USER GUIDE | UG:115 PFC MiniTM Power Factor Corrected AC-DC Switcher March 2010 Contents Page Overview of Product 1 Mechanical Considerations 2 PFC Mini Do’s and Don’ts 3 Technical Description 3 PFC Mini Configuration Layout 5 Part Numbering 6 Quick Install Instructions 7 Overview Mechanical Drawings 10 Output Connectors 11 Interface Connections 12 Output Power De-rating 20 Specifications 21 Current Share Boards 24 Low Leakage Version 27 Low Output Ripple 27 The PFC Mini i
Standard Features n Power Factor Correction: 0.99 at 115 Vac; 0.
When selecting a mounting location and orientation, the unit should be positioned so airflow is not restricted. Maintain a 2" (5,1 cm) minimum clearance at both ends of the PFC Mini, and route all cables so airflow is not obstructed. The power supply draws air in at the fan side/AC input side and exhausts air out the load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fans move approximately 20 CFM of air.
EN61000-3-2). The boost converter delivers a regulated input to the hold-up capacitors and a high-voltage backplane. The backplane supplies power to the DC-DC converters that provide the desired low voltage regulated outputs. Voltage conversion is achieved by Vicor’s family of zero-current switching (ZCS) DC-DC converters. These are forward converters in which the main switching element switches at zero current.
PFC Mini Configuration Layout AC input Fan Fan AC input Fan Fan S 3 -M 2 S1-M1 S2-M1 S3-M1 S1-M1 S2-M1 S 3-M1 Slot 1 Slot 2 Slot 3 Slot 1 Slot 2 Slot 3 Shown above, are two sample PFC Mini configuration layouts. Due to the configurability nature of the PFC Mini, various output combinations are possible. See Page 12 for more information about your output connections. The PFC Mini has three slots and each slot accommodates either full or half-brick modules.
SLO T#3 V375A5C400BN4 E/D#2 SLO T#2 Output #1 VI-J60-CY -S E/D#3 V375A5C400BN4 E/D#1 SLOT #1 Output #2 VI-J63-CW-S E/D#3 Configuration Example: SLOT# 1 VOLTS AMPS WATTS 5.0 80 800 2 Modules V375A5C400BN4* V375 V375A5C400BN4* V375A5C40 3 (M1) 5.0 10 50 VI-J60-CY-S* VI- 3 (M2) 24.0 4.2 100 VI-J63-CW -S* VI- * Actual module part numbers may vary depending on customer configuration E/D = Enable/Disable Part Numbering PFC Mini PMx1-x2 x (x4)-xxxx(-x5)(-x6) eg.
PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see Page 10) Mounting the PFC Mini n Mount the PFC Mini on either of two sides. n Use #8-32 or 4 mm mounting screws. Maximum penetration should not exceed 0.16" (4 mm). n Maintain 2" (5,1 cm) clearance at both ends of power supply for airflow. Input Connections Input Power MBJ1 n Apply input AC power to terminal block MBJ1 using a pressure NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS.
Sense Connections Note: PFC Mini units built after 12/2000 have been equipped with a feature called Autosense. If no Sense connections are made, the PFC Mini will automatically operate in Local Sense mode. If Remote Sense connections are made, the PFC Mini will operate in a Remote Sense mode. For units built before 12/2000 (units without Autosense), Sense connections must ALWAYS be made. Not connecting Sense Lines to their respective outputs can cause failure to the unit.
J3 INTERFACE CONNECTION MATING HDWR: HOUSING: AMP P/N 205204-4 TERMINALS: AMP P/N 66506-9 SCREW LOCK: AMP P/N 205980-4 CRIMP TOOL: AMP 58448-3 J3 INTERFACE PIN OUT J3-1 J3-2 J3-3 J3-4 E/D-1 E/D-2 E/D-3 SIGNAL GROUND Interface Connections n J3-1 to 3 are Enable/Disable for cards 1-3, respectively. n J3-4 is Signal Ground, J3-5 is +5V, J3-6 is AC Power OK, and J3-7 is General Shutdown. n Use mating receptacle AMP P/N 205204-4 with terminals AMP P/N 66506-9.
.487 12.36 .920 23.37 43.69 ±0.51 UG:115 L1 L2/N 2.210 1.600 vicorpower.com 133.81 AIR FLOW 56.13 40.64 5.268 3 4 A COMPLETE SET OF MATING CONNECTORS CAN BE PURCHASED FROMWESTCOR BY SPECIFYING CONNECTOR KIT P/N: 19-130047 REF DESIGNATION LEGEND MB = MOTHER BOARD S1 = (SLOT 1) DAUGHTERBOARD MODULES E/D 1. S2 = (SLOT 2) DAUGHTERBOARD MODULES E/D 2. S3 = (SLOT 3) DAUGHTERBOARD MODULES E/D 3. WITH OPTIONAL BUSBAR. 2 1. INTERPRET DRAWING PER ANSI Y14.5-1994.
Output Connectors for PFC Mini A. OUTPUT STUDS - SINGLE OUTPUT (when populated with full-size modules) -V OUT 10-32 OUTPUT STUDS SxJ2 REMOTE SENSE/TRIM PIN CONNECTOR +V OUT 3 2 1 - SENSE + SENSE TRIM MATING CONNECTOR: HOUSING: MOLEX P/N 50-57-9403 TERMINALS: MOLEX P/N 16-02-0103 USE CRIMP TOOL: MOLEX P/N 11-01-0208 B.
PFC Mini Connector Kit (19-130047) Listing (Avaialble for purchase) Item Qty 1 3 10 2 ** Description Vendor #1 Part # HOUSING 3 POS .100 CTR W/LATCH MOLEX 50-57-9403 TERM FEM CRIMP 22-24AWG SEL GOLD MOLEX 16-02-0103 CRIMP TOOL FOR ITEM 2 MOLEX 11-01-0208 205204-4 3 1 HOUSING FEMALE D-SUB 09 PIN AMP 3 10 TERM MALE CRIMP 22-24 AWG TIN AMP 66506-9 3 1 SCREW LOCK MALE (1 PAIR) AMP 205980-4 CRIMP TOOL FOR ITEM 3 AMP 58448-3 ** 4 3 HOUSING 18 POS .
In order to minimize parasitic cable inductance and reduce EMI, the output power cables should be routed in close proximity to one another, and large current loops should be avoided. To avoid excessive voltage drop, do not undersize power cables, especially for high-current outputs. Excessive cable inductance coupled with large capacitive loading can introduce instability in switching power supplies. This problem can be avoided with proper system design.
+Sense/ –Sense (SxJ2/SxJ1) Current PFC Mini units are shipped with Autosense installed. If the unit does not have Autosense, sense selection is very important. In units without Autosense, the Sense lines for the outputs are shipped from the factory with Local Sense installed. If Remote Sense is desired the Local Sense jumpers can be removed for individual outputs. If the Local Sense jumpers are removed, the Sense lines must be connected for Remote Sense.
Figure 6. Remote Sense +Out +Sense Load -Sense -Out Use 20-22 AWG Twisted Pair Wires Figure 7. External Trim +P +Out Use 20-22 AWG Twisted Pair Wires (Remote Sense) R1 SxJ2-2 +Sense To Error Amplifier + RTH R5 R8 R2 SxJ2-1 R6 R3 SxJ2-3 -Sense V1 V Ref - R7 Load + V2 - R4 -P -Out Use 20-22 AWG Twisted Pair Wires Table 1. Module Internal Reference Voltages and Thevenin Resistances Output Module Vref RTH VI-200/VI-J00 ≥3.3 V 2.5 V 10.0 kΩ VI-200/VI-J00 <3.3 V 0.97 V 3.
Example: ±10% Trim adjust on a 12 V nominal output. Figure 7 shows a typical variable trim circuit. Using a 10 k trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: V1 = Vref + 10% = 2.75 V Given: Vref = 2.5 V (see Table 1) IR5 = (2.75 V - Vref)/RTH = (2.75 V - 2.5 V)/10 kΩ = 25 µA Given: RTH = 10 kΩ (see Table 1) Setting the bottom limit: VR6 = 2.5 V - 10% = 2.25 V And since IR5 = IR6 = 25 µA, R6 = VR6/IR6= 2.25 V/25 µA = 90 kΩ V2 = V1 + VR6 = 2.75 V + 2.
Enable/Disable Control of Maxi, Mini, Micro Series Module Arrays When using the Enable/Disable function on an output that consists of two or more Maxi/Mini series modules, it is necessary to connect the Enable/Disable pins of the corresponding module locations together such that both modules are commanded to turn ON or OFF simultaneously.
Figure 10. AC OK J3 +5V 10K 2.49K Pin 6 Bus Monitor PN2222 AC Power OK Pin 4 Signal Ground Auxiliary VCC +5 V/0.3 A (J3-5) The VCC on J3-5 is an auxiliary 5 V regulated power source. 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. Figure 11. Auxiliary Vcc 78M05 +5V/300 mA J3 J3-5 Auxiliary Vcc 0.
Minor Changes for PFC Mini Shipped October 2005 Onwards As part of our philosophy of continuous improvement for the PFC Mini, Vicor made a number of changes to the unit. Usually such actions have no impact on form, fit, or function of the supplies. In this instance, the improvements required minor changes in the external appearance of the supply. The fans have been moved 0.62" and are now centered. The D-Sub logic connector has also been rotated 90 degrees.
PFC Mini Output Power vs. Input Voltage PFC Mini Output Power vs. AC Input Voltage 1600 1400 Output Power 1200 1000 800 638 600 400 200 0 85 105 125 145 165 185 200 205 225 245 265 AC Input Voltage PFC Mini Output Power vs. DC Input Voltage 1600 1400 Output Power 1200 1000 800 750 600 400 200 0 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 DC Input Voltage UG:115 vicorpower.com Applications Engineering: 800 927.
Specifications General Number of Outputs 1–6 Efficiency >80% cURus – UL 60950-1, CSA 60950-1; cTÜVus – EN 60950-1, UL 60950-1, CSA 60950-1 Safety Approvals CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC Note: certain MI chassis may not carry all safety approvals Maximum Output Power+ >800 W at 115 Vac; (+Not to exceed an input 1,500 W at 230 Vac current of 10 A) Note: Only PFC Minis populated with 12 V Maxi modules are limited to 500 W max. per slot.
Environmental (Cont.) Mil-STD 810 Shock and Vibration Derate 2.6% total output power for each 1,000 ft to a maximum (MI Chassis) Altitude operating altitude of 15,000 ft. Non-operating storage maximum altitude is 40 K. 75% maximum load Humidity 0 to 95% non condensing Product Weight 5.5 lbs. (2,5 kg) Dimensions 1.72" H (43,6 mm) x 6.0" W (152,4 mm) x 12.2" L (309,9 mm) 2 years limited warranty. Warranty [c] See vicorpower.com for complete warranty statement.
Maxi, Mini, Micro Series Modules (Maxi and Mini Modules Only) Parameter MIN Setpoint Accuracy [d] Load Regulation TYP MAX UNITS ±0.5 ±1 % of Vnom See module design guide % of Vnom for exact specifications ±0.1 Temperature Regulation 0.002 0.005 %/°C Notes -20°C to 100°C Long Term Drift Output Ripple & Noise: ≤10 V out 100 mV 20 MHz bandwidth >10 V out 1.
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.
Current Share Boards - Optional Feature (Cont.) Requirements: 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.
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.
Low Leakage Version (Available upon request) If Low Leakage is required, Vicor has a PFC Mini model variant (must be requested). This model enables the user to meet various additional specifications. The advantage of the Low Leakage PFC Mini power supply is in multiple power supply systems that have one AC input. This option will lower the input leakage current for these products to 500 μA or less (may vary if Maxi, Mini, Micro series modules are used. Contact Applications Engineering for more details.
NOTES: UG:115 vicorpower.com Applications Engineering: 800 927.
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.
