Vicor 4kW MegaPAC AC-DC Switchers User Manual
USER GUIDE | UG:107
S
NRTL
CUS
3 Phase MegaPACTM
4kW MegaPAC
TM
AC-DC Switcher
August 2013
Contents Page
Overview 1
of Product
Mechanical 2
Considerations
MegaPAC 3
Do’s and Don’ts
Technical Description 4
Configuring and 5
Reconfiguring
MegaPACs
ConverterPAC 6
Description
Part Numbering 10
Quick Install 12
Instructions
Mechanical Drawings 15
Interface Connections 17
Specifications 24
Current Share Boards 26
Low Leakage Version 29
4kW MegaPAC
3 Phase MegaPAC
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,
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 oers 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 dierent 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 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.
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 1
Standard Features
n Input: 3Æ 208/240 Vac Wye or Delta, 1Æ 180-264 (47-500Hz) or 260–352 Vdc
n Power Output: 3 Phase MegaPAC: 2,000W with 3Æ input; 1,200W
with 1Æ input; 1–20 outputs
4kW MegaPAC: 4,000W with 3Æ input; 1,500W
with 1Æ input; 1–20 outputs
n 10 slots (up to 20 outputs)
n Fan cooled (the 4kW MegaPAC has 2 fans)
n Full power to 45°C; half power to 65°C
n Power factor correction (passive) 0.92 PF (3Æ input)
n Conducted EMI meets EN 55022 Level A
n AC Power OK and AC Power Fail status signals
n Output Sequencing and General Shutdown
(Consult Applications Engineering for automatic sequencing circuitry.)
n Autosense (Refer to page 11 and page 15 for more information on Autosense)
n Overcurrent protection on all outputs
n Overtemperature limiting (not applicable with VI-J00 modules)
n Output overvoltage protection (not applicable with VI-J00 modules)
n Ride-Through time: >20 ms at nominal line (full load)
n Size: 4 kW MegaPAC: 4.9"H x 7.5"W x 14"L
(124,5mm x 190,5mm x 355,6mm) Regular chassis
Size: 3 Phase MegaPAC: 4.9"H x 7.5"W x 12.3"L
(124,5mm x 190,5mm x 312,4mm) Regular chassis
n Safety Agency Approvals: CE Mark, UL, CSA, TUV
Optional Features
n DC OK status signal
n Output voltage adjustment range with built-in potentiometer
n Reversed fan airflow direction
n Industrial-grade screening of output converters
n Current Share Boards - See page 27 and 28
Mechanical Considerations
The 3 Phase MegaPAC and 4kW MegaPAC can be mounted on any of four surfaces using
standard 8-32 or 4 mm screws. The chassis comes with four mounting points on each
surface; maximum allowable torque is 20 lb-in.
The maximum penetration is 0.15 in. (3,8 mm).
When selecting a mounting location and orientation, the unit should be positioned so
air flow is not restricted. Maintain a 2" minimum clearance at both ends of the 3 Phase
MegaPAC and 4kW MegaPAC 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. 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.
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 2
Avoid excessive bending of output power cables aer 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 shortout to neighboring output studs. The 3 Phase MegaPAC and 4kW MegaPAC is supplied
with serrated, flanged hex-nuts on all output studs, so thread locking compounds or lock
washers are not required. The maximum torque recommended on flanged nuts is 45 lbin. Never loosen the inner nut on a 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.
MegaPAC Do’s and Don’ts
n For units without Autosense, do not leave ConverterPAC Sense lines open. Always
terminate them at their respective outputs locally or at the load. Use twisted
pair 22-24 AWG wire. If ConverterPAC has Autosense, no local sense connection
is required. See page 13 and 17 for more information on Autosense.
n If needed, use Connector Kit # 19-130041 for the 3 Phase/4kW MegaPACs.
n Always fill all output slots of the MegaPAC. If a slot is not filled with a
ConverterPAC, it should be filled with an airblock. Airblocks are plastic assemblies
whose main function is to fill up an empty slot. Any airflow escape from an empty
slot, significantly degrade thermal performance can result in overheating and
damage to the power supply.
n Do not unplug ConverterPACs while input power is applied. They are not
designed for hot-plug applications.
n Do not restrict airflow to the unit. Leave 2 inch minimum space in front and
behind the supply. The cooling fan draws air into the unit and forces it out at the
output power terminals.
n For power expansion, use booster ConverterPACs. Viewing the unit from the output
terminal side, always insert boosters to the right side of the driver.
n Do not use boosters as independent outputs. Disconnecting bus bars will damage
booster ConverterPACs.
n Always ensure that output hex-nuts arer properly torqued before applying
power to supply.
n For booster arrays, do not remove busbars.
n Run the output (+/–) power cables next to each other to minimize inductance.
n Wait 5 minutes aer shutting o power before inserting or removing ConverterPACs.
n The MegaPACs does not have user serviceable components. They must be returned to
the factory for repairs. Contact Customer Service for a RMA number before returning
the unit. Do not attempt to repair or modify the power supply in any manner other
than the exchange of ConverterPACs as described in this User Guide.
n Insert proper fault protection at power supply input terminals (i.e., a fuse).
n Use proper size wires to avoid overheating and excessive voltage drop.
n Never loosen the inner nut on a ConverterPAC.
n Verify output nuts are tight before powering up.
n Only use the regular length ConverterPACs in the 3 Phase/4kW MegaPAC chassis.
You cannot use any of the Extended Length ConverterPACS which are only used in
the EL (Low Noise) products.
n Keep in mind that currently, the UniPAC ConverterPAC can only be used in
the 4kW MegaPAC.
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 3
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 highvoltage backplane and provide low-noise, independently regulated and fully isolated
outputs.
Input AC mains voltage (L1, L2, L3 and GND) is applied to an agency approved mating
plug. The input current is passed through an EMI filter designed to meet EN 55022 Level
A before it is passed to a three-phase full-wave bridge rectifier. The rectifier charges
storage capacitors and delivers unregulated 300 Vdc to a backplane aer passing
through a large choke that improves input power factor. The power factor typically
exceeds 0.9 depending upon load, line voltage, frequency and line balance. Inrush
current is actively controlled with an IGBT and never exceeds 30A peak regardless of hot
or cold starts.
A housekeeping supply, isolated from the AC input, powers the brushless DC cooling
fan and other input monitoring circuits, in addition to providing an auxiliary +5V power
source for the user. The 4kW MEGAPAC HAS A SECOND FAN FOR EXTRA COOLING.
Excessive input currents caused by loss of a phase or excessive output loading in single
phase operation will safely shut down the unit until input power is recycled. This occurs
when the peak input current reaches 30A . An analog temperature monitor is provided,
as well as overtemperature shutdown. An active-high TTL compatible Enable control is
included for each ConverterPAC assembly, as well as an active-low General Shutdown
control; the polarities, active-high or active-low, are factory set. The 3 Phase MegaPAC
and 4kW MegaPAC can be safely paralleled (with another of its own kind) with accurate
current sharing for high power systems. All interface signals are safety isolated using a
common floating return.
Upon power-up, all outputs are first disabled to limit the inrush current, and to allow
the unregulated bus to reach correct operating levels for ConverterPAC assemblies. The
internal housekeeping supply comes up within 500 ms aer input power is applied, and
the AC Power OK signal asserts to a TTL "1," indicating the input power is OK. The low
voltage power outputs come up within 10-20 ms aer the AC Power OK asserts to a TTL
"1." Output ramp-up time from Enable or General Shutdown is 10-20 ms. Output fall
time from Disable is dependent on load, but is typically a few hundred microseconds.
Figure 1.
3 Phase MegaPAC and 4kW
MegaPAC Architectures
J1
Input
Power
J10
Customer
Interface
3 Phase/4kW MegaPAC Chassis
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 4
EN 55022
Level A
Start-up Control
Circuits
Opto-isolated
Control/Status
3 Phase
Full-Wave
Rectifier
DC Brushless
Cooling Fan
PFC Choke
IGBT
Isolated
Housekeeping
Power Supply
Fuse
ConverterPAC (Up to 10)
DC/DC
Converter
+P, -P
Output
Power
Remote Sense,
Trim Interface
Power Good
Interface
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. For outputs
greater than 500 Watts (in the 4kW MegaPAC), a driver UniPAC and one or more booster
UniPACs will be used. Arrays of drivers and boosters should be configured so all
boosters are placed in the slots to the immediate right of the driver when looking at the
output end of the MegaPAC.
Prior to removing or installing ConverterPACs, you must remove power from the
MegaPAC and wait 5 minutes. Failure to do so can result in personal injury or
damage to the supply.
Take standard ESD precautions when handling ConverterPACs.
Removing ConverterPACs
ConverterPACs can be removed by loosening the captive screw at the base. Once this
screw has been loosened, the ConverterPAC will slide out of the chassis. Once a
ConverterPAC has been removed, the empty slot MUST be filled with either another
ConverterPAC of the same length or an airblock. If the slot is le empty, it will
provide an airflow escape and cause failure to the power supply.
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. Power and interface connections can
be made aer the ConverterPAC has been installed.
Installing Booster ConverterPACs to Increase Output Power
ConverterPACs can be paralleled for more power. Additional power to an output is
obtained by connecting one or more boosters in parallel with a single driver. The
driver can be placed in any open slot. All boosters should be inserted in the slots to
the immediate right of the driver, as viewed from the output end of the MegaPAC.
Figure 2 shows a driver placed in slots #1 and 3 boosters placed in slots # 2 to 4. Aer
inserting the driver and boosters, they are paralleled using bus bars across the positive
and negative output studs. Drivers should not be paralleled with each other. Bus bars
between a driver and booster(s) should never be disconnected. For help in identifying
boosters and drivers, refer to the Part Numbering section on page 10. Please note that
total output voltage should not exceed the converter baseplate-output isolation rating of
400V. 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
4
1
2
3
Driver
Boosters: Slots 2, 3, 4
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 5
L1 L2 L3
5
6
8
7
9
10
Remote Sense
VI-200
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
Remote Sense
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
Remote Sense
Output #2 Adjust
Output #2
Output #1
Remote Sense
Output #1 Adjust
Remote Sense
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
+ Vout
- Vout
Remote Interface
Voltage Limit Adjust
Current Limit Adjust
Remote Sense
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
VI-J00
VI-J00 VI-J00
M2
M1
ModuPAC
JuniorPAC
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 or between dierent AC input chassis. They can be added, moved, or changed
as necessary. The following ConverterPACs can be used in the 3 Phase and 4kW
MegaPACs.
ModuPAC
+
The ModuPAC output assembly consists of a VI-200 Vicor DC to DC converter that
converts the unregulated high voltage bus to the desired regulated output voltage. Each
_
ModuPAC can provide up to 200 Watts of power. Multiple ModuPACs can be paralleled
in a driver-booster configuration to provide more power.
+
JuniorPAC
The JuniorPAC consists of a VI-J00 Vicor DC to DC converter that converts the
_
unregulated high voltage bus to the desired regulated output voltage. JuniorPACs can
provide up to 100 Watts of output power.
M1
DualPAC
This output assembly consists of two VI-J00 Vicor DC to DC converters that convert the
M2
unregulated high voltage bus to the desired regulated output voltages.
VI-J00 RAM
VI-200/BatMOD
Maxi
DualPAC
RAMPAC
BatPAC
UniPAC
+
RAMPAC
This output assembly consists of a VI-J00 Vicor DC to DC converter with a Ripple
_
Attenuator Module (RAM) and is designed for applications requiring low output ripple/
noise.
+
BatPAC
The BatPAC output assembly consists of a VI-200 BatMod current source that converts
_
the unregulated high voltage bus to the desired regulated output voltage. The BatPAC is
a 200 Watts programmable current source that can be configured as a battery charger.
UniPAC
+
The UniPAC output assembly consists of a Maxi Vicor DC-DC module that converts
the unregulated high voltage bus to the desired regulated output voltage. UniPACs can
_
provide up to 500W of power. Multiple UniPACs can be paralleled in a driver-booster
configuration to provide more power. The UniPAC can only be used in the 4kW
MegaPAC (not in the 3 Phase MegaPAC or any other MegaPACs).
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 6
M-1 STATUS
M-1 VOLTAGE ADJUSTMENT
M-4 STATUS
M-3 STATUS
M-2 VOLTAGE ADJUSTMENT
M-2 STATUS
M-4 VOLTAGE ADJUSTMENT
M-3 VOLTAGE ADJUSTMENT
CONNECTOR J1
FlexPAC
ConverterPAC Functional Description (Cont.)
FlexPAC
The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the
high output bus to the desired output voltage. Each FlexPAC output can be manually
trimmed from 2V to 25V and supports up to 5 amps with a maximum output powerof
50W per output. All outputs maintain less than 50mV noise over the entire output
range. All outputs support local sense only. For electrical trim options and specific
output sequencing contact the factory
List of ConverterPACs used in the 3 Phase/4kW MegaPACs and their features
ConverterPAC OVP OCP OTL RS/AS* LS/AS* PG TrimPot
ModuPAC Std Std Std AS* AS* Opt Opt
JuniorPAC N/A Std N/A AS* AS* Opt Opt
DualPAC N/A Std N/A AS* AS* N/A Opt
RAMPAC N/A Std N/A AS* AS* Opt Opt
BatPAC N/A Std N/A N/A N/A N/A Std
UniPAC** Std Std N/A AS* AS* Opt Opt
* See page 13 and 17 for more information on Autosense.
** Currently, the UniPAC (XU) can only be used in the 4kW MegaPAC.
OVP Overvoltage Protection (latching) OCP Overcurrent Protection (auto-recovery)
OTL Overtemperature Limiting (latching) RS Remote Sense
PG Power Good (DC OK TTL Signal) LS Local Sense
AS Autosense
Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC,
JuniorPAC and RamPAC.
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 7
DUALPAC
BATPAC
DualPAC
20-130182-TAB
ConverterPAC Output and Connector Pin Identification for the
3 Phase/4kW MegaPACs
J1-B-PIN1
J2-B-PIN1
OUTPUT ADJUST
J1-A-PIN1
J2-A-PIN1
OUTPUT ADJUST
(OUTPUT CONNECTORS)
1 AND 4 +V OUT
1
4
2 AND 5 -V OUT
2
5
6
3
3 +R/SENSE 6 -R/SENSE
J2
(REMOTE SENSE)
TRIM PIN ACCESS
1
2
+ SENSE
3
- SENSE
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-2060
TERMINALS- MOLEX P/N: 39-00-0039
CRIMP TOOL MOLEX P/N: 11-01-0197
MATING HDWR:
HOUSING- MOLEX P/N: 50-57-9403
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 11-01-0208
J1
DUALPAC - COMPONENT SIDE VIEW
BatPAC
Output A
48V/2.1A
+ V0UT
CURRENT LIMIT ADJUST
VOLTAGE LIMIT ADJUST
- VOUT
J2-PIN1
M2
M1
Output B
12V/8.3A
Example: D12V/8.3A-48V/2.1A
J2 (BATPAC REMOTE INTERFACE)
CURRENT LIMIT ADJUST
4
3
VOLTAGE LIMIT ADJUST
2
CURRENT MONITOR
1
- VOUT
J1-B (M1)
J1-A (M2)
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0043
TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 8
ConverterPAC Output and Connector Pin Identification for the
UNIPAC
3 Phase/4kW MegaPACs (Cont.)
UniPAC
ModuPAC
JuniorPAC
RamPAC
+ V0UT
OUTPUT ADJUST
- VOUT
P2-PIN1
+ V0UT
J2-PIN1
0UTPUT ADJUST
- VOUT
J3-PIN1
P2 REMOTE SENSE TRIM/SC & POWER GOOD
+SENSE
7
6
-SENSE
5
TRIM
4
Vcc IN
3
POWER GOOD
2
POWER GOOD INVERTED
1
SIGNAL GROUND
(REMOTE SENSE)
J2
TRIM PIN ACCESS
1
2
+ SENSE
3
- SENSE
J3 DC OK (POWER GOOD)
Vcc IN
4
3
POWER GOOD
2
POWER GOOD INVERTED
1
SIGNAL GROUND
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0073
TERMINALS- MOLEX P/N: 39-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
MATING HDWR:
HOUSING- MOLEX P/N: 50-57-9403
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 11-01-0208
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0043
TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
FlexPAC
M-1 STATUS
M-2 STATUS
M-1 VOLTAGE ADJUSTMENT
M-2 VOLTAGE ADJUSTMENT
CONNECTOR J1
M-3 VOLTAGE ADJUSTMENT
M-4 VOLTAGE ADJUSTMENT
M-3 STATUS
M-4 STATUS
MATING HDWR:
HOUSING MOLEX P/N 39-01-2120
TERMINALS MOLEX P/N 39-00-0039
CRIMP TOOL MOLEX P/N 11-01-0197
Note: The UniPAC can ONLY be used in the 4kW MegaPAC.
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 9
Part Numbering
3Ø MegaPAC MPx1-5x2xxxx
eg. MP4-510108
MP = MP
x1 = number of outputs
9 = 3 Phase MegaPAC chassis
x2 = number of modules
xxxx = assigned by Westcor
4kW MegaPAC MPx1-4x2xxxx-x3x4-x5-x
With VI-200/VI-J00 eg. MP10-410008-23
With Maxi eg. MX10-410008-23
MP = MP
6
x1 = number of outputs
4 = 4kW MegaPAC chassis
x2 = number of modules
xxxx = assigned by Westcor
x
= Optional Code 2 = VI-J00 or VI-200 module in slot #1; 3 = Maxi in Slot 1
3
x4 = Optional Code 2 = VI-J00 or VI-200 module in slot #10; 3 = Maxi in Slot 10
x5 = Optional Code
x6 = Optional Code
ConverterPAC XxDV/xEAx
eg. M15V/10A
eg. M15V/10ADF
eg. D15V/6.7A-12V/8.3AT
X = ConverterPAC type - If RoHS precede with a “G”
F
M = ModuPAC D = DualPAC R = RamPAC J = JuniorPAC B = BatPAC
XU = UniPAC (currently only used in the 4kW MegaPAC)
xD = Voltage out
x
= Current out (rounded to 1 decimal point)
E
xF = Can be multiple options* (see below)
UG:107 vicorpower.com Applications Engineering: 800 927.9474 Page 10
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