USER GUIDE | UG:105 PFC MegaPACTM Power Factor Corrected AC-DC Switchers May 2013 Contents Page Overview of Product 1 Mechanical Considerations 3 MegaPAC Do’s and Don’ts 3 Technical Description 4 Configuring and Reconfiguring MegaPACs 5 Overview ConverterPAC Description 6 The PFC MegaPAC family of supplies combine power factor correction (PFC) with the inherent configurability of all Vicor MegaPAC products.
Manufactured at Vicor, the entire family of MegaPAC power supplies is completely user-configurable. If output requirements change, i.e., more power or a different output voltage is needed, upgrading is easy: simply unlock a single screw and replace the slide-in ConverterPAC assembly with one that is of the same length and has the desired voltage power rating.
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. Maintain a 2" minimum clearance at both ends of the PFC MegaPAC and route all cables so airflow is not obstructed.
n Avoid running input and output wiring in close proximity as this may cause noise related problems. n PFC MegaPACs are NOT user serviceable. Please contact our customer service department at 1-800-735-6200 for repair assistance. Please be advised that attempts to repair or modify the power supply will void the warranty. n A proper fault protection device (fuse or breaker) should be used in series with the input terminals.
The ride-through (holdup) time is the amount of time the load can be supported before loss of output regulation after the loss of input power. Detecting the loss of input power takes a finite time period after which the AC Power OK signal goes from a TTL “1” to “0." This signal is available for use within 1.2 seconds after initial power-up and can be used to indicate an impending loss of power. At least 3 ms of warning time is given.
Installing Booster ConverterPACs to Increase Output Power ConverterPACs can be paralleled for more power. Additional power to an output is obtained by connecting one or more boosters in parallel with a single driver. The driver can be placed in any open slot. All boosters should be inserted in the slots to the immediate right of the driver as viewed from the output end of the MegaPAC. Figure 2 shows a driver placed in slots #1 and 3 boosters placed in slots # 2 to 4.
+ _ VI-J00 JuniorPAC JuniorPAC The JuniorPAC consists of a VI-J00 DC to DC converter that converts the high voltage bus to the desired regulated output voltage. JuniorPACs can provide up to 100 Watts of + Vout output power and are fused with a single PC-Tron, DC-rated, fast-acting fuse. A passive Remote Sense Output Adjust LC filter is used to reduce output ripple/noise down to 1% typical, and 2% maximum - Vout peak-to-peak from 10% to 100% of rated load.
List of ConverterPACs used in the PFC MegaPAC and PFC MegaPAC-High Power and their features ConverterPAC OVP OCP OTL RS/AS LS/AS PG TrimPot ModuPAC Std Std Std AS* AS* Opt Opt JuniorPAC N/A Std N/A AS* AS* Opt Opt DualPAC N/A Std N/A AS* AS* N/A Opt RAMPAC N/A Std N/A AS* AS* Opt Opt BatPAC N/A Std N/A N/A N/A N/A Std FinPAC** Std Std N/A AS* AS* Opt Opt FlexPAC Std Std Std LS LS N/A Std * See pages 12 and 13 for more information on Autosense.
Part Numbering (Cont.) * ConverterPAC options B Booster module D F S 1 Trimpot removed for external BatPAC adjustment DC OK or Power Good 2 Full 50-110% output adjustment T 90-110% output adjustment4 F1 50-107.5% output adjustment T1 90-107.5% output adjustment F2 50-105% output adjustment T2 90-105% output adjustment F3 50-102.5% output adjustment T3 90-102.
DUALPAC 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 J3 DC OK (POWER GOOD) J3-PIN1 DualPAC J1-B-PIN1 J2-B-PIN1 OUTPUT ADJ.
ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC BatPAC + V0UT J2 (BATPAC REMOTE INTERFACE) CURRENT LIMIT ADJUST VOLTAGE LIMIT ADJUST - VOUT 4 3 2 1 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 4 3 2 1 P2-PIN1 HOUSING- MOLEX P/N: 39-01-0073 TRIM Vcc IN POWER G
PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 15) Mounting the PFC MegaPAC and PFC MegaPAC-High Power n Mount the power supply on any of its four sides. n 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. n Maintain 2" (5,1cm) clearance at either end for airflow. Input Connections L2MODUPAC/JR.
Sense Connector J2 (and P2 for the FinPAC): J2 Sense Connector J2 Pin J2-1 Trim Pin Access J2-2 +Sense J3-3 -Sense 1 2 3 n 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.) n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided. n J2-2 is the +Sense and J2-3 is the -Sense. P2 Sense Connector n Attach terminals to 22-24 AWG twisted pair wire using Molex tool #11-01-0208.
DC OK (Power Good) DC OK (Power Good) Connection J3 (and P2 for FinPAC) J3 n DC OK is only available as an option and is not always present. 4 3 2 1 Pin J3-4 J3-3 J3-2 J3-1 Vcc Power Good Power Good Inverted Signal Ground n J3-4 is Vcc In, J3-3 is Power Good, J3-2 is Power Good inverted, and J3-1 is Signal Ground.
4 5 6 47 TO 500 Hz UG:105 vicorpower.com LABEL NO: 94-00046 REV B 47 TO 500 Hz L2 LABEL NO: 94-00046 REV B FAN .25 [6.35] .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 L2 DO NOT OPERATE WITHOUT EARTH GROUND INPUTS 115/230 VAC NOTE: SET SCREW MAXIMUM TORQUE = 4.
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 32-00-58-0, purchased from other sources) can be used to prevent fraying.
Signal Ground (J10-10) Signal Ground (see Figure 4 and Connector Pin Identification on page 14) is an isolated ground reference for all J10 interfacing 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 J9. Figure 4. Interface Connector J10-1 J10-2 J10-3 J10-4 J10-5 J10-6 J10 4 5 6 1 2 3 7 8 9 10 11 12 E/D-1 E/D-2 E/D-3 E/D-4 E/D-5 E/D-6 J10-7 J10-8 J10-9 J10-10 J10-11 J10-12 E/D-7 E/D-8 Vcc +5V, 0.
Enable/Disable control of Maxi/Mini/Micro 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.
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 14). It is capable of sourcing 0.5 mA at >3.2 V and sink 16mA at < 0.5 V. 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.
Power Good (J3-3) The optional Power Good signal on J3-3 is referenced to Signal Ground on J3-1, 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. If the Trim option is also used, the Power Good trip points DO NOT track with the trimmed voltage.
Figure 10. Sense Leads +P +Out (Local Sense) (Remote Sense) +Sense Load Use 22-24 AWG Twisted Pair Wires -Sense -P -Out 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/DC converter used on the ConverterPAC.
Table 1. Module Internal Reference Voltages and Thevenin Resistances. Output Module Vref RTH VI-200/VI-J00 ³3.3 V 2.50 V 10.0 kW VI-200/VI-J00 <3.3 V 0.97 V 3.88 kW Maxi/Mini/Micro (Pre-Defined) 1.23 V 1.0 kW Maxi/Mini/Micro (User Defined) 1.23 V Consult Factory Figure 11.
Specifications Input Characterisitcs Input Voltage 85-264 Vac, 47-500 Hz 100-380 Vdc Power Factor 0.99 @ 115 Vac ; 0.95 @ 230 Vac - both at full load (47-63 Hz) 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 Surge Immunity FCC Class A; EN55022 Class A (Certain configurations meet B.
Specifications (Cont.) Environmental Characteristics Storage Temperature -40°C to 85°C 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 40 K.
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 Item Qty 1 1 12 2 ** 3 8 Description Vendor #1 Part # HOUSING 12 POS.
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 12. 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 Description 1 Power 2 T1 3 -V1 4 T2 5 -V2 6 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 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.
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-J00 dual output DualPACs Requirement: 5 V must start before the 3.3 V output. If the 5 V output is lost, the 3.3 V output must turn off.
Figure 17. Output Sequencing Wire Interconnect 1 2 3 4 5 6 7 8 6 12 5 11 4 10 3 9 2 8 1 7 L L 1 2 3.3V Output 5V with "D" option (DC OK) Figure 17 shows the correct wiring connections between the Power Good Connector (J3) of a 5 V ModuPAC and the Input Interface Connector (J10) of a typical PFC MegaPAC configuration. In this example, the 3.3 V ModuPAC is located in the slot #7 and the 5 V ModuPAC (with the DC OK option) is located in slot #8.
Output Sequencing (Cont.) Channel #1: 5 V Output Channel #2: 3.3 V Output Channel #3: 5 V DC OK signal Figure 18. Startup Waveforms 5V Output 3.3V Output 5V DC OK Figure 18. Startup Waveforms Figure 19. Shutdown Waveforms 5V Output 3.3V Output 5V DC OK Figure 19. Shutdown Waveforms UG:105 vicorpower.com Applications Engineering: 800 927.
NOTES: UG:105 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.
