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VICOR PFC MegaPAC-EL User Manual

Power factor corrected ac-dc switchers
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USER GUIDE | UG:119
PFC MegaPAC-EL
PFC MegaPAC-HPEL
Power Factor Corrected AC-DC Switchers
Contents
Page
Overview
PFC MegaPAC-EL/HPEL
Connector Kit (19-130040)
TM
TM
1
2
2
3
3
4
5
7
8
Overview
The PFC MegaPAC-EL and PFC MegaPAC High Power Low Noise (HPEL) combine power factor
correction (PFC) with the configurability of the MegaPAC family of power supplies. The
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PFC MegaPAC-EL and PFC MegaPAC-HPEL provide up to 1,600W and 2,400W of output power
respectively and have power densities of 4.3W/in
and can provide as many as 16 outputs. The PFC MegaPAC-EL and PFC MegaPAC-HPEL have the same
input and output connections, mounting points and the same dimensions: 3.4 x 6.0 x 15.6in
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[85,6 x 152,4 x 396,2mm]. Note that length of older units were 15.5in [393,6mm].
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A complete power supply is configured at the factory by selecting and inserting up to eight (four - six
for the PFC MegaPAC-HPEL depending on ConverterPACs used) same length slide-in output assemblies
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called ConverterPACs. ConverterPACs™ incorporate one or two VI-200™ / VI-J00™ and / or Maxi Vicor
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DC-DC converters and are available in a wide selection of output voltage and power levels. The net
result is a power supply that offers the advantages of a custom supply, but is assembled from standard
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and modular building blocks.
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
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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. 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 400V). The driver is to the left of the
boosters when looking at the output end of the supply. A user-friendly interface provides control and
output sequencing capability (see Page 16 for more information about this capability), in addition to
25
useful status indicators. Please consult our Applications Engineering Department if you have other
special requirements.
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28
Note: This user guide contains references to parts and products that are no longer available for new designs.
They remain included for reference only.
3
3
and 6.5W/in
respectively. The chassis has eight slots
UG:119
Page 1

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  • Page 1: Table Of Contents

    The chassis has eight slots PFC MegaPAC-EL and PFC and can provide as many as 16 outputs. The PFC MegaPAC-EL and PFC MegaPAC-HPEL have the same MegaPAC-HPEL input and output connections, mounting points and the same dimensions: 3.4 x 6.0 x 15.6in Mechanical Drawing [85,6 x 152,4 x 396,2mm].

  • Page 2: Standard Features

    1,600W at 230V PFC MegaPAC-HPEL™: 2,400W at 230V 1,200W at 115V 1,200W at 115V Outputs: PFC MegaPAC-EL and HPEL: Up to 16 outputs Output ripple: 10mV or 0.15% whichever is greater Fan Cooled Full-power to 40°C; half power to 60°C...

  • Page 3: Mechanical Considerations

    When selecting a mounting location and orientation, the unit should be positioned so air flow is not restricted. Maintain a 2in minimum clearance at both ends of the PFC MegaPAC-EL and PFC MegaPAC-HPEL and route all cables so airflow is not obstructed. The standard unit draws air in at the fan side / AC input side and exhausts air out the load side.

  • Page 4: Technical Description

    EMI / RFI emissions and high efficiencies. At initial power up, the PFC MegaPAC-EL and PFC MegaPAC-HPEL outputs are disabled to limit the inrush current and to allow the DC bus potential to settle out to the correct operating level.

  • Page 5: Configuring And Reconfiguring Megapacs

    1.2s after initial power up and can be used to indicate an impending loss of power. At least 3ms of warning time is given. Following the loss of input power, the outputs are disabled when the bus voltage drops below its operating threshold. Figure 1 High Voltage PFC MegaPAC-EL™ and Input DC Bus Soft Start Power...
  • Page 6 Installing ConverterPACs as Drivers ConverterPACs™ can be installed in empty slots by simply sliding in the new ConverterPAC and securing the screw at the base. Torque the retaining screw to 0.23N . m (2lb . in); do not overtighten. Power and interface connections can be made after the ConverterPAC has been installed.

  • Page 7: Converterpac Functional Description

    JuniorQPAC™ (LJ) VI-J00 The JuniorQPAC output assembly consists of a VI-J00 Vicor DC-DC converter that converts the unregulated high-voltage bus to the desired regulated output voltage. OVP and OTL is not available. Please note that for the QPAC (L) the output voltage from either output terminal to chassis should not exceed 400V , or peak.

  • Page 8: Part Numbering

    List of ConverterPACs™ used in the PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ Low Noise and their features ConverterPAC RS/AS* LS/AS* TrimPot QPAC (L) DualQPAC (LD) JuniorQPAC(LJ) FinQPAC(PZL)+ Overvoltage Protection (latching) Remote Sense Overcurrent Protection (auto-recovery) Local Sense Overtemperature Limiting Autosense Power Good (DC OK TTL Signal) + Maxi OTL is non-latching See Pages 11 and 12 for more information on Autosense.
  • Page 9 T & F options: Optional for all ConverterPACs used in this power supply EXCEPT the DualQPAC™. R option: N/A to any ConverterPACs used in the PFC MegaPAC-EL™ / PFC MegaPAC-HPEL™. V options: N/A to any ConverterPACs used in the PFC MegaPAC-EL / PFC MegaPAC-HPEL.

  • Page 10: Converterpac Output And Connector Pin Identification

    QPAC VI-200 MODULE ConverterPAC™ Output and Connector Pin Identification QPAC™ +VOUT J2 REMOTE SENSE TRIM/SC & POWER GOOD JuniorQPAC™ MATING HDWR: HOUSING- MOLEX P/N: 39-01-0073 TERMINALS- MOLEX P/N: 39-00-0031 CRIMP TOOL MOLEX P/N: 57005-5000 OUTPUT ADJUST –VOUT +SENSE –SENSE TRIM VCC IN DUAL QPAC POWER GOOD...

  • Page 11: Pfc Megapac-El And -Hpel Quick Install Instructions

    PFC MegaPAC-EL™ and -HPEL Quick Install Instructions (For Mechanical Drawing, see Page 14) Mounting the PFC MegaPAC-EL and PFC MegaPAC-HPEL™ Mount the power supply on any of its four sides. Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15in [3,8 mm].
  • Page 12 Sense Connector J2 (and P2 for the FinQPAC™): J2-PIN1 Sense connections do not have to be made if either the Local Sense option was ordered (older units) or if Autosense is present (see previous note on Autosense). TRIM TOP Attach opposite ends of Sense lines to point where regulation is desired. TRIM BOT Verify that Sense lines are not cross-connected before applying input power.
  • Page 13 DC OK (Power Good) Connection J2 (and P2 for FinQPAC™) +SENSE –SENSE DC OK is only available as an option and is not present unless requested. TRIM For the QPAC™, refer to the J2 connector. J2-3 is Power Good. VCC IN For the FinQPAC, refer to the P2 connector.

  • Page 14: Pfc Megapac-El And Pfc Megapac-Hpel Mechanical Drawing

    PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ Mechanical Drawing INPUTS DO NOT 115/230 VAC OPERATE WITHOUT 47 TO 500 Hz 300VDC EARTH GROUND NOTE: SET SCREW MAXIMUM TORQUE = 4.4 INCH POUNDS LABEL NO: 94-00046 REV B UG:119 Page 14...

  • Page 15: Interface Connections

    +/–Sense terminals MUST be connected to their respective outputs before the PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ are powered up. (NEVER disconnect the +Out and –Out load wires while the supply is operating as disconnecting WILL cause damage to the power supply).
  • Page 16 6V to these inputs at any time. If driven from an electromechanical switch or relay, a capacitor should be connected to eliminate the effects of switch bounce. Figure 5 Enable / disable and general shutdown PFC MegaPAC-EL™ Using external transistors to drive enable/diable logic Enable/Disable Output 1 TTL "1" (OFF) General Shutdown TTL "0"...
  • Page 17 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.
  • Page 18 Figure 7 AC OK Power Fail 2.49K AC Power OK PN2222 Signal Ground Auxiliary VCC +5V / 0.3A (J10-9) The VCC on J10-9 is an auxiliary 5V regulated power source (see Figure 8 and Connector Pin Identification on Page 16). It is +5V ±5% with respect to Signal Ground and can supply 300mA maximum.
  • Page 19 Power Good Inverted (J2-2 / P2-2) This is the inverse of the Power Good signal and is referenced to Signal Ground on J2-1 / P2-1. Signal Ground (J1-1 / P2-1) Signal Ground on J2-1/P2-1 is an isolated secondary ground reference for J2/P2 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 J9.
  • Page 20 External Trim (J2-5/P2-5) 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.
  • Page 21 Example: ±10% Trim adjust on a 12V nominal output. Figure 11 shows a typical variable Trim circuit. Using a 10kΩ trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: + 10% = 2.75V Given: V = 2.5V (see Table 1) = (2.75V –...

  • Page 22: Specifications

    Overcurrent Trip Point 115% typical of full load capability of Maxi modules Overvoltage Protection 115 – 135% on VI-200 on QPAC™ and FinQPAC™ Efficiency 80% typical PFC MegaPAC-EL™ PFC MegaPAC-HPEL™ Output Power 1,600W at 230V 2,400W at 230V 1,200W at 115V 1,200W at 115V Not to exceed an input current of 15A.

  • Page 23: Output Studs

    See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal output voltage. The maximum operating temperature is 40°C. If using a VI-200 with output voltage less than 12V and more than 150W, the operating temperature decreases to 35°C.

  • Page 24: Output Power Derating

    105 125 145 165 185 200 215 235 255 265 Input Voltage (V or V (For V , 100V applies) PFC MegaPAC-EL™ and -HPEL Connector Kit (19-130040) Listing Item Description Vendor #1 Part # HOUSING 12 POS.165 CTR W/LATCH MOLEX...

  • Page 25: Current Share Boards - Optional Feature

    100mV conductional voltage drop in the negative return path. Constructed as a current source to drive the Trim pin of a Vicor module, the design uses an accurate comparator circuit to monitor the power returns. In addition, the circuit is unidirectional and can only trim an output voltage up.
  • Page 26 Requirements: For proper operation, the power supplies being paralleled should be enabled at the same time. –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.

  • Page 27: Current Share Boards - Optional Feature Diagram

    Current Share Boards - Optional Feature Diagram Figure 13 Mechanical drawing 0.13in [3.3mm] Dia Non Plated thru hole four places 0.13in [3.3mm] Dia Non Plated thru hole four places Molex CT43045F surface-mountable connector. 0.390in height above board. 1.74" 1.500" [44.2mm] [38.1mm] Molex CT43045F surface-mountable connector.

  • Page 28: Output Sequencing

    . Any QPAC that has the DC OK option will also have the four-Pin J3 DC OK connector installed. To order a QPAC with the DC OK option, please contact the Vicor customer service department for assistance. The DC OK option monitors the output voltage of a given ConverterPAC and provides a TTL logic signal depending on its output voltage.
  • Page 29 Figure 16 J3 DC OK connector DC OK (Power Good) J3-4 VCC J3-3 Power Good J3-2 Power Good Inverted J3-1 Signal Ground Figure 17 Output sequencing wire interconnect 3.3V Output 5V with "D" option (DC OK) UG:119 Page 29...
  • Page 30 Channel #1: 5V Output Channel #2: 3.3V Output Channel #3: 5V DC OK signal Figure 18 Start-up waveforms 5V Output 5V Output 3.3V Output 3.3V Output 5V DC OK 5V DC OK Figure 19 Shut-down waveforms 5V Output 5V Output 3.3V Output 3.3V Output 5V DC OK...
  • Page 31 For more information about this or other Vicor products, or for assistance with component-based power system design, contact the Vicor office nearest you. The Vicor comprehensive line of power solutions includes modular, high-density DC-DC converters and accessory components, configurable power supplies and custom power systems.
  • Page 32 ANY AND ALL LIABILITY FOR INCLUSION AND/OR USE OF VICOR PRODUCTS IN SUCH EQUIPMENT OR APPLICATIONS AND THEREFORE SUCH INCLUSION AND/OR USE IS AT YOUR OWN RISK. Terms of Sale The purchase and sale of Vicor products is subject to the Vicor Corporation Terms and Conditions of Sale which are available at: (http://www.vicorpower.com/termsconditionswarranty) Export Control This document as well as the item(s) described herein may be subject to export control regulations.
  • Page 33 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Vicor MX5-7515993-2 WX1-469241-2 MP7-776895 MX1-7813094-MC MX4-7410349-2-EL MX1-7416769-G MP4- 748248-G MX2-7716574-2 WM7-1714178 MX1-7417419-2 WP6-76552 MX4-7715229-2 MP8-78105 MX2-787600- G-EL WP7-776894 WP9-793964-EL MP1-73518 WX1-46513-32-2 MX2-7413375-2-EL MP1-718698 MX1- 7411958-G WX4-7813278-2-OD MP4-78556 MX2-7511055-MI MX4-7415433-2 WX2-78510 WP15-7152433-EL...

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