PFC Micro Design Guide PFC Micro™ Power Factor Corrected AC-DC Switcher Design Guide and “Quick Install” Instructions www.vicorpower.
PFC Micro Design Guide TABLE OF CONTENT Overview of Product...........................................................................................................................3 Part Numbering...................................................................................................................................3 Mechanical Considerations.................................................................................................................4 PFC Micro Do’s and Don't................
PFC Micro Design Guide PFC Micro™ Power Factor Corrected AC-DC Switcher Overview The PFC Micro is an low profile switching power supply that combines the advantages of power factor correction (PFC) and high power density. This guide covers both standard and rugged COTS (MI) versions of the supply.
PFC Micro Design Guide Part Numbering PCx1-x2 x3 (x4)-xxxx-x5 e.g. PC6-06-5012-G PFC Micro x1 Number of outputs x2 x3 Number of VI-200/VI-J00 modules x4 Optional Factory assigned Number of Maxi, Mini and Micro modules xxxx Sequential number assigned by Westcor x5 Optional Factory assigned note: x5 = MI for rugged chassis, =MC for rugged chassis w/conformal coating Mechanical Considerations The PFC Micro can be mounted on one of three surfaces using standard 8-32 or 4 mm screws.
PFC Micro Design Guide Technical Description The PFC Micro consists of an off-line single phase, power-factor-corrected front end, EMI filter, cooling fan, customer interface, power supply control circuit, associated housekeeping circuits, and a selection of Vicor’s VI200/VI-J00 and/or Maxi DC-DC converters. Input AC mains voltage is applied to input connector MB1J1. The input current is passed through an EMI filter designed to meet conducted noise limit "A" specifications of FCC Part 15.
PFC Micro Design Guide PFC Micro “Quick Install” Instructions (For mechanical drawings, see page 8) Mounting the PFC Micro * The PFC Micro can be mounted on either of three sides. * Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.25in. (6mm) on the side and 0.125 in. (3mm) on the bottom. * Maintain 2" (5,1cm) clearance at both ends of power supply for airflow. Input Connections Input Power MBJ1 * Input AC power is applied to connector MBJ1. * Maximum torque is 5 in.
PFC Micro Design Guide * Attach terminals to 24-30 AWG stranded twisted pair wire using Molex tool # 11-01-0208. * Attach opposite end of sense lines to their respective outputs to point where regulation is desired. Verify that sense lines are not cross-connected.
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PFC Micro Design Guide Output Connections for the PFC Micro A. OUTPUT STUDS - SINGLE OUTPUT (when populated with full size module) -V OUT 10-32 OUTPUT STUDS SxJ2 REMOTE SENSE/TRIM PIN CONNECTOR +V OUT 3 2 1 - SENSE + SENSE TRIM MATING CONNECTOR: HOUSING: MOLEX (50-57-9403) TERMINAL FEM CRIMP 24-30 AWG: MOLEX (16-02-0103) USE CRIMP TOOL: MOLEX (11-01-0208) B.
PFC Micro Design Guide Interface Connections Chassis Input Power Terminals (MBJ1) Input AC power is applied through connector MBJ1 using Molex mating connector 39-01-4051. Use 16 AWG wire with Molex Socket Pin 39-00-0090 and Crimp Tool 11-01-0199. A fault clearing device, such as a fuse or circuit breaker, with a maximum 10A rating at the power supply input is required for safety agency compliance. It should be sized to handle the start-up inrush current of 8.5A peak at 115 Vac and 17A peak at 230 Vac.
PFC Micro Design Guide User Interface Connections Signal Ground (CBJ3-1) Signal Ground on CBJ3-1 is an isolated secondary ground reference for all CBJ3 interfacing signals. This is not the same as Earth Ground on input power connector MBJ1. Bi -directional I/O lines (CBJ3-4 to CBJ3-9) (Enable/Disable or Module Power Good Status) Enable/Disable Mode Enable/Disable mode is the default condition for these I/O lines. In this mode, the control pins allow the outputs to be sequenced either ON or OFF.
PFC Micro Design Guide PowerGood Read with Good Module PowerGood Read with Defective Module Pg.
PFC Micro Design Guide General Shutdown /GSD (CBJ3-10) The GSD control pin on CBJ3-10 allows simultaneous shutdown of all outputs. This pin must be pulled down to less than 0.7V, and will typically source 250μA (1mA maximum) to shut down all outputs. The GSD pin should be open circuited or driven high to a logic high voltage of 3.5V or greater when not in use, or when the outputs are to be enabled. Do not apply more than 5V to this input.
PFC Micro Design Guide The Sense connector for a single output board is a 3 pin connector providing the +Sense connection on S1/S2 J2-2 and the -Sense connection on S1/S2 J2-3. The Sense connector for a dual output board is provided on the 18 pin output connector that also provides the output and trim connections. +Sense and -Sense for the first output are located on S1/S2 J1-13 and S1/S2 J1-15, respectively. +Sense and -Sense for the second output are located on S1/S2 J1-4 and S1/S2 J1-5, respectively.
PFC Micro Design Guide Example: ±10% trim adjust on a 12V nominal output. Figure 6 shows a typical variable trim circuit. Using a 10k trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: V1= Vref + 10% = 2.75V Given: Vref = 2.5V (see Table 2) IR5 = (2.75V - Vref)/RTH = (2.75V - 2.5V)/10kΩ = 25μA Given: RTH = 10kΩ (see Table 2) Setting the bottom limit: VR6 = 2.5V - 10% = 2.25V And since IR5 = IR6 = 25μA, R6 = VR6/IR6= 2.25V/25μA = 90kΩ V2 = V1 + VR6 = 2.75V + 2.
PFC Micro Design Guide Specifications (Typical at 25°C, nominal line and 75% load, unless otherwise specified) GENERAL Number of Outputs Modules Efficiency Safety Agency Approvals Maximum Output Power 1-6 VI/E-200 and VI/E-J00: Two VI/E-200s or Four V/EI-J00s Maxi: Two Maxis, Four Minis or Six Micros Typically > 75% cURus – UL 60950-1, CSA 60950-1; cTUVus – EN 60950-1, UL 60950-1, CSA 60950-1 CE Mark – Low Voltage Directive, 2006/95/EC Note: certain wide temp range MI chassis will not carry all approvals
PFC Micro Design Guide OUTPUT VI-200/VI-J00 Modules Parameter MIN. Setpoint Accuracy* Load/line Regulation Load/line Regulation Temperature Regulation Long Term Drift Output Ripple & Noise: ≤ 10V out > 10 V out Voltage Trim Range VI-200/VI-J00 Slots Total Remote Sense Compensation OVP Set Point1 Current Limit Short Circuit Current Overtemperature Limiting 0.5 115 105 120 (1052) TYP. MAX. UNITS NOTES 0.5 0.05 0.2 0.01 0.02 1 0.5 0.5 0.
PFC Micro Design Guide Output Power Derating Power Limit Exceeded Safe operating Area Pg.
PFC Micro Design Guide Output Power Derating -Continued 1. For all module configurations. The PFC Micro or an individual output may be limited by module power limitations e.g. 5V Maxi module is 400W maximum. One cannot exceed the output power rating of the PFC Micro regardless of the module capability. 2. Also see Output Power vs Input Voltage charts on page 17. 3. Please note that a PFC Micro configuration that uses a Molex connector is limited to 9A/pin (27A per output).
PFC Micro Design Guide CURRENT SHARE BOARD - 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 Micro Design Guide CURRENT SHARE BOARD -Continued 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.
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PFC Micro 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.
