3 Phase MegaPAC™ AC-DC Switcher Operator’s Manual and “Quick Install” Instructions wer www.vicr.com/westcor.html Rev.
3 Phase MegaPAC Owner’s Manual 3 Phase MegaPAC™ AC-DC Switcher 3 Phase MegaPAC “Quick Install” Instructions Mounting the 3 Phase MegaPAC * The 3 Phases MegaPAC can be mounted on any of four sides. * Use #8-32 or M4 mounting screws. Maximum penetration should not exceed 0.15" (3,8mm). * A minimum of 2" (5,1cm) clearance must be maintained at either end of the supply in order to insure proper airflow and cooling.
Phase MegaPAC Owner’s Manual Sense Connections on DualQPACs: * Using J1A, 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 stranded wire using Molex tool #11-010197. * Attach opposite end of Sense lines to point where regulation is desired. * Verify that Sense lines are not cross-connected before applying input power.
3 Phase MegaPAC Owner’s Manual Input Connections Input Power J1 * Input AC power is applied to terminal block J1 using mating receptacle AMP #54483-4 with #53892-4 crimp or #54329-1 solder terminals provided. * Use size 10 AWG wire with soldered terminals. * A fuse or circuit breaker is recommended in the input line. Input Connectors J1 L1 L2 L3 Interface Connections J10 * Use 25 pin D-sub connector provided. * J10-7 to 11 and J10-20 to 24 are Enable/Disable for slots 1-10.
3 Phase MegaPAC Owner’s Manual 3 Phase MegaPAC™ AC-DC Switcher Overview The 3 Phase MegaPAC is a field-configurable, single or multiple output switcher, providing up to 2000W of output power and up to 20 regulated, fully isolated outputs. It achieves power density of 4.6 watts per cubic inch. A modular package design allows the user to instantly configure efficient, off-line power supplies. This is accomplished by inserting up to 10 ConverterPAC output assemblies into a 3-Phase-front-end chassis.
3 Phase MegaPAC Owner’s Manual Technical Description A 3 Phase MegaPAC is configured by installing ConverterPAC assemblies into a 3-Phase-front-end chassis. The chassis takes AC input power and performs filtering and rectification functions. The ConverterPACs plug into a high-voltage backplane and provide low-noise, independently regulated and fully isolated outputs. Input AC mains voltage (L1, L2, L3 and GND) is applied to an agency-approved mating plug.
3 Phase MegaPAC Owner’s Manual ConverterPAC Functional Description ConverterPACs are the family of slide-in output assemblies used in MegaPAC power supplies. ConverterPACs are interchangeable within a MegaPAC so they can be added, moved, or changed as necessary. They are also interchangeable between different AC input MegaPAC chassis. A ConverterPAC removed from a Mini MegaPAC could be used in a 4kW MegaPAC, for example.
3 Phase MegaPAC Owner’s Manual BatPAC The BatPAC output assembly consists of a VI-200 BatMod current source that converts the unregulated high voltage bus to the desired regulated output voltage. The converter is fused with a PCTron, DC-rated, fast-acting fuse. The BatPAC is a 200 watt programmable current source that can be configured as a battery charger. Overvoltage and overtemperature protection are not available.
3 Phase MegaPAC Owner’s Manual Configuring and Reconfiguring MegaPACs ConverterPACs can be easily added, replaced, or moved by sliding the assemblies in or out of a MegaPAC chassis. Most ConverterPACs are driver ModuPACs and can be inserted into any available slot. For outputs greater than 200 watts, a driver ModuPAC and one or more booster ModuPACs will be used.
3 Phase MegaPAC Owner’s Manual Input Connectors J1 L1 L2 L3 Figure 10. Input Panel Connector 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.
3 Phase MegaPAC Owner’s Manual Enable/Disable and General Shutdown (GSD) The Enable/Disable control lines allow ConverterPAC outputs to be sequenced either on or off. For DualPACs, both outputs are sequenced. In parallel arrays, only the driver ConverterPAC needs to be sequenced. The GSD control line on J10-5 allows simultaneous shutdown of all ConverterPAC outputs. An internal jumper selects polarity, either active-high or active-low.
3 Phase MegaPAC Owner’s Manual AC Power Fail (J10-19) J10-19 is the inverse of AC Power OK, and goes to a TTL “1” when the input AC power is not OK. It is capable of sourcing 10 mA maximum. The fan out is 20. Phase Fail (Input Overcurrent) (J10-14) J10-14 is a TTL level active-high signal that is asserted when the peak input current reaches 30A due to the loss of an input phase, or severe line imbalance. This occurs when one input phase is lost with approximately 1400W output loading.
3 Phase MegaPAC Owner’s Manual ConverterPAC 2.49K 2.49K 10K J3 4 Vcc In 3 Power Good 2 Power Good Inverted 2N2222 1 Signal Ground Figure 15. Power Good and 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.
3 Phase MegaPAC Owner’s Manual External Trim (J2-1) Output voltage can be trimmed using an optional factory-installed trim potentiometer or with the Trim pin (see Figure 18). 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.
3 Phase MegaPAC Owner’s Manual Example: ±10% Trim adjust on a 12V nominal output. Figure 17 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 2) 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.
3 Phase MegaPAC Owner’s Manual Mechanical Considerations The 3 Phase MegaPAC can be mounted on any of four surfaces using standard 8-32/M4 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.
3 Phase MegaPAC Owner’s Manual ConverterPAC Output and Connector Pin Identification ModuPAC JuniorPAC RAMPAC Sense Connector + Vout Remote Sense Output Adjust Pin 1 Trim Pin Access 2 +Sense 3 -Sense 1 2 3 - Vout Molex #50-57-9403 housing, using #16-02-0103 terminals and 22-24 AWG stranded wire. Use Molex tool #11-01-0208.
3 Phase MegaPAC Owner’s Manual 3 Phase MegaPAC Mechanical Drawings TOP VIEW - EXTENDED LENGTH TOP VIEW - REGULAR LENGTH 2.25 (57,2mm) DO NOT LOOSEN OR TIGHTEN INNER NUTS .50 (12,7mm) BOTTOM SIDE 4 MOUNTING HOLES EACH SURFACE (M4/#8-32, .15 (3,8mm) MAX. PENETRATION) DO NOT LOOSEN OR TIGHTEN INNER NUTS .50 (12,7mm) (BOTTOM SIDE) 5.10 (129,5mm) (TOP SIDE) 7.50 (190,5mm) 1/4 - 20 ZINC PLATED STEEL, SERRATED FLANGED NUTS 45 LB-IN MAX. 6.50 (165,1mm) (BOTTOM SIDE) 7.50 (190,5mm) 6.
3 Phase MegaPAC Owner’s Manual Output Power Derating Rev. 1/99 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 978-749-3524 or -3525 Pg.
3 Phase MegaPAC Owner’s Manual Specifications Input Characteristics Input Voltage 208/240 Vac, 3 Phase, 4 Wire 180-264 Vac, 1 Phase (47-500Hz) 260-380 Vdc Power Factor .92 (3 Phase operation) Line Regulation 0.2% max.
3 Phase MegaPAC Owner’s Manual Part Numbering PFC Mini PMx1-x2x3-xxx x1 x2 x3 xxx Number of outputs Number of VI-200 and VI-J00 modules Number of VI-900 and VI-800 modules Sequential number assigned by Westcor PFC MegaPAC M P x A - 7 x B xxx e g. MP 5- 7 8143 xA xB xxx No. of outputs No. of modules Assigned by Westcor A/R MegaPAC M P x A - 9 x B xxx e g. MP 5- 9 8143 xA xB xxx No. of outputs No. of modules Assigned by Westcor Mini MegaPAC M M x A - 1 x B x xx e g. MM4- 1 411 2 xA xB xxx No.
3 Phase MegaPAC Owner’s Manual Notes Pg. 22 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 978-749-3524 or -3525 Rev.
3 Phase MegaPAC Owner’s Manual Notes Rev. 1/99 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 978-749-3524 or -3525 Pg.
Vicor Corporation, Corp. Headquarters 25 Frontage Road Andover, MA 01810 Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Vicor Corporation 377 E.
