Vicor 4kW MegaPAC-EL AC-DC Switchers User Manual

USER GUIDE | UG:108

S

NRTL

CUS

End of Life - Not Recommended for New Designs

3 Phase MegaPAC-ELTM (Low Noise)
4kW MegaPAC-EL

TM

(Low Noise)

AC-DC Switchers

September 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 - EL and 4kW MegaPAC - EL are field-configurable, single or
multiple output switchers, providing up to 2,000 W (3 Phase MegaPAC/EL- Low Noise)
to 4,000 W of output power (4kW MegaPAC/EL-Low Noise). The chassis has 10 slots
and provides up to 20 regulated, fully isolated outputs. It achieves power densities of

3.6 W per cubic inch (3 Phase MegaPAC/EL (Low Noise)) to 6.4 W per cubic inch (4kW
MegaPAC/EL (Low Noise). The dimensions for the 3 Phase MegaPAC/EL (Low Noise)
are 4.9"H x 7.5"W x 15.2"L (124,5mm x 190,5mm x 429,3mm) and the dimensions for
the 4kW MegaPAC/EL (Low Noise) are 4.9"H x 7.5"W x 16.9"L (124,5mm x 190,5mm x
386,1mm). The 4kW MegaPAC/EL (Low Noise) is longer than the 3 Phase MegaPAC/EL
(Low Noise) to accommodate a 2nd fan.

A complete power supply is configured 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 MaxiVicor DC to DC converters and are available in
a wide selection of output voltage and power levels. The net result is a power supply
that oers the advantages of a custom supply, but is assembled from standard and
modular building blocks. For detailed information about all ConverterPACs, refer to
the ConverterPAC information sheets. The 4kW MegaPAC-EL (Low Noise) uses VI-200/
VI-J00 and Maxi Vicor DC to DC converters while the 3 Phase MegaPAC-EL (Low Noise)
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 dierent output voltage is needed, upgrading is easy: simply unlock a
single screw and replace the slide-in ConverterPAC with another Extended Length
ConverterPAC that 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
400 V). 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:108 vicorpower.com Applications Engineering: 800 927.9474 Page 1

Standard Features

End of Life - Not Recommended for New Designs

n Input: 3Æ 208/240 Vac Wye or Delta, 1Æ 180-264 (47-500Hz) or 260–352 Vdc

n Power Output: 3 Phase MegaPAC: 2,000 W with 3Æ input; 1,200 W with 1Æ input

4kW MegaPAC: 4,000 W with 3Æ input; 1,500 W with 1Æ input

n 10 slots (upto 20 outputs)

n Fan cooled (4kW MegaPAC-EL has 2 fans)

n Full power to 45°C; half power to 65°C

n Power Factor Correction - passive - to 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 Auto Sense capability Refer to page 12 and page 16 for more information on Autosense

n Overcurrent protection on all outputs

n Overtemperature limiting (not applicable with VI-J00)

n Overvoltage protection (not applicable with VI-J00 modules)

n Size: 3 Phase MegaPAC - EL: 4.9"H x 7.5"W x 15.2"L

(124,5mm x 190,5mm x 429,3mm) Extended chassis

Size: 4kW MegaPAC - EL: 4.9"H x 7.5"W x 16.9"L
(124,5mm x 190,5mm x 386,1mm) Extended chassis

n Safety Agency Approvals: cURus, cTUVus, CE Mark

Optional Features

n DC OK status signal

n Output voltage adjustment range with built-in potentiometer

n Reversed fan airflow direction

n Current Share Boards - see page 25

Mechanical Considerations

The 3 Phase MegaPAC - EL and 4kW MegaPAC - EL 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 20 lb-in. The maximum
penetration is 0.15 in. (3,8mm).

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 - EL and 4kW MegaPAC - EL 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 - EL and 4kW MegaPAC - EL. For the 4kW MegaPAC - EL, the
fans move approximately 50 CFM of air while for the 3 Phase MegaPAC -EL, the fan
moves approximately 30 CFM of air. The 4kW MegaPAC - EL has a second fan for
additional cooling.

Avoid excessive bending of output power cables aer they are connected to the 3
Phase MegaPAC - EL or the 4kW MegaPAC - EL. 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. The 3 Phase MegaPAC - EL and

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 2

4kW MegaPAC - EL are supplied with serrated, flanged hex-nuts on all output studs.

End of Life - Not Recommended for New Designs

Therefore, thread locking compounds or lock washers are not required. The maximum
torque recommended on flanged nuts is 45 lb-in. 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 to 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 12 and 16 for more information on Autosense.

n If needed, use Connector Kit # 19-130041 for the 3 Phase/4kW

MegaPACs/EL - Low Noise.

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 airlfow escape from an empty
slot significantly degrades thermal performance, and 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 are 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 aer 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 unitDo not attempt to repair or modify the power supply in any manner other
than the exchange of ConverterPACs as described in this Design 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 Keep in mind that the Regular Length ConverterPACs cannot be inserted in

the 3 Phase/4kW MegaPAC/ELs - Low Noise chassis because the Regular Length
ConverterPACs are too short to fit in the extended length chassis. The Extended
Length ConverterPACs are sometimes referred to as the QuietPAC (or QPAC)
Family of Low Noise ConverterPACs.

n Currently, the QPAC (XQ) is only used in the 4kW MegaPAC/EL (Low Noise).

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 3

Technical Description

End of Life - Not Recommended for New Designs

The 3 Phase MegaPAC - EL and 4kW MegaPAC - EL 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 aer 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 30 A peak regardless of
hot or cold starts or input volatage.

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 +5 V
power source for the user. The 4kW MegaPAC - EL 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 30 A. 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. Two (or more) 3 Phase
MegaPAC - ELs can be safely paralleled with accurate current sharing for high power
systems. Two (or more) 4kW MegaPAC - ELs can be safely paralleled 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 aer 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 aer 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 - EL and

4kW MegaPAC - EL Architecture

2nd Fan here

in the 4kW

MegaPAC-EL

J1
Input
Power

J10
Customer
Interface

3 Phase/4kW MegaPAC/EL (Low Noise) Chassis

EN 55022

Level A

Start-up Control

Circuits

Opto-isolated

Control/Status

3 Phase

Full-Wave

Rectifier

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 4

IGBT

Isolated
Housekeeping
Power Supply

DC Brushless

Cooling Fan

PFC Choke

+P, -P
Output

Fuse

QPAC ConverterPACs (Up to 10)

DC/DC

Converter

Power

Remote Sense,
Trim Interface

Power Good
Interface

Configuring and Reconfiguring MegaPACs

End of Life - Not Recommended for New Designs

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 QPAC
ConverterPACs and can be inserted into any available slot. For outputs greater than
200 Watts, a driver QPAC and one or more booster QPACs will be used. For outputs
greater than 500 Watts, a driver QPAC (XQ) (in the 4kW MegaPAC - EL) and one or more
booster QPAC (XQs) 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 QPAC 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 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 aer the ConverterPAC has been installed.

Installing Booster ConverterPACs to Increase Output Power

Most ConverterPACs of the same length 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. Aer 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. For
the 3 Phase/4kW MegaPAC/ELs (Low Noise), all the driver and booster ConverterPACs
must consist of the Extended Length ConverterPACs. Bus bars between a driver and
booster (s) should never be disconnected. For help in identifying boosters and drivers,
refer to the section on Part Numbering on page 9. Please note that total output voltage
should not exceed the converter baseplate-output isolation rating of 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: Slots 2, 3, 4

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 5

1

L1 L2 L3

2

4

3

5

6

8

7

9

10

+

_

VI-200

End of Life - Not Recommended for New Designs

QPAC (L)

QPAC (XL)

ConverterPAC Functional Description (See ConverterPAC Datasheet/Design Guide for

complete information on all ConverterPACs.)

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 dierent AC input MegaPAC chassis. They can be added, moved, or
changed as necessary. A key feature of the Extended Length ConverterPAC is the low
ripple and noise output to 10mV p-p or 0.15%, whichever is greater. The following
ConverterPACs can be used in the 3 Phase MegaPAC - EL and 4kW MegaPAC - EL.

QPAC (L or XQ)

The QPAC (L) and QPAC (XQ) output assemblies consist of a VI-200/VI-J00 and a Maxi
Vicor DC to DC converters respectively. They convert the unregulated high voltage bus
to the desired regulated output voltage. Each QPAC (L) can provide up to 200 Watts of
output power, and booster QPACs can be added in parallel for more power. Each QPAC
(XQ) can provide up to 500 Watts of output power and slave QPACs can be added in
parallel for more power. The QPAC (XQ) can only be used in the 4kW MegaPAC-EL (Low
Noise). An active preload ensures the DC to DC converter operates in its highest noise
performance range. As the load on the module increases, the preload removes itself
from the circuit. Ripple and common mode noise filters on the output reduce ripple
under any load condition to 10 mV p-p or 0.15%, whichever is greater. QPACs can only
be ordered in the extended length Low Noise MegaPAC products. Please note that for

all QPACs, the output voltage from either output terminal to chassis should not
exceed 400 Volts DC, or peak.

VI-J00

VI-J00

VI-J00

Junior QPAC

DualQPAC

DualQPAC (LD)

The DualQPAC output assembly consists of two VI-J00 Vicor DC to DC converters that
provides two isolated output voltages. DualQPACs can provide up to 100 Watts of output
power from each output. An active preload ensures the DC to DC converters operate in
their highest noise performance range. As the load on the module increases, the preload
removes itself from the circuit. Ripple and common mode noise filters on the output
reduce ripple under any load condition to 10 mV p-p or 0.15%, whichever is greater.
DualQPACs can only be ordered in the extended length Low Noise MegaPAC products.

Please note that for all DualQPACs, the output voltage from either output terminal
to chassis should not exceed 400 Volts DC, or peak.

Junior QPAC (LJ)

The Junior QPAC output assembly consists of one VI-J00 Vicor DC to DC converters
that provide one isolated output voltages. The Junior QPAC can provide up to 100 Watts
of output power from each output and can only be ordered in the extended length Low
Noise MegaPAC products. Please note that for all Junior QPACs, the output voltage

from either output terminal to chassis should not exceed 400 Volts DC, or peak.

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 6

List of ConverterPACs used and their features

End of Life - Not Recommended for New Designs

ConverterPAC OVP OCP OTL RS/AS* LS/AS* PG TrimPot

QPAC (L ) Std Std Std AS* AS* Opt Opt

QPAC (XQ)** Std Std Std Std Opt Opt Opt

DualQPAC (LD) N/A Std N/A AS* AS* Std N/A

Junior QPAC (LJ) N/A Std N/A AS* AS* Opt Opt

* See page 12 and 16 for more information on Autosense.
** Currently, the QPAC (XQ) can only be used in the 4kW MegaPAC/EL.

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

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 7

ConverterPAC Output and Connector Pin Identification -

QPAC (L and XL)

End of Life - Not Recommended for New Designs

3 Phase/4kW MegaPACs/EL (Low Noise)

QPAC (L and XQ)

Jr. QPAC

DualPAC

+ V0UT

OUTPUT ADJUST

- VOUT

P2-PIN1

J1-B-PIN1

7

TRIM TOP

6

TRIM BOT

5

N/C

4

Vcc IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

J1-A-PIN1

P2 REMOTE SENSE TRIM/SC
& POWER GOOD

MATING HDWR:

HOUSING- MOLEX P/N: 39-01-0073
TERMINALS- MOLEX P/N: 39-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000

+SENSE

7
6

-SENSE

5

TRIM

4

Vcc IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

J1-B

(OUTPUT CONNECTORS)

1 AND 4 +V OUT

1

4

2 AND 5 -V OUT

2

5

3 +R/SENSE 6 -R/SENSE

6

3

J1-A

(OUTPUT CONNECTORS)

1 AND 4 +V OUT

1

4

2 AND 5 -V OUT

2

5

3 +R/SENSE 6 -R/SENSE

6

3

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: 39-01-2060

TERMINALS- MOLEX P/N: 39-00-0039

CRIMP TOOL MOLEX P/N: 11-01-0197

UG:108 vicorpower.com Applications Engineering: 800 927.9474 Page 8

Part Numbering

End of Life - Not Recommended for New Designs

3Ø MegaPAC-EL MP*xA-5xBxxx-EL

eg. MP4-510108-EL

MP = MP

xA = number of outputs

5 = 3Ø MegaPAC - EL Prefix

xB = number of modules

xxx = assigned by Westcor

EL = Indicates extended length chassis for use with QPACs

4kW MegaPAC-EL MP*xA-4xBxxx-xG-xH-EL

With VI-200/VI-J00 eg. MP10-410008-23-EL
With Maxi eg. MX10-410008-23-EL

MP = MP
xA = number of outputs
4 = 4kW MegaPAC chassis
xB = number of modules
xxx = assigned by Westcor

x

= Optional Code 2 = VI-J00 or VI-200 module in slot #1; 3 = Maxi in Slot 1

G

xH = Optional Code 2 = VI-J00 or VI-200 module in slot #10; 3 = Maxi in Slot 10
EL = Indicates extended length chassis for use with QPACs

* If a Maxi module is used, the part number changes from MP to MX.

ConverterPAC XxDV/xEAx

eg. L15V/10A
eg. L15V/10ADFIL
eg. LD15V/6.7A-12V/8.3AT

X = ConverterPAC type - If RoHS precede with a “G”

F

L = QPAC LD = DualQPAC LJ = Jr QPAC XU = Maxi QPAC
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:108 vicorpower.com Applications Engineering: 800 927.9474 Page 9