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VICOR UG:106 User Manual

Autoranging megapac ac-dc switcher

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USER GUIDE | UG:106
Autoranging MegaPAC
AC-DC Switcher
June 2013
Contents
Page
Overview
of Product
Mechanical
Considerations
MegaPAC
Do's and Don'ts
Technical Description
Configuring and
Reconfiguring
MegaPACs
ConverterPAC
Description
Part Numbering
ConverterPAC Output
and Connector Pin
Identification
Quick Install
10
Instructions
Mechanical Drawings
13
14
20
21
23
TM
1
2
3
3
5
Overview
The Autoranging MegaPAC AC-DC switcher allows users to instantly configure high
efficiency, off-line power supplies that operate on either 115 or 230 Vac (47-500 Hz), or
6
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).
7
A complete power supply is configured at the factory by selecting and inserting up to
9
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 offers 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 Westcor, a division of 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 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 left 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.
UG:106
Page 1

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Summary of Contents for VICOR UG:106

  • Page 1: Table Of Contents

    ConverterPACs. ConverterPACs and Connector Pin incorporate one or two VI-200/VI-J00 and/or Maxi Vicor DC to DC converters and are Identification available in a wide array of output voltage and power levels. The net result is a power...
  • Page 2 ConverterPAC. This nut supports the hardware inside the ConverterPAC and is factory torqued. Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such applications, a shock absorption mounting design is required. UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 2...
  • Page 3 This operates as a full wave bridge rectifier on 230 Vac, and voltage doubler on 115 Vac, delivering unregulated 300 Vdc to a high voltage backplane. The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired low voltage, regulated outputs. UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 3...
  • 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;...
  • Page 5 400 V. For detailed guideline on how outputs should be placed in series, please refer to the Applications note available on the website at www.vicorpower.com. Figure 2. Paralleling ConverterPACs Bus Bars for Paralleling Loosen screw to remove ConverterPAC Driver Boosters UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 5...
  • Page 6 Remote Interface settings are controlled using potentiometers that come as a standard feature, or through BatPAC Trim pin access as an option. BatPACs are available for 12V, 24V and 48V battery systems. UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 6...
  • Page 7 Overvoltage Protection (latching) Overcurrent Protection (auto-recovery) Overtemperature Limiting (latching) Remote Sense Power Good (DC OK TTL Signal) Local Sense Autosense Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC, JuniorPAC and RamPAC. UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 7...
  • Page 8 Applications Engineering. T options: Optional for all ConverterPACs EXCEPT the BatPAC and DualQPAC V options: Optional ONLY on the ModuPAC, DualPAC and JuniorPAC. N/A on all other ConverterPACs. Requires 15% minimum load. UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 8...
  • Page 9 M-1 VOLTAGE ADJUSTMENT M-2 VOLTAGE ADJUSTMENT MATING HDWR: CONNECTOR HOUSING MOLEX P/N 39-01-2120 TERMINALS MOLEX P/N 39-00-0039 CRIMP TOOL MOLEX P/N 11-01-0197 M-3 VOLTAGE ADJUSTMENT M-4 VOLTAGE ADJUSTMENT M-3 STATUS M-4 STATUS UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 9...
  • Page 10 Pins 1 and 4 are Positive, while pins 2 and 5 are the Return. 3 +REMOTE SENSE Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197. 6 -REMOTE SENSE DualPAC Output Connector UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 10...
  • Page 11 Use Molex mating receptacle #50-57-9403 with #16-02-0103 J2-2 +Sense J2-3 -Sense terminals provided. Sense Connector Attach terminals to 22-24 AWG stranded wire using Molex tool # 11-01-0208. J2-1 provides Trim access. For FlexPAC trim see FlexPAC Data Sheet UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 11...
  • Page 12 J10 INTERFACE J10-1 E/D-1 J10-2 E/D-2 J10-3 E/D-3 J10-4 E/D-4 J10-5 E/D-5 J10-6 E/D-6 J10-7 E/D-7 J10-8 E/D-8 J10-9 Vcc +5V, 0.3A J10-10 SIGNAL GROUND J10-11 AC POWER OK J10-12 GEN SHUTDOWN UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 12...
  • Page 13 PFC MegaPAC Mechanical Drawing UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 13...
  • Page 14: Interface Connections

    Sense connections are not required on booster ConverterPACs or if the Local Sense option is specified. (Local Sense mode means that the Remote Sense lines are not connected.) Sense pins can be accessed on J1A/J1B or J2A/J2B on dual output units. UG:106 vicorpower.com Applications Engineering: 800 927.9474...
  • Page 15 OFF. Pin 1 (or Pin 12 for GSD) is pulled Low with respect to Signal Ground. Enable/Disable Output 1 Enable/Disable Control General Shutdown TTL "1" (OFF) TTL "0" (ON) Signal Ground UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 15...
  • Page 16 DC Power Good circuit on a ConverterPAC. If used for this purpose, the Signal Ground on J10-10 must also be connected to the J3-1 Signal Ground pin of the ConverterPAC. Figure 7. Auxiliary Vcc +5V/300 mA Auxiliary Vcc 78M05 0.1 µF Signal Ground UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 16...
  • Page 17 Input current to this pin is limited by an internal resistor to 3 mA. If the J10 Auxiliary Vcc is connected to Vcc In on J3-4, then the J10 Signal Ground must be connected to Signal Ground on J3-1.Earth Ground on input power connector J9. UG:106 vicorpower.com Applications Engineering: 800 927.9474...
  • Page 18 Standard voltages include 2 V, 3.3 V, 5 V, 10 V, 12 V, 15 V, 24 V, 28 V, and 48 V. If using a nonstandard voltage, or if a ConverterPAC is ordered with a Trim option, the resistor calculations will differ from those on page 19. Please consult the factory for assistance. UG:106 vicorpower.com Applications Engineering: 800 927.9474...
  • Page 19 13.2 V and down to 10.8 V. For further information on external trimming, refer to Chapter 5 of the Applications Manual or consult the factory for assistance. CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS THAT ARE 5 V OR LESS. UG:106 vicorpower.com Applications Engineering: 800 927.9474...
  • Page 20: Specifications

    * See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal output voltage. ** The maximum operating temperature is 45°C. If one is using a VI-200 with output voltage less than 12 V and more than 150 Watts, the operating temperature decreases to 40°C.
  • Page 21 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 22: Current Share Boards

    4. Use 4 non-plated through holes with standoffs for mounting. 5. CSB01 MUST be used for current sharing VI-200/VI-J00 converters. 6. CSB02 MUST be used for current sharing Maxi converters . Please note: The CSB is NOT intended for Hotswap Applications UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 22...
  • Page 23: Low Leakage Version

    Junior QPAC (LJ) For RoHS compliant versions a preceeding G is added to the part number. Please note: The MegaPACs (including the Low Leakage versions) are not UL 2601/60601 compliant or EN60601 compliant. UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 23...
  • Page 24 NOTES: UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 24...
  • Page 25: Vicorpower.com Applications Engineering: 800 927.9474

    UNDER ANy PATENT OR PATENT RIGHTS OF VICOR. VICOR COMPONENTS ARE NOT DESIGNED TO BE USED IN APPLICATIONS, SUCH AS LIFE SUPPORT SySTEMS, WHEREIN A FAILURE OR MALFUNCTION COULD RESULT IN INJURy OR DEATH. ALL SALES ARE SUBJECT TO VICOR'S TERMS AND CONDITIONS OF SALE, WHICH ARE AVAILABLE UPON REqUEST.