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UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 1

Autoranging MegaPAC

AC-DC Switcher

USER GUIDE | UG:106

June 2013

Overview

The Autoranging MegaPAC AC-DC switcher allows users to instantly conﬁgure high

eciency, o-line power supplies that operate on either 115 or 230 Vac (47-500 Hz), or

260-380 Vdc. The Autoranging MegaPAC provides up to 1,600 W of output power with a

power density of 6.6 W per cubic inch. The chassis has 8 slots and can provide up to 16

isolated outputs. Its dimensions are 3.4"H x 6.0"W x 11.9"L (86,4 x 152,4 x 302,3).

A complete power supply is conﬁgured at the factory by selecting and inserting up to

eight 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 array 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 ConverterPACs, refer

to the ConverterPAC information sheets. Currently, the ConverterPACs used in the

Autoranging MegaPAC only use VI-200/VI-J00 Vicor DC to DC converters.

Refer to page 6 for a brief overview of the ConverterPACs used.

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 assembly with a same length ConverterPAC and one that

has the desired voltage power rating. For additional ﬂexibility, 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 3

Conﬁguring and 5

Reconﬁguring

MegaPACs

ConverterPAC 6

Description

Part Numbering 7

ConverterPAC Output 9

and Connector Pin

Identiﬁcation

Quick Install 10

Instructions

Mechanical Drawings 13

Interface Connections 14

Speciﬁcations 20

Current Share Boards 21

Low Leakage Version 23

End of Life - Not Recommended for New Designs

Summary of content (25 pages)

PAGE 1
End of Life - Not Recommended for New Designs USER GUIDE | UG:106 Autoranging MegaPACTM AC-DC Switcher June 2013 Contents Page Overview of Product 1 Mechanical Considerations 2 MegaPAC Do’s and Don’ts 3 Technical Description 3 Configuring and Reconfiguring MegaPACs 5 ConverterPAC Description 6 Part Numbering 7 ConverterPAC Output and Connector Pin Identification 9 Overview Quick Install Instructions 10 Mechanical Drawings 13 Interface Connections 14 Specifications 20 Current Sh
PAGE 2
Standard Features n Input Voltage: 90-132 or 180-264 Vac, 47-500 Hz, or 260-380 Vdc n Output Power: 1,600 W at 230 Vac or 300 Vdc, 1,200 W at 115 Vac n Outputs: 8 slots (up to 16 outputs) n Fan Cooled n Full power output to 45°C; half power to 65°C n Soft start for limiting inrush current n Conducted EMI meets EN55022 level A specifications n AC Power OK status signal n Output Sequencing and General Shutdown (Consult Applications Engineering for automatic sequencing circuitry.
PAGE 3
MegaPAC Do’s and Don’ts n For units without Autosense, do not leave ConverterPAC Sense lines open. Always terminate them to their respective output locally or at the load. If ConverterPAC has Autosense, no local sense connection is required. See page 11 and page 14 for more information on Autosense. n If needed, use Connector Kit # 19-130040 for the Autoranging MegaPAC. n Always fill all output slots of the MegaPAC.
PAGE 4
Voltage conversion in the output assemblies 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. This patented topology has a number of unique attributes: low switching losses; high frequency operation resulting in reduced size for magnetics and capacitors; excellent line and load regulation; wide adjustment range for output; low EMI/RFI emission and high efficiencies.
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. (Currently, the exceptions are the FinPACs which can only be used in the PFC MegaPAC-High Power and the UniPACs which can only be used in the 4 kW MegaPAC.
PAGE 6
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 and between different AC input MegaPAC chassis. They can be added, moved, or changed as necessary. The following ConverterPACs can be used in the Autoranging MegaPAC.
PAGE 7
ConverterPAC Functional Description (Cont.) FlexPAC The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the high voltage bus to the desired output voltage. Each FlexPAC output can be manually trimmed from 2 V to 25 V and supports up to 5 amps with a maximum output power of 50 W per output. All outputs maintain less than 50 mV noise over the entire output range. All outputs support local sense only. For electrical trim options and specific output sequencing contact the factory.
PAGE 8
Part Numbering PFC MegaPAC MPxA-9xBxxxx eg. MP5-981439 MP = MP xA = number of outputs 9 = autoranging Chassis prefix xB = number of modules xxxx = assigned by Vicor ConverterPAC XxDV/xEAxF eg. M15V/10A eg. M15V/10ADFI eg. D15V/6.7A-12V/8.
PAGE 9
ConverterPAC Output and Connector Pin Identification for the A/R MegaPAC ModuPAC JuniorPAC RAMPAC MODUPAC/JR.
PAGE 10
A/R MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 13) Mounting the Autoranging MegaPAC n The Autoranging 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 Maintain 2" (5,1cm) clearance at either end for airflow. n Maximum allowable torque is 20 lb-in.
PAGE 11
A/R MegaPAC “Quick Install” Instructions (Cont.) Sense Connections Sense Connector J2 Pin J2-1 Trim Pin Access J2-2 +Sense J2-3 -Sense 1 2 3 Sense Connector Note: Newer power supplies have a new feature called Autosense. If Remote Sense connections are not made or needed, no Local Sense selection is necessary - simply hook up the output 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 12
A/R MegaPAC “Quick Install” Instructions (Cont.) DC OK (Power Good) J3 4 3 2 1 Pin J3-4 J3-3 J3-2 J3-1 Vcc Power Good Power Good Inverted Signal Ground DC OK (Power Good) Connection J3 n DC OK is available as an option and is only present when requested. n J3-4 is Vcc In , J3-3 is Power Good, J3-2 is Power Good inverted, and J3-1 is Signal Ground. n Use Molex mating receptacle #39-01-0043 with #39-00-0031 terminals provided.
PAGE 13
vicorpower.com NOTE AC INPUTS 100-120 VAC 200-240 VAC AUTORANGING L2 (SCALE: NONE) MAX TORQUE ON SET SCREWS - 10 IN LBS THIS POWER SUPPLY CAN BE CONNECTED TO ANY SINGLE PHASE AC SOURCE OPERATING FROM 47 TO 500 Hz L1/N INPUT LEGEND DO NOT RUN W/O EARTH GROUND HERE. 1.06 (26.9 MM) .50 (12.7 MM) .60 (15.2 MM) 3.52 (89.4 MM) 6.04 (153.4 MM) J10 J9-1 EARTH GROUND J9-2 AC HOT J9-3 AC NEUTRAL .47 (12.0MM) .220 (5.6 MM) 2.920 (74.2 MM) FAN (DIRECTION OF AIR FLOW OPTIONAL) .20 SQ. (5.
PAGE 14
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 10 AWG. The maximum torque recommended is 10 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.
PAGE 15
Interface Connections (Cont.) Signal Ground (J10-10) Signal Ground (see Figure 4 and Connector Pin Identification on Page 12) is an isolated ground used as a 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.
PAGE 16
Interface Connections (Cont.) 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 6 and Connector Pin Identification on Page 12). It is capable of sourcing 0.5 mA at >3.2 V and sink 16 mA 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.
PAGE 17
Interface Connections (Cont.) 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 (see Figure 8). 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.
PAGE 18
Interface Connections (Cont.) +Sense/–Sense -J2-2 and J2-3 (See page 10 for information on Autosense) The +Sense on J2-2 should be connected to the +Power Out, and the –Sense on J2-3 to the –Power Out terminal. Do not reverse or leave the Sense pins open. Sense pins can be terminated locally at the output of the power supply, in which case the power supply will provide regulation at the output terminals. The voltage appearing at the load may drop slightly due to voltage drop in the power cables.
PAGE 19
Interface Connections (Cont.) Figure 10. External Trim Use 22-24 AWG Twisted Pair Wires (Remote Sense) +P +Out R1 J2-2 +Sense To Error Amplifier + RTH R5 R8 R2 J2-1 R6 R3 - J2-3 -Sense V1 - 2.5V Bandigap Load + V2 R7 R4 -P -Out Use 22-24 AWG Twisted Pair Wires 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 Example: ±10% Trim adjust on a 12 V nominal output.
PAGE 20
Specifications Input Characterisitcs Input Voltage 115-230 Vac, 1 Phase, 90-132 Vac, 180-264 Vac, (47-500 Hz) 260-352 Vdc Power Factor (passive) 0.
PAGE 21
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.
PAGE 22
Current Share Boards - Optional Feature (Cont.) (page 2) 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 11. Mechanical Drawing 24.0" +/- 1.
PAGE 23
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 24
NOTES: UG:106 vicorpower.com Applications Engineering: 800 927.
PAGE 25
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.