Specifications

ManualsBrandsVICOR ManualsComputer equipment3 Phase MegaPAC

1-800-927-9474

20-1

The MegaPAC

™

Family

AC-DC, DC-DC Switching Power Supplies

Overview

The MegaPAC family is a line of field configurable switching power supplies that leverage

Vicor’s DC-DC converters to provide maximum flexibility. Developing a custom power supply

is as easy as selecting a MegaPAC chassis and sliding in the appropriate output assemblies,

called ConverterPACs. With five different chassis, five different ConverterPAC styles and

thousands of voltage and power combinations, there is a MegaPAC to fit almost any need.

Designing a customized power supply begins with selecting a chassis from the MegaPAC

family; the PFC MegaPAC, Autoranging MegaPAC, Mini MegaPAC, Three Phase MegaPAC or

DC MegaPAC. One or more can accept input voltages from 85 to 264Vac, 208/240 three phase,

or 10 to 380Vdc. Maximum output power ranges up to 4000W, and all five are fan cooled.

Standard features include output sequencing, general shutdown, AC OK and overcurrent

protection.

Customized design continues by selecting the ConverterPACs that meet your requirements. Each

ConverterPAC can be configured to provide one or two separate output voltages and up to 400W

of power. Multiple ConverterPACs can be connected in parallel to achieve higher power levels.

Best of all, ConverterPACs can be added or replaced with the turn of just one screw.

MegaPAC Family Products

Power Factor Corrected (PFC) MegaPAC

Technical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

Output Power Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5

Autoranging/Mini MegaPAC

Technical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6

Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7

Three Phase MegaPAC

Technical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9

Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10

DC MegaPAC

Technical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Input Voltage Range and Vin OK Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16

ConverterPAC Functional Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16

MegaPAC Mechanical Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19

MegaPAC Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20

ConverterPAC Derating Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Summary of content (22 pages)

PAGE 1
20 The MegaPAC™ Family AC-DC, DC-DC Switching Power Supplies Overview The MegaPAC family is a line of field configurable switching power supplies that leverage Vicor’s DC-DC converters to provide maximum flexibility. Developing a custom power supply is as easy as selecting a MegaPAC chassis and sliding in the appropriate output assemblies, called ConverterPACs.
PAGE 2
Applications Manual PFC MegaPAC Technical Description The PFC MegaPAC chassis consists of an off-line single phase, power factor corrected front end, EMC filter, cooling fan, customer interface and associated housekeeping circuits. Input AC mains voltage (L1, L2/N and GND) is applied to a terminal block. The input current is passed through an EMC filter designed to meet conducted noise limit “B” specifications of FCC Part 15 and VDE 0871 and EN55022 level “B”.
PAGE 3
MegaPAC™ Family AC-DC, DC-DC Switchers PFC MegaPAC 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 12 AWG. The maximum torque recommended is 10 in-lbs. J9-1 (GND) is Earth Ground for safety; J9-2 (L2) is the Hot connection; J9-3 (L1/N) is the other Hot or input Neutral connection. Figure 1.
PAGE 4
Applications Manual PFC Interface Connections (cont) Signal Ground (J10-10) Signal Ground on J10-10 is an isolated secondary ground reference for all J10 interfacing signals, and for ModuPAC output status signals such as Power Good. This is not the same as Earth Ground on input power connector J9. Enable/Disable (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.
PAGE 5
MegaPAC™ Family AC-DC, DC-DC Switchers PFC Interface Connections (cont) Auxiliary Vcc +5V/0.3A (J10-9) The Vcc on J10-9 is an auxiliary 5V regulated power source. It is +5Vdc +/–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.
PAGE 6
Applications Manual Autoranging MegaPAC/Mini MegaPAC Technical Description The MegaPAC and Mini MegaPAC chassis consist of an off-line single phase AC front end, EMC filter, cooling fan, customer interface and associated housekeeping circuits. Input AC mains voltage (L1, L2/N and GND) is applied to a terminal block. The input current is passed through an EMC filter designed to meet conducted noise limit “A” specifications of FCC Part 15 and VDE 0871.
PAGE 7
MegaPAC™ Family AC-DC, DC-DC Switchers Autoranging MegaPAC/Mini MegaPAC Interface Connections 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 associated for an output to come up when measured from release of the Enable/Disable pin is 5-10 ms.
PAGE 8
Applications Manual Autoranging MegaPAC/Mini MegaPAC Interface Connections (cont) Figure 10. Enable/Disable General Shutdown 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.
PAGE 9
MegaPAC™ Family AC-DC, DC-DC Switchers Autoranging MegaPAC/Mini MegaPAC Interface Connections (cont) Vcc (J3-1) The Vcc on J3-1 is an input that requires +5V either from the Auxiliary Vcc on J10-9, or from another source. Input current to this pin is limited by an internal resistor to 3 mA. If the Auxiliary Vcc on J10-9 is connected to Vcc on J3-1, then Signal Ground J10-10 must also be connected to Signal Ground on J3-4.
PAGE 10
Applications Manual Three Phase MegaPAC Technical Description (cont) Upon power-up, all outputs are first disabled to limit the inrush current, and to allow the unregulated 300Vdc to reach correct operating levels for ConverterPAC assemblies. The internal housekeeping supply comes up within 500 ms after input power is applied, at which time the AC Power OK signal asserts to a TTL “1,” indicating that the input power is OK.
PAGE 11
MegaPAC™ Family AC-DC, DC-DC Switchers Three Phase MegaPAC Interface Connections (cont) For standard Three Phase MegaPACs, the Enable/Disable controls are configured as active-high with internal pull-up; outputs are enabled when these pins are open-circuited or allowed to exceed 4.5V with respect to Signal Ground. Outputs are disabled when the Enable/Disable control lines are pulled low to less than 0.7V.
PAGE 12
Applications Manual Three Phase MegaPAC Interface Connections (cont) Figure 15. Analog Temperature and Overtemperature Warning J10 MC34074 100 + 4.99K 4 Analog Temperature 4.99K 100K 4.99K + Vref +5V 3 Overtemperature Warning 1, 2, 12, 15 Signal Ground LM393 Overtemperature Shutdown If the inlet ambient air temperature exceeds the following factory set levels, then all outputs are disabled. For standard units the shutdown trip point is between 70˚C to 81˚C.
PAGE 13
MegaPAC™ Family AC-DC, DC-DC Switchers DC MegaPAC Technical Description The DC MegaPAC chassis consists of an EMC filter, cooling fan, customer interface and associated housekeeping circuits. Input DC voltage (+Vin, –Vin and GND) is applied to the input connectors. The input current is passed through an EMC filter designed to meet British Telecom specifications. At start-up, inrush current is limited by a thermistor.
PAGE 14
Applications Manual DC MegaPAC Interface Connections (cont) of 42V), a fast-blow fuse of 50 Amps is recommended. Start-up inrush current is limited by a 10Ω thermistor and in most cases will be less than nominal line current during operation. Start-up inrush current can be calculated by I = MaxVin/10 (where MaxVin is the maximum operating voltage, see Table 1, page 20-16). Example: for a nominal 48V input, the maximum operating voltage is 60V, therefore, I = 60V/10 = 6 Amps. Figure 19.
PAGE 15
MegaPAC™ Family AC-DC, DC-DC Switchers DC MegaPAC Interface Connections (cont) Input Power OK (J10-18) This is an active high TTL compatible signal on pin J10-18, and provides a status indication of the DC input power. It is capable of sinking 20 mA maximum. This signal switches to a TTL “1” when Vin voltage is within specification. See Table 1, page 20-16 for specifications.
PAGE 16
Applications Manual DC MegaPAC Input Voltage Range and Vin OK Limits Table 1. Code 0 1 W 2 3 N 4 Operating Range Nominal Low High Vdc Line Line 12V 10V 20V 24V 21V 32V 24V Wide 18V 36V 36V 21V 56V 48V 42V 60V 48V Wide 36V 76V 72V 55V 100V Vin OK Trigger Low Line High Line Cut off Cut off 6V to 10V 20V to 23V 16V to 21V 32V to 36V 12V to 18V 36V to 41V 11V to 21V 56V to 63V 34V to 42V 60V to 68V 23V to 36V 76V to 86V 40V to 55V 100V to 112V* *Do not apply greater than 100V to the input of the DC MegaPAC.
PAGE 17
MegaPAC™ Family AC-DC, DC-DC Switchers ConverterPAC Functional Descriptions (cont) The JuniorPAC contains output overcurrent protection which recovers automatically when the overcurrent condition is removed. Overvoltage and overtemperature protection are not available. DualPAC This output assembly consists of two VI-J00 DC-DC converters that convert the unregulated high voltage bus to the desired regulated output voltages. The assembly is fused with a single PC-Tron 3A fast-acting fuse.
PAGE 18
Applications Manual ConverterPAC Functional Descriptions (cont) 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. It is capable of sinking 20 mA maximum when 5V is used as Vcc. 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.
PAGE 19
MegaPAC™ Family AC-DC, DC-DC Switchers ConverterPAC Functional Descriptions (cont) Figure 23. Sense Leads (Local Sense) +P +Out (Remote Sense) J2-2 +Sense Load J2-3 -Sense -P -Out Use 20-22 AWG Twisted Pair Wires Trim (J2) The Trim pin on J2-1 may be used to control the output voltage. It is referenced to the –Sense pin on J2-3. For DualPACs, the Trim pins are available on connectors designated as J2A-1 and J2B-1 for outputs A and B, respectively.
PAGE 20
Applications Manual MegaPAC Mechanical Considerations (cont) Avoid excessive bending of output power cables after they are connected to the MegaPAC. For high-current outputs, use cable-ties to support heavy cables to minimize mechanical stress on output studs. Be careful to not short-out to neighboring output studs. The MegaPAC is supplied with serrated, flanged hex-nuts on all output studs, therefore, Loc-tite® or lock washers are not required. The maximum torque recommended on flanged nuts is 45 in.
PAGE 21
MegaPAC™ Family AC-DC, DC-DC Switchers ConverterPAC Derating Curves Figure 25. Autoranging/Mini/DC/3-Phase MegaPAC Thermal Derating Curve (5V ConverterPACs) ModuPAC, BatPAC 200 Load Power (Watts) 175 150 125 75W Max. @ 65˚C RAMPAC, DualPAC, JPAC 100 75 37.5W Max. @ 65˚C 50 25 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (˚C) Autoranging/Mini/DC/3-Phase MegaPAC Thermal Derating Curve (12-95V ConverterPACs) Figure 26.
PAGE 22
Applications Manual ConverterPAC Derating Curves (cont) PFC MegaPAC Thermal Derating Curve (5V ConverterPACs) Figure 27. ModuPAC, BatPAC 200 175 Load Power (Watts) 150 125 RAMPAC, DualPAC, JPAC 100 75W Max. @ 60˚C 75 37.5W Max. @ 60˚C 50 25 0 5 10 15 20 25 30 35 40 45 50 55 60 Ambient Temperature (˚C) PFC MegaPAC Thermal Derating Curve (12-48V ConverterPACs) Figure 28. ModuPAC, BatPAC 200 Load Power (Watts) 175 150 100W Max. @ 60˚C 125 RAMPAC, DualPAC, JPAC 100 50W Max.