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UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 1

3 Phase MegaPAC

4kW MegaPAC

AC-DC Switcher

USER GUIDE | UG:107

August 2013

Overview

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

output switchers providing up to 2,000 W (3 Phase MegaPAC) to 4,000 W (4kW

MegaPAC) of output power. The chassis has 10 slots and can provide up to 40 regulated,

fully isolated outputs. It achieves power densities of 4.4 Watts per cubic inch (3 Phase

MegaPAC) to 7.8 Watts (4kW MegaPAC) per cubic inch. The dimensions of the 3 Phase

MegaPAC are 4.9"H x 7.5"W x 12.3"L (124,5 mm x 190,5 mm x 312,4 mm) and the

dimensions of the 4kW MegaPAC are 4.9"H x 7.5"W x 14"L (124,5 mm x 190,5 mm x

355,6 mm). The 4kW MegaPAC is longer than the 3 Phase MegaPAC to

accommodate a 2nd fan.

A complete power supply is conﬁgured at the factory 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 Maxi Vicor DC to DC converters and are

available in a wide selection of outputs 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 ConverterPACS, refer to

the ConverterPAC information sheet. The 4kW MegaPAC uses VI-200/VI-J00 and Maxi

Vicor DC to DC converters while the 3 Phase MegaPAC 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 one of the same length and 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 400V). 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

Summary of content (31 pages)

PAGE 1
USER GUIDE | UG:107 3 Phase MegaPACTM 4kW MegaPACTM AC-DC Switcher August 2013 ® S C Contents C 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 Current Share Boards 26 Low Leakage Version 29 3 Phase MegaPAC Overview The 3 Phase
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: 2,000W with 3Æ input; 1,200W with 1Æ input; 1–20 outputs 4kW MegaPAC: 4,000W with 3Æ input; 1,500W with 1Æ input; 1–20 outputs n 10 slots (up to 20 outputs) n Fan cooled (the 4kW MegaPAC has 2 fans) n Full power to 45°C; half power to 65°C n Power factor correction (passive) 0.
PAGE 3
Avoid excessive bending of output power cables after they are connected to the 4kW MegaPAC or 3 Phase MegaPAC. For high-current outputs, use cable ties to support heavy cables in order to minimize mechanical stress on output studs. Be careful not to shortout to neighboring output studs. The 3 Phase MegaPAC and 4kW MegaPAC is supplied with serrated, flanged hex-nuts on all output studs, so thread locking compounds or lock washers are not required. The maximum torque recommended on flanged nuts is 45 lbin.
PAGE 4
Technical Description The 3 Phase MegaPAC and 4kW MegaPAC 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 ConverterPACs and can be inserted into any available slot. For outputs greater than 200 Watts, a driver ConverterPAC and one or more booster ConverterPACs will be used. For outputs greater than 500 Watts (in the 4kW MegaPAC), a driver UniPAC and one or more booster UniPACs will be used.
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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 chassis. They can be added, moved, or changed as necessary. The following ConverterPACs can be used in the 3 Phase and 4kW MegaPACs.
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ConverterPAC Functional Description (Cont.) FlexPAC The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the high output 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 powerof 50W per output. All outputs maintain less than 50mV noise over the entire output range. All outputs support local sense only.
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ConverterPAC Output and Connector Pin Identification for the 3 Phase/4kW MegaPACs DUALPAC J1 (OUTPUT CONNECTORS) DualPAC J1-B-PIN1 J2-B-PIN1 OUTPUT ADJUST J1-A-PIN1 1 2 1 AND 4 +V OUT HOUSING- MOLEX P/N: 39-01-2060 2 AND 5 -V OUT 6 3 3 +R/SENSE 6 -R/SENSE TERMINALS- MOLEX P/N: 39-00-0039 CRIMP TOOL MOLEX P/N: 11-01-0197 J2 (REMOTE SENSE) J2-A-PIN1 1 2 3 OUTPUT ADJUST MATING HDWR: 4 5 MATING HDWR: TRIM PIN ACCESS HOUSING- MOLEX P/N: 50-57-9403 + SENSE TERMINALS- MOLEX P/N: 16-02-0103 CR
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ConverterPAC Output and Connector Pin Identification for the 3 Phase/4kW MegaPACs (Cont.
PAGE 10
Part Numbering 3Ø MegaPAC MPx1-5x2xxxx eg. MP4-510108 MP = MP x1 = number of outputs 9 = 3 Phase MegaPAC chassis x2 = number of modules xxxx = assigned by Vicor 4kW MegaPAC MPx1-4x2xxxx-x3x4-x5-x6 With VI-200/VI-J00 With Maxi eg. MP10-410008-23 eg.
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* ConverterPAC options B Booster module (SI for FasTrak) M M 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.
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3 Phase and 4kW MegaPACs “Quick Install” Instructions (For Mechanical Drawing, see pages 15) Mounting the 3 Phase MegaPAC and 4kW MegaPAC n The 3 Phase MegaPAC and 4kW MegaPAC 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.
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3 Phase and 4kW MegaPACs “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.
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3 Phase and 4kW MegaPACs “Quick Install” Instructions (Cont.) Sense Connector J2 1 2 3 Pin J2-1 Trim Pin Access J2-2 +Sense J2-3 -Sense J2 Connectors J2 Trim Connection (and P2 for UniPACs) n The J2 remote Trim connection should only be used if the local Trim option has not been installed. (A “T” or an “F” in the ConverterPAC part number means the Trim option is installed; e.g. M5V/40AT.
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3 Phase MegaPAC Mechanical Drawings AMP NO. 746862-2 PLUG FOR FLAT RIBBON CABLE MATES WITH HSG AMP NO. 747547-2 PLUS SLIDE LATCH OR SIMILAR. J2-PIN1 2 .560 (14.2 MM) +P8 TYP. -P8 TYP. BUS BARS - FOR PARALLEL OUTPUTS (10.2 MM) CL .40 R4 "TRIMPOT" PRESENT WHEN ADJUSTABLE OUTPUT OPTION IS SPECIFIED 1.852 (47.0 MM) J2B-PIN1 (SAME AS J2) .240 (6.1MM) R4 R12 J1B-PIN1 (DUALPAC) J2A-PIN1 (SAME AS J2) 1.852 (47.0 MM) J1A-PIN1 (DUALPAC) AIR BLOCK (EXAMPLE) L1 L2 L3 J3-PIN1 2.068 (52.5 MM) 1.
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4.90 (124.5 MM) 7.50 (190.5 MM) (16X) M4/#8-32 TAPPED HOLE .15 MAX. PENETRATION vicorpower.com Applications Engineering: 800 927.9474 1.64 (41.8 MM) STANDARD AIR FLOW 2.25 (57.2 MM) 2.25 (57.2 MM) .50 (12.7 MM) 2.25 (57.2 MM) 12.28 (311.9 MM) 11.95 (303.5 MM) 6.75 (171.5 MM) 6.75 (171.5 MM) 6.75 (171.5 MM) LABEL LOCATED APPROXIMATELY AS SHOWN DO NOT LOOSEN OR TIGHTEN INNER NUTS .65 (16.5 MM) 4.00 (101.6 MM) 1.40 (35.6 MM) .25 (6.
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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 2,000-4,000W with operation on 208 Vac, 3Æ input, a 20A fuse in each input line is acceptable.
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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, and can be used 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 19
Interface Connections (Cont.) Enable/Disable Control of Maxi Module Arrays When using the Enable/Disable function on an output that consists of two or more Maxi modules, it is necessary to connect the E/D pins of the corresponding module locations together such that both modules are commanded to turn ON or OFF simultaneously. Example: Slots 1 through 6 have been configured as a single output parallel array (see Fig.
PAGE 20
Interface Connections (Cont.) 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.
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Interface Connections (Cont.) Auxiliary Vcc +5V/0.3A (J10-16, 17) The Vcc on J10-16, 17 is an auxiliary 5 V regulated power source (see Figure 8 and Connector Pin Identification of page 18). It is +5 Vdc +/–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 22
Interface Connections (Cont.) Power Good Inverted (J3-2) This is the inverse of the Power Good signal and is referenced to Signal Ground on J3-1. Signal Ground (J3-1) Signal Ground on J3-1 is an isolated secondary ground reference for J3 status signals. It is used to provide a reference point for the Power Good circuitry and is not the same as Earth Ground on input power connector J1. 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.
PAGE 23
External Trim (J2-1) Output voltage can be trimmed using an optional factory-installed Trim potentiometer or with the Trim pin (see Figure 11). 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 to DC converter used on the ConverterPAC.
PAGE 24
Setting the bottom limit: VR6 = 2.5 V - 10% = 2.25 V And since IR5 = IR6 = 25 mA, R6 = VR6/IR6= 2.25 V/25 mA = 90 kW V2 = V1 + VR6 = 2.75 V + 2.25 V = 5 V IR7 = V2/R7 = 5 V/10 kW = 500 mA IR8 = IR7 + IR6 = 525 mA VR8 = (Vnom +10%) - V2 = 13.2 V - 5 V = 8.2 V Given: Vnom = 12 V R8 = VR8/IR8 = 8.2 V/525 mA = 15.62 kΩ Using the previous resistor combination, a 12 V output can be trimmed externally up to 13.2 V and down to 10.8 V.
PAGE 25
Specifications Input Characterisitcs Input Voltage 3Æ 208/240 Vac, 1Æ 180-264 Vac, (47-500Hz) 260-352 Vdc Power Factor (passive) 0.
PAGE 26
Current Share Boards - Optional Feature "Current sharing" also know 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.
PAGE 27
1. For proper operation, the power supplies being paralleled should be enabled at the same time. 2. -Out conductors must be of equal length and wire gauge. Separate -Out conductors must be used from each supply to the load, or the use of a "Y" connection to a common point must be used as shown in figure 1. Each leg of the "Y" must have a minimum of a few millivolts of drop in order for proper operation. 50mV to 100mV of drop will provide from 5% to 1% accuracy. 3.
PAGE 28
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 Power 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 29
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.
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NOTES: UG:107 vicorpower.com Applications Engineering: 800 927.
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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.