PFC MegaPAC Design Guide PFC MegaPAC™ Power Factor Corrected AC-DC Switchers Design Guide and “Quick Install” Instructions www.vicorpower.com Rev.
PFC MegaPAC Design Guide TABLE OF CONTENT Overview of Product...........................................................................................................................3 Mechanical Considerations.................................................................................................................4 MegaPAC Do’s and Don’ts.................................................................................................................4 Technical Description..........................
PFC MegaPAC Design Guide PFC MegaPAC™ Power Factor Corrected AC-DC Switchers Overview The PFC MegaPAC family of supplies combine power factor correction (PFC) with the inherent configurability of all Westcor MegaPAC products. This design guide covers 4 model variations: 1. PFC MegaPAC 1600W max, standard chassis 2. PFC MegaPAC MI 1600W max, rugged COTS chassis 3. PFC MegaPAC High Power 2400W max, standard chassis 4.
PFC MegaPAC Design Guide Mechanical Considerations The PFC MegaPAC can be mounted on any of four surfaces using standard 8-32 or 4mm screws. The chassis comes with four mounting points on each surface; maximum allowable torque is 5.5 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 Design Guide Technical Description The PFC MegaPAC chassis consists of an off-line single phase, power-factor-corrected front end, EMI filter, cooling fan, customer interface and associated housekeeping circuits. Input AC mains voltage (L1, L2 and GND) is applied to a terminal block. The input current is passed through an EMI filter designed to meet conducted noise limit “B” specifications of FCC Part 15, VDE 0871, and EN55022 class A At start-up, inrush current is limited by a PTC thermistor.
PFC MegaPAC Design Guide 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. (Currently, two exceptions are the FinPACs which can only be used in the high power chassis and the UniPACs which can only be used in the 4kW MegaPAC.
PFC MegaPAC Design Guide ConverterPAC Functional Description (See ConverterPAC Datasheet and/or Design Guide for complete information on all ConverterPACs.) ConverterPACs are the family of slide-in output assemblies used in MegaPAC power supplies. Most ConverterPACs of the same length are interchangeable within a MegaPAC and between different AC input MegaPAC chassis (Exceptions are the FinPAC and UniPAC). They can be added, moved, or changed as necessary.
PFC MegaPAC Design Guide ConverterPAC Functional Description (See ConverterPAC Datasheet and/or Design Guide for complete information on all ConverterPACs.) Continued FlexPAC The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the high voltage bus to the desired output voltage. Each FlexPAC output can be manually trimmed from 2V to 25V and supports up to 5 amps with a maximum output power of 50W per output.
PFC MegaPAC Design Guide Part Numbering PFC MegaPAC Mpaa-7bcccc-v-xx p = P for standard chassis. p = X for high power chassis aa = number of outputs b = number of DC-DC modules and FlexPACs cccccc = customer specific configuration code v = optional revision code and may be blank.
PFC MegaPAC Design Guide ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC ModuPAC JuniorPAC RAMPAC J2 (REMOTE SENSE) + V0UT J2-PIN1 OUTPUT ADJUST 1 2 3 MATING HDWR: TRIM PIN ACCESS HOUSING- MOLEX P/N: 50-57-9403 + SENSE TERMINALS- MOLEX P/N: 16-02-0103 CRIMP TOOL MOLEX P/N: 11-01-0208 - SENSE - VOUT MATING HDWR: J3 DC OK (POWER GOOD) J3-PIN1 DualPAC J1-B-PIN1 J2-B-PIN1 OUTPUT ADJ.
PFC MegaPAC Design Guide ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC BatPAC + V0UT J2 (BATPAC REMOTE INTERFACE) 4 3 2 1 CURRENT LIMIT ADJUST VOLTAGE LIMIT ADJUST - VOUT MATING HDWR: CURRENT LIMIT ADJUST HOUSING- MOLEX P/N: 39-01-0043 VOLTAGE LIMIT ADJUST TERMINALS- MOLEX P/N: 30-00-0031 CRIMP TOOL MOLEX P/N: 57005-5000 CURRENT MONITOR - VOUT J3-PIN1 FinPAC + 0UT P2 REMOTE SENSE TRIM/SC & POWER GOOD OUTPUT ADJUST - OUT P2-PIN1 7 6 5 4 3 2 1 +SENSE MATING HDWR:
PFC MegaPAC Design Guide PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 15) Mounting the PFC MegaPAC and PFC MegaPAC-High Power * Mount the power supply on any of its four sides. * Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15" (3,8mm). The maximum allowable torque is 5.5 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.
PFC MegaPAC Design Guide Sense Connector J2 (and P2 for the FinPAC): * Sense connections do not have to be made if the Local Sense option was ordered or 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.
PFC MegaPAC Design Guide DC OK (Power Good) DC OK (Power Good) Connection J3 (and P2 for FinPAC) * DC OK is only available as an option and is not always present. * J3-4 is Vcc In, J3-3 is Power Good, J3-2 is Power Good inverted, and J3-1 is Signal Ground. * Use Molex mating receptacle #39-01-0043 with #39-00-0031 terminals provided. * Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000. * For the FinPAC, refer to the P2 Connector. P2-3 is Power Good.
Rev. 4/2010 Vicor 800-735-6200 4 5 6 47 TO 500 Hz LABEL NO: 94-00046 REV B Westcor Division 408-522-5280 L2 LABEL NO: 94-00046 REV B FAN .25 [6.35] Applications Engineering 800-927-9474 .21 [5.33] 2.92 [74.17] .47 [11.94] 5.10 [129.54] (DIRECTION OF AIR FLOW OPTIONAL) DO NOT OPERATE WITHOUT EARTH GROUND 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.
PFC MegaPAC Design Guide Interface Connections Chassis Input Power Terminals (J9) Input AC power is applied to terminal block J9 using a pressure screw terminal that accepts a maximum wire size of 14 AWG. The insulation should be stripped .35 inches and the maximum torque applied to the screws should not exceed 4.4 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 Design Guide Enable/Disable (J10-1 to J10-8) The Enable/Disable control pins allow ConverterPAC outputs to be sequenced either on or off. J10-1 through J10-8 are the control pins for output positions 1 through 8, respectively (see Figure 5 and Connector Pin Identification on page 9). For DualPACs and FlexPACs both outputs are sequenced. In parallel array using VI/VE modules only the driver ConverterPAC need be controlled. The Enable/Disable pins should be pulled low to less than 0.
PFC MegaPAC Design Guide AC OK / Power Fail (J10-11) This is an active high TTL compatible signal and provides a status indication of the AC input power (see Figure 7 and Connector Pin Identification on page 9). It is capable of sourcing 0.5mA at >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.
PFC MegaPAC Design Guide 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 Design Guide OUTPUT MODULE VI-200/VI-J00 ≥3.3V VI-200/VI-J00 <3.3V Maxi/Mini/Micro (Pre-Defined) Vref 2.50V 0.97V 1.23V RTH 10.0 kΩ 3.88kΩ 1.0 kΩ 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 R7 J2-3 -Sense Load + V2 - R4 -P -Out Use 22-24 AWG Twisted Pair Wires Figure 11. External Trim Maxi/Mini/Micro (User Defined) 1.23V Consult Factory Table 1.
PFC MegaPAC Design Guide Specifications 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 25A pk @ 115 Vrms and 230 Vrms Ride Through Time >20 ms at nominal line, full load Power Fail >3 ms warning Conducted EMI FCC Class A; EN55022 Class A (Certain configurations meet B.
PFC MegaPAC Design Guide Environmental Characteristics 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.
PFC MegaPAC Design Guide PFC MegaPAC Output Power Derating 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) PFC MegaPAC Connector Kit (19-130040) Listing Rev. 4/2010 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg.
PFC MegaPAC Design Guide Current Share Boards - Optional Feature "Current sharing" also known as Load Sharing, is the ability to divide the output current evenly across all active power supplies. This greatly reduces stresses on each power supply and allows them to run cooler, resulting in higher reliability. Standard "current sharing" techniques typically utilize shunt resistors or Hall Effect devices to measure the current from each power supply.
PFC MegaPAC Design Guide 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 Design Guide Low Leakage Version If Low Leakage is required, the MegaPAC Family of Power Supplies has a model variant (must be requested). This model enables the user to meet various additional specifications. Presently, the PFC MegaPAC, Mini MegaPAC and Autoranging MegaPAC are available in Low Leakage versions. Other models can be made available.
PFC MegaPAC Design Guide 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 VI-200/VI-J00 dual output DualPACs Requirement: 5V must start before the 3.3V output. If the 5V output is lost, the 3.3V output must turn off.
PFC MegaPAC Design Guide 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 28 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Rev.
PFC MegaPAC Design Guide Notes Rev. 4/2010 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg.
PFC MegaPAC Design Guide 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.
