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.
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...
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.
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.
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.
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.
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.
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
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
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
