
Note:
1. All ConverterPACs except the FinQPAC occupy one slot. The FinQPAC occupies two slots.
2. New output studs have been installed on the ConverterPACs and are 1/8th inch longer. Refer to pages 12 and 19 for more information.
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 9
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
PFC MegaPAC-EL and PFC MegaPAC-HPEL “Quick Install”
Instructions (For Mechanical Drawing, see page 12)
Mounting the PFC MegaPAC-EL and PFC MegaPAC-HPEL
* 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 20 lb-in.
* Maintain 2" (5,1cm) clearance at either end for airflow.
Input Connections
Input Power J9
* Apply input AC power to terminal block J9 using a pressure screw terminal.
* Strip length of AC power conductors to be 0.35 inches.
* Maximum torque is 4.4 lb-in.
* Place a fuse or circuit breaker in the input line for safety reasons.
* Use a maximum wire size of 14 AWG with soldered terminals.
* 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.
Output Connections
Power Connections
Installing ring lugs and/or bus bars on output studs:
* The upper stud is Positive and the lower stud is the Return.
* Newer outputs studs are 1/8th inch longer. See pgs. 12 and 19 for more information.
* Remove nut.
* Place ring lug over output stud.
* Replace and tighten outer nut to a maximum torque of 45 lb-in. Do Not OverTighten Nuts.
* Verify all output nuts are properly installed before turning on supply.
Installing power connectors on DualQPACs (J1A and J1B):
* Use Molex mating receptacle #39-01-2060 with #39-00-0039 terminals provided.
* Pins 1 and 4 are Positive, while pins 2 and 5 are the Return.
* Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197.
Sense Connections
Note: Newer power supplies have the Autosense feature. For these units, if Remote
Sense connections are not made or needed, no Local Sense selection is necessary - simply 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.
Input Panel Connectors
L1
L2
INPUTS
115/230 VAC
47 TO 500 Hz
300VDC
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
LABEL NO: 94-00046 REV B
Single Output QPAC
+ Vout
J2 Pin 1
Vtrim Pot Adjust (Option)
- Vout
J3 pin 1 (DC OK Option)
DualQPAC Output Connector
J1-B
(OUTPUT CONNECTORS)
1 AND 4 +V OUT
4
5
1
2
6
3
3 +R/SENSE 6 -R/SENSE
J1-A
(OUTPUT CONNECTORS)
2 AND 5 -V OUT
1 AND 4 +V OUT
4
5
1
2
2 AND 5 -V OUT
6
3
3 +R/SENSE 6 -R/SENSE
J2 Sense Connector
J2
1
2
3
Pin
J2-1 Trim Pin Access
J2-2 +Sense
J3-3 -Sense
P2 Sense Connector
Sense Connector J2 (and P2 for the FinQPAC):
* Sense connections do not have to be made if either the Local Sense option was
ordered (older units) or if Autosense is present (see above note on Autosense.)
* Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided.
* J2-2 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.
* Verify that Sense lines are not cross-connected before applying input power.
* For the FinQPAC, P2-7 is the + Sense and P2-6 is the -Sense.
* 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.
Pg 10
Vicor 800-735-6200
Westcor Division 408-522-5280
7
6
5
4
3
2
1
Applications Engineering 800-927-9474
+SENSE
-SENSE
TRIM
Vcc IN
POWER GOOD
POWER GOOD INVERTED
SIGNAL GROUND
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Sense Connections on DualQPACs:
*
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 FinQPAC) or the J1A and J1B connectors.
*
If using J2 or P2 connector, see instructions on page 10.
*
On J1A 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
provided.
*
Attach terminals to 18-24 AWG twisted pair wire using Molex
tool #11-01-0197.
*
Verify that Sense lines are not cross-connected before applying
input power.
DualQPAC Sense Connector
Trim Pin Connection J2 for QPACs (and P2 for FinQPAC)
* The Trim J2 connection should only be made if the Trim option has not been
installed. (A “T” or an “F” in the ConverterPAC part number means the Trim
option is installed; e.g. M5V/40AT.)
* Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals
provided.
* Attach terminals to 22-24 AWG stranded wire using Molex tool #11-01-0208.
* J2-1 provides Trim access.
* For the FinQPAC, 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.
Trim Pin Connection J2 for DualQPACs
* The Trim J2 connection should only be made if the Trim option has not been
installed.
* J2-7 is Trim B and J2-6 is Trim A.
* Use Molex mating receptacle #39-01-0073 and #39-00-0031 terminals provided.
* Attach terminals to 22-28 AWG twisted pair wire using Molex tool #570055000.
.
DC OK (Power Good) Connection J3 (and P2 for FinQPAC)
* 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 FinQPAC, 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
* J10-1 to 8 are Enable/Disable for slots 1-8.
* J10-9 is Vcc, J10-10 is Signal Ground, J10-11 is AC Power OK, and J10-12 is
General Shutdown.
* Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197.
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
(OUTPUT CONNECTORS)
J1-B
1 AND 4 +V OUT
4
5
1
2
2 AND 5 -V OUT
6
3
3 +R/SENSE 6 -R/SENSE
J1-A
(OUTPUT CONNECTORS)
1 AND 4 +V OUT
4
5
1
2
2 AND 5 -V OUT
6
3
3 +R/SENSE 6 -R/SENSE
J2 Trim Pin Connector
J2
Pin
J2-1 Trim Pin Access
J2-2 +Sense
J3-3 -Sense
1
2
3
P2 Trim Pin Connector
7
6
5
TRIM TOP B
4
3
2
1
Vcc IN
POWER GOOD
TRIM BOT A
N/C
POWER GOOD INVERTED
SIGNAL GROUND
Trim Pin Connector For DualQPAC
J2-PIN1
7
6
5
TRIM TOP B
4
3
2
1
Vcc IN
POWER GOOD
TRIM BOT A
N/C
POWER GOOD INVERTED
SIGNAL GROUND
DC OK (Power Good)
J3
Pin
J3-4
J3-3
J3-2
J3-1
4
3
2
1
Vcc
Power Good
Power Good Inverted
Signal Ground
P2 DC OK Connector
+SENSE
7
6
5
-SENSE
TRIM
Vcc IN
POWER GOOD
4
3
2
1
POWER GOOD INVERTED
SIGNAL GROUND
J10
5
6
1
2
3
4
7
8
9
10 11 12
J10 INTERFACE
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
Applications Engineering 800-927-9474
J10-7
J10-8
J10-9
J10-10
J10-11
J10-12
E/D-7
E/D-8
Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
Pg. 11
Pg 12
Vicor 800-735-6200
47 TO 500 Hz
LABEL NO: 94-00046 REV B
Westcor Division 408-522-5280
L2
Applications Engineering 800-927-9474
ORIGINAL
FLANGED
NUT
RE-DESIGNED
OUTPUT PANEL AND STUDS
LABEL NO: 94-00046 REV B
.25 [6.35]
BRASS
INSERT
2.75 [69.85]
(T0P AND BOTH SIDES)
CUSTOMER MOUNTING HOLES (16X)
M4 OR #8-32 THREAD MAXIMUM
SCREW PENETRATION .150 [4.00 MM]
FROM OUTSIDE SURFACE.
10.01 [254.25]
(ORIGINAL LENGTH)
15.50 [393.63]
10.01 [254.25]
(RE-DESIGNED LENGTH)
15.62 [396.81]
10.01 [254.25]
1.40 [35.56]
.73 [18.52]
1.46 [37.03]
1/4 - 20 SERRATED FLANGED
NUT ZINC PLATED STEEL
WITH OPTIONAL BUSS BARS
.41 [10.35]
ORIGINAL STUD
AND PANEL
.53 [13.39]
RE-DESIGNED STUD
AND PANEL
NOTE: EITHER THE ORIGINAL OR RE-DESIGNED OUTPUT STUD AND PANEL COMBINATION
MAY BE PRESENT. THE NEW OUTPUT PANEL HAS A BRASS INSERT AND THE
STUD IS 1/8 INCH LONGER.
2.92 [74.17]
.470 [11.94]
5.100 [129.54]
.21 [5.33]
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
FAN
(DIRECTION OF AIR
FLOW OPTIONAL)
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
300VDC
47 TO 500 Hz
L2
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
INPUTS
115/230 VAC
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1
300VDC
INPUT CONNECTIONS
L1
INPUTS
115/230 VAC
14 AWG WIRE
3.37 [85.60]
2.92 [74.17]
.21 [5.33]
MATING HDWR:
HOUSING-MOLEX P/N: 39-01-2120.
TERMINALS-MOLEX P/N: 39-00-0039
CRIMP TOOL-MOLEX P/N: 11-01-0122
L1
CLAMPING SCREWS
6.04 [153.42]
9 10 11 12
6
8
5
7
4
3
2
1
J10
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
E/D-7
E/D-8
Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
J10 INTERFACE
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
J10-7
J10-8
J10-9
J10-1O
J10-11
J10-12
15.18 [385.69]
2.77 [70.23]
3.28 [83.19]
.47 [11.94]
5.10 (129.5 MM)
7 SP. @ .7285
(18.5 MM)
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
PFC MegaPAC-EL and PFC MegaPAC-HPEL Mechanical Drawing
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
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 lb-in. The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N 32-0058-0, 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) are the other Hot connections. For Input DC power, L2 is (+) and L1 is (-).
A fault clearing device, such as a fuse or circuit breaker with a maximum 15A rating at the power supply input is
required for safety agency compliance. It should be sized to handle the start-up inrush current of 17A at 115 Vac
and 34A at 230 Vac.
L1
L1
L2
INPUTS
115/230 VAC
47 TO 500 Hz
300VDC
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
L2
INPUTS
115/230 VAC
47 TO 500 Hz
300VDC
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
LABEL NO: 94-00046 REV B
J10
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
LABEL NO: 94-00046 REV B
INPUT CONNECTIONS
J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1
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. J1A
pins 1 and 4 are the +Output, and J1A 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 J1A/J1B 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 impedance 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.
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-EL and PFC MegaPAC-HPEL are powered up. Regardless of the output polarity
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 J1A/J1B
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
5
6
1
2
3
4
7
8
9
10 11 12
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
J10-7
J10-8
J10-9
J10-10
J10-11
J10-12
E/D-7
E/D-8
Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
Figure 4. Interface Connector
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 13
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
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 DualQPACs, both outputs are sequenced. In parallel arrays, 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 circuited 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.
J10
9
Enable/Disable Output 1
1
0
TTL "1" (OFF)
TTL "0" (ON)
General Shutdown
Signal Ground
PFC MegaPAC-EL
Vcc
1
12
10
Figure 5: Enable/Disable and General Shutdown
Enable/Disable control of 2nd Generation Module Arrays
When using the Enable/Disable function on an output that consists of two or more 2nd Gen modules, it 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 L3.3V/40A
2
4
6
Slot# 7 L5V/40A
MegaPAC
Power Factor Corrected
J1
123
Slot# 6 PFL48V/12.5AJS1
10
Slot# 5
Slot# 4 PFL48V/12.5AJS1
Slot# 3
Slot# 2 PFL48V/12.5AN
Slot# 1
Figure 6. Enable/Disable Control of 2nd Gen 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 from an electromechanical switch or relay, a capacitor should be
connected to eliminate the effects of switch bounce.
Pg 14
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
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 >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.
J10
+5V
2.49K
10K
PN2222
11 AC Power OK
10 Signal Ground
Figure 7: AC OK Power Fail
Auxiliary Vcc +5V/0.3A (J10-9)
The Vcc on J10-9 is an auxiliary 5V regulated power source (see Figure 8 and Connector Pin Identification on
page 9). It is +5 Vdc +/–5% with respect to Signal Ground and can supply 300 mA maximum. It is short-circuitproof, 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 Ground on J10-10 must also be
connected to the J3-1 Signal Ground pin of the ConverterPAC.
78M05
J10
9 Auxiliary Vcc
+5V/300 mA
0.1 µF
10 Signal Ground
Figure 8. Auxiliary Vcc
Power Good (J3-3)
The optional Power Good signal on J3-3 is referenced to Signal Ground on J3-1, and indicates the status of the output voltage. This signal is asserted a TTL “1” when the output voltage is above 95% of nominal. It is a TTL “0”
when the output voltage is below 85% of nominal. If the Trim option is 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
2.49K
2.49K
2N2222
10K
J3
4
Vcc In
3
Power Good
2
1
Power Good Inverted
Signal Ground
Figure 9. Power Good and Vcc
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 reference point for the Power Good circuitry and is not the same as Earth Ground on input power connector J9.
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 15
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Vcc In (J3-4)
The Vcc In on J3-4 is an input that requires +5V either from 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 J34, then the J10 Signal Ground must be connected to Signal Ground on J3-1.
+Sense/–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 J2-3 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 DualQPACs, the +Sense pins are available on connectors designated as J2A-2 and J2B-2 for outputs A and B,
respectively. –Sense pins are on J2A-3 and J2B-3, respectively. These pins are also duplicated on the power connectors J1A and J1B.
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 or Remote) terminated to their respective output for the
unit to operate properly.
+P +Out
(Local Sense)
(Remote Sense)
+Sense
Load
Use 22-24 AWG
Twisted Pair Wires
-Sense
-P -Out
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 converter 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 measured 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 nominal, 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 pretrimmed at the factory if a nonstandard output voltage is requested. Standard 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.
Pg 16
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
OUTPUT MODULE
VI-200/VI-J00 ≥3.3V
VI-200/VI-J00 <3.3V
2nd Generation (Pre-Defined)
2nd Generation (User Defined)
Vref
2.50V
0.97V
1.23V
1.23V
RTH
10.0 kΩ
3.88kΩ
1.0 kΩ
Consult Factory
Use 22-24 AWG
Twisted Pair Wires
+P +Out
(Remote Sense)
R1
J2-2 +Sense
To Error
Amplifier
+ RTH R5
V1
V Ref
-
R8
R2
J2-1
R6
R3
Load
+
V2
R7
-
J2-3 -Sense
R4
-P -Out
Use 22-24 AWG Twisted Pair Wires
Figure 11. External Trim
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 calculated as follows:
V1= Vref + 10% = 2.75V
Given: Vref = 2.5V (see Table 1)
IR5 = (2.75V - Vref)/RTH = (2.75V - 2.5V)/10kΩ = 25µA
Setting the bottom limit:
VR6 = 2.5V - 10% = 2.25V
And since IR5 = IR6 = 25µA,
R6 = VR6/IR6= 2.25V/25µA = 90kΩ
V2 = V1 + VR6 = 2.75V + 2.25V = 5V
IR7 = V2/R7 = 5V/10kΩ = 500µA
IR8 = IR7 + IR6 = 525µA
VR8 = (Vnom +10%) - V2 = 13.2V - 5V = 8.2V
Given: Vnom = 12V
R8 = VR8/IR8 = 8.2V/525µA = 15.62kΩ
Using the above resistor combination, a 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
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 17
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Specifications (Typical at 25°C, nominal line and 75% load, unless otherwise specified)
Input Characteristics
Input Voltage
85-264 Vac, 47-500 Hz
100-380 Vdc
Power Factor
0.99 @ 115 Vac
0.95 @ 230 Vac
Inrush Current
33A pk @ 115 Vac; 65A pk @ 230 Vac
Ride Through Time
>20 ms at nominal line, full load
Power Fail
>3 ms warning
Conducted EMI
EN55022 Class B; FCC Class B
Surge Immunity
EN 61000-4-5 Installation Class 3, Performance Criteria B
(Temporary loss of output power may occur which is self recoverable)
Dielectric Withstand
Primary to Chassis GND = 2,121 Vdc
Primary to Secondary = 4,242 Vdc
Secondary to Chassis GND = 750 Vdc
Output Characteristics
Line/Load Regulation:
Ist Gen: ± 0.2% max.10% to full load
± 0.5% max. No load to 10% load
2nd Gen:± 0.20% max. to 0.3% max LL to HL, Full Load
2nd Gen: ± 0.1% No load to full load
Line Regulation*
Load Regulation*
1st Gen Setpoint Accuracy*
2nd Gen Setpoint Accuracy
1% for standard voltages; 2% for special or adjustable voltages
1% for standard voltages; 2% for special, adjustable voltages and 48 Vdc
outputs
Ripple and Noise
0.15% or 10 mV p-p, whichever is greater, 75% min. load;
Output Trim Range
10% -110% of nominal voltage 2nd Gen modules
50% -110% of nominal voltage 1st Gen modules
90% -110% of nominal voltage 1st Gen modules 10-15V
Overcurrent Trip Point
105-125% of full load capability of 1st Gen modules
115% typical of full load capability of 2nd Gen modules
Overvoltage Protection
115-135% on QPAC and FinQPAC
Efficiency
80% typical
Output Power
PFC MegaPAC-EL
1,600 W at 230 Vac;
1,200 W at 115 Vac+
PFC MegaPAC-HPEL
2,400 W at 230 Vac;
1,200 W at 115 Vac+
+ Note; Not to exceed an input current of 15A.
Environmental Characteristics
Pg 18
Storage Temperature
-40°C to 85°C
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
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Specifications (continued)
Operating Temperature**
-20°C to 40°C full power; -20°C to 60°C half power
Humidity
0 to 95% non-condensing
Safety Agency Approvals
TUV CUE
Standards: CSA-C22.2 No. 60950-00, UL 60950 3rd Edition, EN 60950:2000
CE Mark to the LVD, 73/23/EEC amended by 93/68/EEC
Product Weights (fully configured) PFC MegaPAC-EL
12.8 lbs (5,8 kgs)
Warranty
PFC MegaPAC-HPEL
13.1 lbs (6kgs)
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
FinQPAC 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 are 1/8" longer to allow for multiple
lugs. They are fully compatible with the original flanged nut ConverterPACs for use in parallel arrays. Other advantages 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.
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 19
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
PFC MegaPAC-HPEL Output Power Derating
Output Power vs. Input Voltage (VAC) (47-500Hz)
Output Power vs Input Voltage (Vac) (47-500 HZ)
2,400W @ 200 Vac
Output Power (Watts)
2400
2200
Derate at 12W/volt
Power Exceeded
2000
1800
1600
1400
Safe Operating Area
1200
1000
85
95
105 125 145 165 185 200 215 235 255 265
Input Voltage (Vac or Vdc)
(For VDC, 100V min applies)
Output Power vs. Input Voltage (VDC)
PFC MegaPAC-EL/HPEL Connector Kit (19-130040) Listing
(
g
g
)
ITEM
QTY
DESCRIPTION
1
1
HOUSING 12 POS.165 CTR W/LATCH
2
12
TERMINAL FEM CRIMP 18-24 AWG TIN
**
CRIMP TOOL FOR ITEM 2
3
8
HOUSING 7 POS.098 CTR L/PROFILE
4
8
HOUSING 4 POS.098 CTR L/PROFILE
5
94
TERM FEM CRIMP 22-18 AWG PH/BRNZ
**
CRIMP TOOL FOR ITEMS 3 AND 4
6
8
HOUSING 3 POS .1 CTRS W/LATCH
7
27
TERM FEM CRIMP 22-24 AWG SEL/GLD
**
CRIMP TOOL FOR ITEM 7
** ITEMS FOR REF ONLY (NOT INCLUDED IN KIT)
Pg 20
Vicor 800-735-6200
Westcor Division 408-522-5280
VENDOR # 1
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
Applications Engineering 800-927-9474
PART NO.
39-01-2120
39-00-0039
11-01-0197
39-01-0073
39-01-0043
39-01-0031
00-01-0197
50-57-9403
16-02-0103
11-01-0118
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
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" techniques typically utilize
shunt resistors or Hall 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 >100Amps. Hall Effect
devices measure magnetic fields generated by current flowing through a conductor and, although they dissipate no
power, they tend to be large and expensive.
D*
+S
Power Supply 1
24V@1kW
Yellow
-S
T1
Brown
-V1
T2
-V2
Power
Red
D*
+OUT
CSB02
-VOUT
+S
Power Supply 2
24V@1kW
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 circuit 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 currents 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 summing node. This allows current sharing between more
than two supplies by paralleling the T2 output of one
CSB circuit with the T1 output of the next CSB.
Please note: The CSB is not intended for use in Hotswap
Applications.
Vicor 800-735-6200
TRIM
-OUT
First developed by Westcor Engineering for paralleling
MegaPAC supplies, the Box-to-Box Current Share Board
or CSB allows two or more Vicor power supplies to current share by utilizing the inherent voltage drop produced
in the negative output return cable. This eliminates the
need for additional shunt resistors or expensive Hall
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.
Rev. 6/2004
+VOUT
+OUT
TRIM
White
Black
-S
-OUT
Figure 1. CSB Interconnect Example
Requirements:
1. For proper operation, the power supplies being paralleled should 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 provide from 5% to 1% accuracy.
3. -V1 and -V2 for all Box-to-Box circuits must be connected directly at the negative output power studs or terminals to achieve accurate current sharing.
4. D* can be added if redundancy is needed. If redundancy 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.
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 21
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Current Share Boards - Optional Feature (contd)
0.13" (3.3mm) Dia Non
Plated thru hole 4
places
1.74"
(44.2mm)
2
1
4
3
6
5
Molex CT43045F surface mountable
connector. .390" height above board.
1.500"
(38.1mm)
J1 Pinout
Pin
1
2
3
4
5
6
Description
P ow e r
T1
-V1
T2
-V2
No Connection
0.12"
(3.0mm)
0.12"
(3.0mm)
0.900"
(22.9mm)
1.14"
(29.0mm)
Figure 2. Mechanical Drawing
24.0" +/- 1.0"
Red, 22 AWG
Yellow, 22 AWG
P1
Brown, 22 AWG
White, 22 AWG
Black, 22 AWG
Po w e r
T1
-V1
T2
-V2
Figure 3. Cable Drawing
Specifications:
1. Power: 2-50Vdc at 5mA maximum.
2. Accuracy: +/- 1mV between -Vout connections.
3. Output current when not trimming up: +/- 1uA (VI-200/J00), +/-5uA (2nd Generation).
4. Use 4 non-plated through holes with standoffs for mounting.
5. CSB01 MUST be used for current sharing 1st Generation converters (VI-200/J00).
6. CSB02 MUST be used for current sharing 2nd Generation 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.
Pg 22
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Output Sequencing
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 example showing how this may be done.
* DC OK Option is not available for 1st Generation dual output DualQPACs
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 requirement is to configure the 5V QPAC with
+ Vout
the DC OK Option, which is indicated
J2 Pin 1
by a "D" designator in the QPAC's part
DC OK (Power Good)
number, located on the top surface of
Vtrim Pot Adjust (Option) J3
Pin
each QPAC above the +Vout. Any
4 J3-4 Vcc
QPAC that has the DC OK option will
- Vout
3 J3-3 Power Good
2 J3-2 Power Good Inverted
also have the 4 pin J3 DC OK connector
1 J3-1 Signal Ground
installed. To order a QPAC with the DC
OK option, please contact Westcor's
J3 pin 1 (DC OK Option)
Figure 2. J3 DC OK Connector
customer service department for assistance. The DC OK option monitors the
output voltage of a given ConverterPAC
and provides a TTL logic signal depending Figure 1. QPAC Pinout
on its output voltage.
1
2
3
4
5
6
7
8
6
12
5
11
4
10
3
9
2
8
1
7
L
L
1
2
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 5V QPAC and the Input
Interface Connector (J10) of a typical PFC MegaPAC-EL configuration. In this example, the 3.3V QPAC is located
in the slot #7 and the 5V QPAC (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 Vcc voltage properly applied to the 5V QPAC'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 5V QPAC's Power Good signal 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 5 show the startup and shutdown waveforms for the circuit shown in Figure 3.
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 23
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Output Sequencing (contd)
Channel #1: 5V Output
Channel #2: 3.3V Output
Channel #3: 5V DC OK signal
5V Output
3.3V Output
5V DC OK
Figure 4. Startup Waveforms
5V Output
3.3V Output
5V DC OK
Figure 5. Shutdown Waveforms
Pg 24
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Rev. 6/2004
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
Notes
Rev. 6/2004
Vicor 800-735-6200
Westcor Division 408-522-5280
Applications Engineering 800-927-9474
Pg. 25
PFC MegaPAC-EL/PFC MegaPAC-High Power Low Noise
VICOR GLOBAL OFFICES
USA
EUROPE
Vicor Corporation,
Corporate Headquarters
25 Frontage Road
Andover, MA 01810
Tel: 800-735-6200,
Tel: 978-470-2900
Fax: 978-475-6715
Vicor France
Tel: 33-1-3452-1830
Free Phone
France Only:
0800 419 419
Fax: 33-1-3452-2830
Email: vicorfr@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 Corporation
377 E. Butterfield Road
Suite 201
Lombard, IL 60148
Tel: 630-769-8780
Fax: 630-769-8782
Vicor Italy
Tel: +39-02-2247-2326
Free Phone Italy Only:
800-899-677
Fax: +39-02-2247-3166
Email: vicorit@vicr.com
Vicor U.K.
Tel: +44-1276-678-222
Free Phone UK Only:
0800-980-8427
Fax: +44-1276-681-269
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
Vicor, Westcor Division
560 Oakmead Parkway
Sunnyvale, CA 94085
Tel: 408-522-5280
Fax: 408-774-5555
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 DCDC 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
MEGAPAC FAMILY:
• PFC MegaPAC
• PFC MegaPAC (Low Noise/High Power)
• 4kW MegaPAC
• PFC MegaPAC-EL (Low Noise)
• Mini MegaPAC
• 4kW MegaPAC-EL (Low Noise)
• PFC Mini
• PFC Mini-EL
• PFC MegaPAC (High Power)
• Autoranging MegaPAC
• ConverterPACs
OTHERS:
• FlatPAC-EN
Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. No license is granted 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 support systems, wherein a failure or malfunction could result in injury or death. All sales are subject to Vicor's Terms and Conditions of Sale, which are
available upon request.
Specifications are subject to change without notice. The latest data is available on the Vicor website at vicorpower.com
_________________________________________________________________________________________________
www.vicorpower.com
© Vicor Corporation 2004