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USER GUIDE | UG:105
Westcor PFC MegaPAC
Power Factor Corrected AC-DC Switchers
May 2013
Contents
Page
Overview
of Product
Considerations
ConverterPAC
10
12
15
16
23
25
Connector Kit Listing
25
26
29
30
TM
1
3
3
4
5
Overview
The PFC MegaPAC family of supplies combine power factor correction (PFC) with the
inherent configurability of all Westcor MegaPAC products. This design guide covers 4
model variations:
6
1. PFC MegaPAC
2. PFC MegaPAC MI
3. PFC MegaPAC High Power
4. PFC MegaPAC High Power MI
All PFC MegaPACs have the same input and output connections, mounting points, and
the same dimensions:
The extended length (-EL) chassis is covered in a different design guide
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 more) VI-200/VI-J00), Maxi Vicor DC to DC converters and/or
FlexPACs 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 and modular building blocks. Currently, the standard power
chassis uses only FlexPACs and ConverterPACs with VI-200/VI-J00 Vicor DC to DC
converters while the high power chassis accepts FlexPACs and ConverterPACs with
both VI-200/VI-J00 and/or Maxi module. (Refer to page 6 for a brief overview of the
ConverterPACs used.) Using the PowerBench configurator tool available on
www.vicorpower.com, anybody can now configure a PFC MegaPAC (and other Westcor
power supplies) online.
UG:105
1600 W max, standard chassis
1600 W max, rugged COTS chassis
2400 W max, standard chassis
2400 W max, rugged COTS chassis
Page 1
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Related Manuals for VICOR PFC MegaPAC
Summary of Contents for VICOR PFC MegaPAC
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Page 1: Table Of Contents
MegaPAC Do’s and Don’ts Technical Description Configuring and Overview Reconfiguring The PFC MegaPAC family of supplies combine power factor correction (PFC) with the MegaPACs inherent configurability of all Westcor MegaPAC products. This design guide covers 4 model variations: ConverterPAC Description 1. - Page 2 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 one that is of the same length and has the desired voltage power rating.
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Page 3: Mechanical
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). -
Page 4: Technical Description
EMI/RFI emissions and high efficiencies. At initial power-up the PFC MegaPAC outputs are disabled to limit the inrush current and to allow the DC bus potential to settle out to the correct operating level. A low-... -
Page 5: Configuring And
At least 3 ms 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 Input DC Bus PFC MegaPAC and PFC Soft Start Power ConverterPAC #1 Line Filter Rectifier Boost Converter... -
Page 6: Converterpac
MegaPAC and between different AC input MegaPAC chassis (Exceptions are the FinPAC and UniPAC). They can be added, moved, or changed as necessary. The following ConverterPACs can be used in the PFC MegaPAC and/or PFC MegaPAC-High Power. Spec sheets for ConverterPACs are available at www.vicorpower.com... -
Page 7: Description
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 output power and are fused with a single PC-Tron, DC-rated, fast-acting fuse. A passive + Vout Remote Sense LC filter is used to reduce output ripple/noise down to 1% typical, and 2% maximum... - Page 8 High Power except the FinPAC which currently can only be used in the PFC MegaPAC-High Power. (The UniPAC - not listed above - cannot be used either in the PFC MegaPAC or the PFC MegaPAC- High Power. Currently, the UniPAC is only used in the 4 kW MegaPAC.) Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC, JuniorPAC and RamPAC.
- Page 9 Part Numbering (Cont.) * ConverterPAC options B Booster module S Trimpot removed for external D DC OK or Power Good BatPAC adjustment F Full 50-110% output adjustment T 90-110% output adjustment 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 90-102.5% output adjustment...
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Page 10: Converterpac Output And Connector Pin Identification
DUALPAC ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC ModuPAC (REMOTE SENSE) MATING HDWR: + V0UT JuniorPAC HOUSING- MOLEX P/N: 50-57-9403 RAMPAC TRIM PIN ACCESS J2-PIN1 TERMINALS- MOLEX P/N: 16-02-0103 + SENSE CRIMP TOOL MOLEX P/N: 11-01-0208 OUTPUT ADJUST... -
Page 11: Output And Connector
ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC BatPAC + V0UT J2 (BATPAC REMOTE INTERFACE) MATING HDWR: CURRENT LIMIT ADJUST CURRENT LIMIT ADJUST HOUSING- MOLEX P/N: 39-01-0043 VOLTAGE LIMIT ADJUST VOLTAGE LIMIT ADJUST TERMINALS- MOLEX P/N: 30-00-0031 CURRENT MONITOR... -
Page 12: Quick Install
PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 15) Mounting the PFC MegaPAC and PFC MegaPAC-High Power Mount the power supply on any of its four sides. Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15"... -
Page 13: Instructions
Sense Connector J2 (and P2 for the FinPAC): J2 Sense Connector Sense connections do not have to be made if the Local Sense option was ordered or if J2-1 Trim Pin Access Autosense is present (see above note on Autosense.) J2-2 +Sense J3-3 -Sense Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided. - Page 14 DC OK (Power Good) Connection J3 (and P2 for FinPAC) DC OK (Power Good) DC OK is only available as an option and is not always present. J3-4 Vcc J3-3 Power Good J3-4 is Vcc In, J3-3 is Power Good, J3-2 is Power Good inverted, and J3-1 J3-2 Power Good Inverted is Signal Ground.
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Page 15: Mechanical Drawings
PFC MegaPAC Mechanical Drawing INPUTS DO NOT 115/230 VAC OPERATE 47 TO 500 Hz WITHOUT 300VDC EARTH GROUND NOTE: SET SCREW MAXIMUM TORQUE = 4.4 INCH POUNDS LABEL NO: 94-00046 REV B UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 15... -
Page 16: Interface Connections
+/-Sense terminals must be connected to their respective outputs before the PFC MegaPAC and PFC MegaPAC-High Power are powered up. Regardless of the output polarity configured, the +Sense should always connect to the +Power output. The -Sense connects to the -Power output. - Page 17 Figure 5. Enable/Disable and General Shutdown PFC MegaPAC A TTL "1" applied to the base of the transistor turns output OFF. Pin 1 (or Pin 12 for GSD) is pulled Low with respect to Signal Ground.
- Page 18 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. Example: Slots 2, 4 and 6 have been configured as a single output parallel array (see Figure 6) In order to disable the 48 V output, E/D 2, E/D 4 and E/D 6 should be shorted together...
- Page 19 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”...
- Page 20 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.
- Page 21 Figure 10. Sense Leads (Local Sense) (Remote Sense) +P +Out +Sense Use 22-24 AWG Load 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.
- Page 22 Table 1. Output Module Vref Module Internal VI-200/VI-J00 ³3.3 V 2.50 V 10.0 kW Reference Voltages and VI-200/VI-J00 <3.3 V 0.97 V 3.88 kW Thevenin Resistances. Maxi/Mini/Micro (Pre-Defined) 1.23 V 1.0 kW Maxi/Mini/Micro (User Defined) 1.23 V Consult Factory Figure 11. Use 22-24 AWG External Trim Twisted Pair Wires...
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Page 23: Specifications
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... - Page 24 *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 12 V and more than 150 Watts, the operating temperature decreases to 35°C.
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Page 25: Power Derating
Safe Operating Area 1200 1000 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 Description Vendor #1 Part # HOUSING 12 POS.165 CTR W/LATCH... -
Page 26: Current Share Boards
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 27 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"...
- Page 28 Current Share Boards - Optional Feature (Cont.) 0.13" (3.3mm) Dia Non Plated thru hole 4 places Molex CT43045F surface mountable connector. .390" height above board. 1.74" 1.500" (44.2mm) (38.1mm) J1 Pinout P i n D e s c r i p t i o n P o w e r - V 1 0.12"...
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Page 29: 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 30: Output Sequencing
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. - Page 31 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.
- Page 32 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.
- Page 33 NOTES: UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 33...
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Page 34: Vicorpower.com Applications Engineering: 800 927.9474
• MicroPAC • Conduction Cooled MicroPAC Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini, and PFC MegaPAC. INFORMATION FURNISHED By VICOR IS BELIEVED TO BE ACCURATE AND RELIABLE. HOWEVER, NO RESPON- SIBILITy IS ASSUMED By VICOR FOR ITS USE. NO LICENSE IS GRANTED By IMPLICATION OR OTHERWISE UNDER ANy PATENT OR PATENT RIGHTS OF VICOR.
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