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VICOR 3 Phase MegaPAC User Manual

Ac-dc switcher
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USER GUIDE | UG:107
3 Phase MegaPAC
4kW MegaPAC
AC-DC Switcher
August 2013
Contents
Page
Overview
of Product
Mechanical
Considerations
MegaPAC
Do's and Don'ts
Configuring and
Reconfiguring
MegaPACs
ConverterPAC
Description
10
12
Instructions
15
17
24
26
29
TM
TM
1
2
3
4
5
Overview
The 3 Phase MegaPAC and 4kW MegaPAC are field-configurable, single or multiple
output switchers providing up to 2,000 W (3 Phase MegaPAC) to 4,000 W (4kW
MegaPAC) of output power. The chassis has 10 slots and can provide up to 40 regulated,
6
fully isolated outputs. It achieves power densities of 4.4 Watts per cubic inch (3 Phase
MegaPAC) to 7.8 Watts (4kW MegaPAC) per cubic inch. The dimensions of the 3 Phase
MegaPAC are 4.9"H x 7.5"W x 12.3"L (124,5 mm x 190,5 mm x 312,4 mm) and the
dimensions of the 4kW MegaPAC are 4.9"H x 7.5"W x 14"L (124,5 mm x 190,5 mm x
355,6 mm). The 4kW MegaPAC is longer than the 3 Phase MegaPAC to
accommodate a 2nd fan.
A complete power supply is configured at the factory by selecting and inserting up
to ten 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 selection of outputs 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 sheet. The 4kW MegaPAC uses VI-200/VI-J00 and Maxi
Vicor DC to DC converters while the 3 Phase MegaPAC uses VI-200/VI-J00 Vicor
DC to DC converters.
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 with one of the same length and has the
desired voltage power rating. For additional flexibility, same length 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, in addition to useful status
indicators. Please consult our Applications Engineering Department if you have other
special requirements.
UG:107
3 Phase MegaPAC
C
4kW MegaPAC
®
S
US
C
NRTL
Page 1

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Summary of Contents for VICOR 3 Phase MegaPAC

  • Page 1: Table Of Contents

    The 3 Phase MegaPAC and 4kW MegaPAC are field-configurable, single or multiple MegaPACs output switchers providing up to 2,000 W (3 Phase MegaPAC) to 4,000 W (4kW MegaPAC) of output power. The chassis has 10 slots and can provide up to 40 regulated, ConverterPAC fully isolated outputs.
  • Page 2 If airflow ducting is used, use caution, as sharp turns could present back pressure to the 3 Phase MegaPAC and 4kW MegaPAC. The fans move approximately 50 CFM of air for the 4kW MegaPAC and 30 CFM for the 3 Phase MegaPAC. The 4kW MegaPAC has a second fan for additional cooling capabilities.
  • Page 3 Avoid excessive bending of output power cables after they are connected to the 4kW MegaPAC or 3 Phase MegaPAC. For high-current outputs, use cable ties to support heavy cables in order to minimize mechanical stress on output studs. Be careful not to short- out to neighboring output studs.

  • Page 4: Technical Description

    Technical Description The 3 Phase MegaPAC and 4kW MegaPAC are configured by installing same length ConverterPAC assemblies into the chassis. The chassis takes AC input power and performs filtering and rectification functions. The ConverterPACs plug into a high- voltage backplane and provide low-noise, independently regulated and fully isolated outputs.
  • 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. For outputs greater than 200 Watts, a driver ConverterPAC and one or more booster ConverterPACs will be used.
  • Page 6 JuniorPAC Output #1 DualPAC Remote Sense Output #1 Adjust This output assembly consists of two VI-J00 Vicor DC to DC converters that convert the VI-J00 VI-J00 Output #2 unregulated high voltage bus to the desired regulated output voltages. Remote Sense...
  • Page 7 ConverterPAC Functional Description (Cont.) FlexPAC The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the M-1 STATUS M-2 STATUS M-1 VOLTAGE ADJUSTMENT high output bus to the desired output voltage. Each FlexPAC output can be manually M-2 VOLTAGE ADJUSTMENT CONNECTOR trimmed from 2V to 25V and supports up to 5 amps with a maximum output powerof...
  • Page 8 ConverterPAC Output and Connector Pin Identification for the 3 Phase/4kW MegaPACs DUALPAC (OUTPUT CONNECTORS) DualPAC MATING HDWR: J1-B-PIN1 1 AND 4 +V OUT HOUSING- MOLEX P/N: 39-01-2060 J2-B-PIN1 2 AND 5 -V OUT TERMINALS- MOLEX P/N: 39-00-0039 CRIMP TOOL MOLEX P/N: 11-01-0197 3 +R/SENSE 6 -R/SENSE OUTPUT ADJUST J1-A-PIN1...
  • Page 9 ConverterPAC Output and Connector Pin Identification for the 3 Phase/4kW MegaPACs (Cont.) UNIPAC UniPAC + V0UT P2 REMOTE SENSE TRIM/SC & POWER GOOD OUTPUT ADJUST +SENSE MATING HDWR: -SENSE HOUSING- MOLEX P/N: 39-01-0073 - VOUT TRIM TERMINALS- MOLEX P/N: 39-00-0031 Vcc IN CRIMP TOOL MOLEX P/N: 57005-5000 POWER GOOD...

  • Page 10: Part Numbering

    Part Numbering 3Ø MegaPAC xxxx eg. MP4-510108 MP = MP = number of outputs 9 = 3 Phase MegaPAC chassis = number of modules xxxx = assigned by Westcor 4kW MegaPAC xxxx-x With VI-200/VI-J00 eg. MP10-410008-23 With Maxi eg. MX10-410008-23...
  • Page 11 * ConverterPAC options B Booster module (SI for FasTrak) M M Grade module D DC OK or Power Good P Preload F Full 50-110% output adjustment R RAM external F1 50-107.5% output adjustment S Trimpot removed for external BatPAC adjustment F2 50-105% output adjustment T 90-110% output adjustment F3 50-102.5% output adjustment...

  • Page 12: Quick Install

    (For Mechanical Drawing, see pages 15) Mounting the 3 Phase MegaPAC and 4kW MegaPAC The 3 Phase MegaPAC and 4kW MegaPAC can be mounted on any of four sides. Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.15" (3,8mm).
  • Page 13 3 Phase and 4kW MegaPACs “Quick Install” Instructions (Cont.) Sense Connections Note: Newer power supplies may have a new feature installed called Autosense. For units with Autosense, if Remote Sense connections are not made or needed, no Local Sense selection is necessary - simply connect the output to the load and the unit will automatically operate in Local Sense.
  • Page 14 3 Phase and 4kW MegaPACs “Quick Install” Instructions (Cont.) Sense Connector J2 Trim Connection (and P2 for UniPACs) J2-1 Trim Pin Access The J2 remote Trim connection should only be used if the local Trim option has not J2-2 +Sense J2-3 -Sense been installed.

  • Page 15: Mechanical Drawings

    3 Phase MegaPAC Mechanical Drawings AMP NO. 746862-2 PLUG J2-PIN1 FOR FLAT RIBBON CABLE MATES WITH HSG AMP NO. .560 (14.2 MM) 747547-2 PLUS SLIDE TYP. LATCH OR SIMILAR. -P8 TYP. BUS BARS - FOR (10.2 MM) PARALLEL OUTPUTS R4 "TRIMPOT" PRESENT WHEN ADJUSTABLE OUTPUT 1.852...
  • Page 16 4kW MegaPAC Mechanical Drawings UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 16...

  • Page 17: Interface Connections

    Interface Connections Chassis Input Power Terminals (J1) Input AC power is applied to a plug-in connector, J1, that accepts soldered terminals with a wire size of 12 AWG. For operation on high voltage DC input, input power can be connected to any two input lines. A fault-clearing device should be installed at the input of the unit.
  • Page 18 Interface Connections (Cont.) Signal Ground (J10-1, J10-2, J10-12, J10-15) Signal Ground (see Figure 4) is an isolated ground reference for all J10 interface 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 J1.
  • Page 19 Interface Connections (Cont.) 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. Example: Slots 1 through 6 have been configured as a single output parallel array (see Fig.
  • Page 20 The ConverterPAC in slot #10 of the first 3 Phase MegaPAC or the 4kW MegaPAC must be either a driver or a booster in a parallel array. ConverterPACs paralleled from chassis to chassis must be of the same type, voltage, and power.
  • Page 21 Interface Connections (Cont.) Auxiliary Vcc +5V/0.3A (J10-16, 17) The Vcc on J10-16, 17 is an auxiliary 5 V regulated power source (see Figure 8 and Connector Pin Identification of page 18). It is +5 Vdc +/–5% with respect to Signal Ground and can supply 300 mA maximum.
  • Page 22 Interface Connections (Cont.) Power Good Inverted (J3-2) This is the inverse of the Power Good signal and is referenced to Signal Ground on J3-1. Signal Ground (J3-1) Signal Ground on J3-1 is an isolated secondary ground reference for J3 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 J1.
  • Page 23 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. If the Trim potentiometer has not been ordered, the Trim pin must be used.
  • Page 24 Setting the bottom limit: = 2.5 V - 10% = 2.25 V And since I = 25 mA, R6 = V = 2.25 V/25 mA = 90 kW = 2.75 V + 2.25 V = 5 V /R7 = 5 V/10 kW = 500 mA = 525 mA = (V +10%) - V...

  • Page 25: Specifications

    Safety Approvals cTUVus – EN 60950-1, UL 60950-1, CSA 60950-1 CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC 3 Phase MegaPAC: 18.1lbs (8.21kgs) fully configured Product Weights 4KW MegaPAC: 21.5lbs (9.77 kgs) fully configured 2 years limited warranty.
  • Page 26 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 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" connection to a common point must be used as shown in figure 1.

  • Page 28: Current Share Boards

    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 Description P o w e r - V 1 0.12"...

  • Page 29: Low Leakage Version

    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.
  • Page 30 NOTES: UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 30...

  • Page 31: 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.

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4kw megapac

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