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UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 1

3 Phase MegaPAC-EL

(Low Noise)

4kW MegaPAC-EL

(Low Noise)

AC-DC Switchers

USER GUIDE | UG:108

September 2013

Overview

The 3 Phase MegaPAC - EL and 4kW MegaPAC - EL are ﬁeld-conﬁgurable, single or

multiple output switchers, providing up to 2,000 W (3 Phase MegaPAC/EL- Low Noise)

to 4,000 W of output power (4kW MegaPAC/EL-Low Noise). The chassis has 10 slots

and provides up to 20 regulated, fully isolated outputs. It achieves power densities of

3.6 W per cubic inch (3 Phase MegaPAC/EL (Low Noise)) to 6.4 W per cubic inch (4kW

MegaPAC/EL (Low Noise). The dimensions for the 3 Phase MegaPAC/EL (Low Noise)

are 4.9"H x 7.5"W x 15.2"L (124,5mm x 190,5mm x 429,3mm) and the dimensions for

the 4kW MegaPAC/EL (Low Noise) are 4.9"H x 7.5"W x 16.9"L (124,5mm x 190,5mm x

386,1mm). The 4kW MegaPAC/EL (Low Noise) is longer than the 3 Phase MegaPAC/EL

(Low Noise) to accommodate a 2nd fan.

A complete power supply is conﬁgured by selecting and inserting up to ten same

length slide-in output assemblies called ConverterPACs. ConverterPACs incorporate

one or two VI-200/VI-J00 and/or MaxiVicor 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 oers the advantages of a custom supply, but is assembled from standard and

modular building blocks. For detailed information about all ConverterPACs, refer to

the ConverterPAC information sheets. The 4kW MegaPAC-EL (Low Noise) uses VI-200/

VI-J00 and Maxi Vicor DC to DC converters while the 3 Phase MegaPAC-EL (Low Noise)

uses VI-200/VI-J00 Vicor DC to DC converters.

Manufactured at Vicor, the entire family of MegaPAC power supplies is completely

user-conﬁgurable. If output requirements change, i.e., more power or a dierent

output voltage is needed, upgrading is easy: simply unlock a single screw and replace

the slide-in ConverterPAC with another Extended Length ConverterPAC that has the

desired voltage power rating. For additional ﬂexibility, same length ConverterPACs

can be connected in parallel to increase output power (booster ConverterPACs), or in

series for higher voltages (total output voltage should not exceed 400 V). The driver is

to the le of the boosters when looking at the output end of the supply. A user-friendly

interface provides control and output sequencing capability, in addition to useful status

indicators. Please consult our Applications Engineering Department if you have other

special requirements.

Contents Page

Overview 1

of Product

Mechanical 2

Considerations

MegaPAC 3

Do’s and Don’ts

Technical Description 4

Conﬁguring and 5

Reconﬁguring

MegaPACs

ConverterPAC 6

Description

Part Numbering 10

Quick Install 12

Instructions

Mechanical Drawings 15

Interface Connections 17

Speciﬁcations 24

Current Share Boards 26

Low Leakage Version 29

NRTL

CUS

3 Phase MegaPAC

4kW MegaPAC

End of Life - Not Recommended for New Designs

Summary of content (30 pages)

PAGE 1
End of Life - Not Recommended for New Designs USER GUIDE | UG:108 3 Phase MegaPAC-ELTM (Low Noise) 4kW MegaPAC-ELTM (Low Noise) AC-DC Switchers September 2013 ® C Contents S US Page Overview of Product 1 Mechanical Considerations 2 MegaPAC Do’s and Don’ts 3 4kW MegaPAC Technical Description 4 Configuring and Reconfiguring MegaPACs 5 ConverterPAC Description 6 Part Numbering 10 Quick Install Instructions 12 Mechanical Drawings 15 Interface Connections 17 Specifications 24 Curren
PAGE 2
Standard Features n Input: 3Æ 208/240 Vac Wye or Delta, 1Æ 180-264 (47-500Hz) or 260–352 Vdc n Power Output: 3 Phase MegaPAC: 2,000 W with 3Æ input; 1,200 W with 1Æ input 4kW MegaPAC: 4,000 W with 3Æ input; 1,500 W with 1Æ input n 10 slots (upto 20 outputs) n Fan cooled (4kW MegaPAC-EL has 2 fans) n Full power to 45°C; half power to 65°C n Power Factor Correction - passive - to 0.
PAGE 3
4kW MegaPAC - EL 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.
PAGE 4
Technical Description The 3 Phase MegaPAC - EL and 4kW MegaPAC - EL are configured by installing same length ConverterPAC assemblies into the chassis. The chassis takes AC input power and performs filtering and rectification functions. The ConverterPACs plug into a highvoltage 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.
PAGE 5
Configuring and Reconfiguring MegaPACs Most ConverterPACs of the same length can be easily added, replaced, or moved by sliding the assemblies in or out of a MegaPAC chassis. They are driver QPAC ConverterPACs and can be inserted into any available slot. For outputs greater than 200 Watts, a driver QPAC and one or more booster QPACs will be used. For outputs greater than 500 Watts, a driver QPAC (XQ) (in the 4kW MegaPAC - EL) and one or more booster QPAC (XQs) will be used.
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ConverterPAC Functional Description (See ConverterPAC Datasheet/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 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 10mV p-p or 0.
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List of ConverterPACs used and their features ConverterPAC OVP OCP OTL RS/AS* LS/AS* PG TrimPot QPAC (L ) Std Std Std AS* AS* Opt Opt QPAC (XQ)** Std Std Std Std Opt Opt Opt DualQPAC (LD) N/A Std N/A AS* AS* Std N/A Junior QPAC (LJ) N/A Std N/A AS* AS* Opt Opt * See page 12 and 16 for more information on Autosense. ** Currently, the QPAC (XQ) can only be used in the 4kW MegaPAC/EL.
PAGE 8
ConverterPAC Output and Connector Pin Identification 3 Phase/4kW MegaPACs/EL (Low Noise) QPAC (L and XL) QPAC (L and XQ) P2 REMOTE SENSE TRIM/SC & POWER GOOD + V0UT Jr.
PAGE 9
Part Numbering 3Ø MegaPAC-EL MP*xA-5xBxxx-EL eg. MP4-510108-EL MP = MP xA = number of outputs 5 = 3Ø MegaPAC - EL Prefix xB = number of modules xxx = assigned by Vicor EL = Indicates extended length chassis for use with QPACs 4kW MegaPAC-EL MP*xA-4xBxxx-xG-xH-EL With VI-200/VI-J00 With Maxi eg. MP10-410008-23-EL eg.
PAGE 10
* ConverterPAC options B Booster module M Military Grade module 1 D DC OK or Power Good P Preload F Full 50-110% output adjustment R RAM external3 F1 50-107.5% output adjustment S Trimpot removed for external BatPAC adjustment F2 50-105% output adjustment T 90-110% output adjustment4 F3 50-102.5% output adjustment T1 90-107.5% output adjustment F4 50-100% output adjustment T2 90-105% output adjustment F5 60-110% output adjustment T3 90-102.
PAGE 11
3 Phase and 4kW MegaPAC-EL “Quick Install” Instructions (For Mechanical Drawing, see page 14 & 15) Mounting the 3 Phase MegaPAC-EL and/or 4kW MegaPAC-EL n The 3 Phase MegaPAC - EL and 4kW MegaPAC - EL can be mounted on any of four sides. n Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.15" (3,8mm). n A minimum of 2" (5,1cm) clearance must be maintained at either end of the supply in order to insure proper airflow and cooling. n Maximum allowable torque is 20 lb-in.
PAGE 12
3 Phase and 4kW MegaPAC-EL “Quick Install” Instructions (Cont.) Sense Connections Note: Newer power supplies may have a new feature installed called Autosense. For units with Autosense, 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.
PAGE 13
3 Phase and 4kW MegaPAC-EL “Quick Install” Instructions (Cont.) J2-PIN1 7 6 5 TRIM TOP 4 3 2 1 Vcc IN POWER GOOD TRIM BOT n The P2 Trim 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. M5 V/40 AT.) N/C POWER GOOD INVERTED SIGNAL GROUND Trim Pin Connector for DualQPAC +SENSE 7 6 5 4 3 2 1 P2 Trim Connection for DualQPACs -SENSE n P2-7 is Trim A and P2-6 is Trim B.
PAGE 14
3 Phase MegaPAC - EL Mechanical Drawings #4-40 CAPTIVE SCREWS TO SECURE QPAC-200 10 PLACES -P8 TYP J10-PIN1 +P8 TYP .560 (14.2 MM) .40 (10.2 MM) q 1.852 (47.0 MM) R4 "TRIMPOT" PRESENT WHEN ADJUSTABLE OPTION IS SPECIFIED 10X 1/8 X 1/2 SLOTS AIRBLOCK (EXAMPLE) .240 (6.1 MM) 1.852 (47.0 MM) 6.56 (166.6 MM) 9=SP @.7285 (18.5 MM) 2.068 (52.5 MM) 1.20 (30.5 MM) 208/4VAC3ÿ 15A47-0HZ L1 L2 L3 1.900 .46 (11.7 MM) .250 +P1 TYP -PI TYP .54 (13.7 MM) 4.90 (124.5 MM) 1.15 J2 PIN 1 J1-PIN 1 (29.
PAGE 15
4kW MegaPAC - EL Mechanical Drawings +P8 TYP -P8 TYP #4-40 CAPTIVE SCREWS TO SECURE QPACS .560 (14.2 MM) 10 PLACES J10-PIN1 .40 (10.2 MM) 1.852 (47.0 MM) R4 "TRIMPOT" PRESENT WHEN ADJUSTABLE OPTION IS SPECIFIED 10X 1/8 X 1/2 SLOTS .240 (6.1 MM) AIRBLOCK (EXAMPLE) 1.852 (47.0 MM) 6.56 (166.6 MM) 9=SP @.7285 1.900 21058A/447-VA0CHZ3ÿ L1L2L3 (18.5 MM) 1.20 (30.5 MM) .46 (11.7 MM) +P1 TYP 2.068 (52.5 MM) .250 -PI TYP J2 PIN 1 4.90 (124.5 MM) 1.15 .54 (13.7 MM) J1-PIN 1 (29.
PAGE 16
Interface Connections Chassis Input Power Terminals (J1) Input AC power is applied to a plug-in connector, J1, that accepts soldered terminals with a wire size of 12 AWG. For operation on high voltage DC input, input power can be connected to any two input lines. A fault-clearing device should be installed at the input of the unit. A user-accessible input fuse is not present within the unit. For an output of 2,000 W - 4,000 W with operation on 208 Vac, 3Æ input, a 20 A fuse in each input line is acceptable.
PAGE 17
Interface Connections (Cont.) Signal Ground (J10-1, J10-2, J10-12, J10-15) Signal Ground (see Figure 4) is an isolated ground reference for all J10 interface signals used as a reference for ConverterPAC output status signals such as Power Good. This is not the same as Earth Ground on input power connector J1. Figure 4.
PAGE 18
Interface Connections (Cont.) Figure 5.
PAGE 19
Interface Connections (Cont.) AC Power OK (J10-18) This signal on J10-18 provides a status indication of the AC input power (see Figure 7). It is active high, TTL compatible and capable of sourcing 10 mA maximum. This signal switches to a TTL “1” when the high voltage bus exceeds low-line condition during turnon, 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.
PAGE 20
Interface Connections (Cont.) Gate IN/Gate OUT (J10-13, 25) The 3 Phase MegaPAC - EL can be paralleled with other 3 Phase MegaPAC - ELs and the 4kW MegaPAC - EL can be paralleled with other 4kW MegaPAC - ELs to increase output power. Paralleling the chassis is similar to paralleling VI-200 (QPAC-L) or Maxi (QPAC-XQ) DC to DC converters.
PAGE 21
Interface Connections (Cont.) Power Good (P2-3) The optional Power Good signal on P2-3 is referenced to Signal Ground on P2-1, 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. In addition to the electrical Power Good signal, the QPAC (XQ) comes with a DC OK LED as a standard feature.
PAGE 22
Interface Connections (Cont.) For DualQPACs, the +Sense pins are available on connectors designated as J1A-3 and J1B-3 for outputs A and B, respectively. –Sense pins are on J1A-6 and J1B-6, respectively. 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.
PAGE 23
Interface Connections (Cont.) Output Module Vref RTH VI-200/VI-J00 ³3.3 V 2.5 V 10.0 kW VI-200/VI-J00 <3.3 V 0.97 V 3.88 kW Maxi (Pre-Defined) 1.23 V 1.0 kW Maxi (User Defined) 1.23 V Consult Factory Figure 11. External Trim +Out Use 22-24 AWG Twisted Pair Wires (Remote Sense) R1 +Sense To Error Amplifier + RTH R5 R8 R2 Trim R6 R3 + V2 R7 - -Sense V1 - V Ref Load R4 -Out Use 22-24 AWG Twisted Pair Wires Example: ±10% Trim adjust on a 12 V nominal output.
PAGE 24
Specifications Input Characterisitcs Input Voltage 208/240 Vac, 3 Phase, 4 Wire; 180-264 Vac, 1 Phase (47-500Hz) 260-352 Vdc Power Factor (passive) 0.
PAGE 25
Specifications (Cont.) Environmental Characteristics Storage Temperature -40°C to 85°C Operating Temperature** -20°C to +45°C full power, -20°C to +65°C half power Humidity 0 to 95% non-condensing Derate 2.6% total output power for each 1,000 ft to a maximum operating Altitude altitude of 15,000 ft. Non-operating storage maximum altitude is 40K.
PAGE 26
Current Share Boards - Optional Feature (Cont.) Please note: The CSB is not intended for use in Hotswap Applications. Figure 12. CSB Interconnect Example D* +VOUT +OUT +S Power Supply 1 24V@1kW TRIM Yellow -S -OUT T1 -V1 Brown T2 -V2 Power Red D* +OUT CSB02 -VOUT +S Power Supply 2 24V@1kW 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.
PAGE 27
Current Share Boards - Optional Feature (Cont.) 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 13. Mechanical Drawing 24.0" +/- 1.
PAGE 28
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.
PAGE 29
NOTES: UG:108 vicorpower.com Applications Engineering: 800 927.
PAGE 30
For Vicor Global Office Locations, please go to: www.vicorpower.com/contact-us or call 800-735-6200. 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 DC-DC converters and accessory components, configurable power supplies, and custom power systems.