Vicor ComPAC Family 50 to 600 Watt DC-DC Switchers User Manual

ComPAC Family

50 to 600 Watt
DC-DC Switchers

Functional and Mechanical Layout

Installation and Operation Guidelines

Application Notes

Product Description

The ComPAC family of user-definable power supplies provides a complete

power solution optimized to meet the voltage, noise, and transient

protection input requirements of commercial, industrial, military, and

telecommunications applications. These switchers are available with one,

two, or three outputs and total output ratings up to 600 Watts. Each unit

incorporates one, two, or three component-level Vicor DC-DC converters in

a chassis-mount housing. ComPAC’s unique modular design accommodates

thousands of different configurations.

2

20 mA Max.

Disable

DIS+

DIS–

+

V

0.1 1 10ms 100 1000

100V

Normal Operating Area

I.S.W.

Full Load

100V

Standard Wide Range

24V Inputs

0.1 1 10ms 100 1000

800V

Normal Operating Area

I.S.W.

Full Load

300V Input

S.D.

160V

0.1 1 10ms 100 1000

Normal Operating Area

I.S.W.

Full Load

48V Input

R.E.

276V

Normal Operating Area

I.S.W.

Full Load

0.1 1 10ms 100 1000

48V Wide Range Input

R.E.

S.D.

R.E.

R.E.

32V

21V

36V

18V

S.D.

76V

125V

60V

100V

42V

500V

400V

200V

36V

S.D.

S.D.

100V

500ms

500ms

Application Notes

Input Connections

Master Disable

DC Input

Earth Ground

Disable +

Disable –

VIN +

VIN –

GND

See fuse chart on page 6

Master Disable Drive Circuit

The Master Disable input is optically isolated and incorporates a reverse polarity
protection diode. Apply a current of up to 20 mA to disable output(s). See ComPAC
data sheet for minimum levels.

Input Operating Voltage

Long Term Safe Operating Curves. I.S.W. = Input Surge Withstand (no

disruption of performance, 1% duty cycle max.).

R.E. = Ratings Exceeded. S.D. = Shutdown. For short duration transient

capability, refer to product specifications.

Thermal Impedance

Note: Not applicable for conduction cooled (–CC) models.

Below are the chassis-to-air thermal impedance values, as a function of airflow,

for ComPAC package configurations that incorporate one, two, and three internal

component DC-DC converters.

Thermal Impedance—Case-to-Air (°C/Watt)

Standard Units With Optional H1 Heatsink

1-Up 2-Up 3-Up 1-Up 2-Up 3-Up

Free Air (Horiz.) 3.6 1.7 1.4 2.1 1.3 1.0

Forced Convection Through Heat sink Fins

50 LFM 2.7 1.4 1.3 1.5 1.1 0.9

100 LFM 2.3 1.3 1.1 1.2 0.9 0.7

250 LFM 1.6 1.0 0.8 0.7 0.5 0.4

500 LFM 1.2 0.7 0.6 0.4 0.3 0.3

750 LFM 0.9 0.5 0.5 0.3 0.2 0.2

1000 LFM 0.8 0.5 0.4 0.2 0.2 0.2

To calculate case temperature: total power dissipated times

thermal impedance plus ambient temperature.

To calculate Watts dissipated per output: output power

divided by efficiency minus output power.

3

Output Trimming

Trim resistors not required for operation at rated output voltage.

+ OUT

+ SENSE

TRIM

— SENSE

— OUT

R2

+Sense and –Sense must be connected locally or remotely (shown).

Resistor Values for Trimming Standard Output Voltages

Nominal Output Voltage 5 V 12 V 15 V 24 V 28 V 48 V Trim Range

R1(KΩ) .953 15.8 22.1 41.2 48.7 90.9

R2(KΩ) 909090909090

Refer to Applications Manual, Chapter 5, for other trimming methods.

+ V

R1

To Load

10K

— V

+10%, -10%

OUT

OUT

4

4.96

(126,0)

4.42

(112,3)

7.380

(187,45)

0.18

(4,6)

6.00

(152,4)

7.00

(177,8)

2.288

(58,12)

2.420

(61,47)

0.20
(5,1)

0.19
(4,8)

5

1

3

2

4

ø.150 ± .005 THRU 6 PLAC
(ø3,81 ± 0,13)

3.58

(90,9)

3.04

(77,2)

4.96

(126,0)

4.562

(115,87)

0.18
(4,6)

6.00

(152,4)

2.281

(57,94)

0.20
(5,1)

0.19
(4,8)

5

1

3

2

4

ø.150 ± .005 THRU 5 PLACES
(ø3,81 ± 0,13)

2.156

(54,76)

0.18
(4,6)

6.00

(152,4)

0.91

(23,1)

2.54

(64,5)

0.20
(5,1)

0.19
(4,8)

0.20
(5,1)

5

1

3

2

4

ø.150 ± .005 THRU 4 PLACES
(ø3,81 ± 0,13)

1.37

(34,80)

0.99

(25,15)

0.5

(12,57)

9.25 ±.120

(235,0 ±3,05)

8.63 ±.025

(219,2

±,64)

0.5

(12,57)

Functional and Mechanical Layout

LC-Series

Single output
50-200 Watts

MC-Series

Single output
100-400 Watts

NC-Series

Single output
300-600 Watts

PC-Series

Dual output
100-400 Watts

QC-Series

Dual output
150-600 Watts

RC-Series

Triple output
150-600 Watts

Inputs

All Models

LC-Series

MC-, PC-Series

NC-, QC-, and RC-Series

Drawing: P.N. 11926

5

2.76

(70,1)

OUTPUT 1 OUTPUT 2

OUTPUT 1

OUTPUT 1 OUTPUT 2 OUTPUT 3

#10-32 STUD
2 PLACES

B

D

C

E

A

#8-32 STUD
6 PLACES

A

E

C

B

D

0

5.59 (141,99)

5.25 (133,35)

5.98 (151,89)

6.37 (161,80)

6.95 (176,53)

.25 TYP

A

E

C

B

D

.75 (19,05)

.41 (10,41)

1.14 (28,96)

1.53 (38,86)

2.11 (53,59)

#10-32 STUD
2 PLACES

A

B

D

C

E

A

B

D

C

E

#8-32 STUD
2 PLACES

A

E

C

B

D

3.17 (80,52)

2.83 (53,59)

3.56 (90,42)

3.95 (100.33)

4.53 (115,06)

2.76

(70,1)

OUTPUT 1 OUTPUT 2

OUTPUT 1

#8-32 STUD
4 PLACES

A

E

C

B

D

0

3.17 (80,52)

2.83 (71,88)

3.56 (90,42)

3.95 (100,33)

4.53 (115,06)

.25 TYP

#10-32 STUD
2 PLACES

A

E

C

B

D

.75 (19,05)

.41 (10,41)

1.14 (28,96)

1.53 (38,86)

2.11 (53,59)

B

D

C

E

A

2.76

(70,1)

OUTPUT 1

#8-32 STUD
2 PLACES

A

E

C

B

D

0

.75 (19,05)

.41 (10,41)

1.14 (28,96)

1.53 (38,86)

2.11 (53,59)

.25 TYP

OPTIONAL HEATSINK (H1)

STANDARD UNITS

1.12

(28,4)

0.41

(10,4)

Measure case temperature on this surface.

Outputs

LC-Series

MC-Series PC-Series

Inputs

1 Ground
2–V

IN

3+V

IN

4 –Disable
5 +Disable

Outputs

A +Out
B +Sense
C Trim
D –Sense
E –Out

Consult factory for outline
drawings of models with
conduction cooled (–CC) option.

NC-Series QC-Series RC-Series

6

Installation and Operation Guidelines

Input Line Fusing. The ComPAC must be fused externally. The table below lists the fuse

ratings for one-, two-, and three-up units (max. output 200, 400, and 600 Watts).

VI Series

200 W 400 W 600 W

24 V Input 10 A/32 V (AGC-10) 20 A/32 V (AGC-20) 35 A/32 V (AGC-35)
24 V Wide Input 12 A/32 V (3AB-12) 20 A/32 V (AGC-20) 35 A/32 V (AGC-35)
48 V Input 8 A/60 V (3AB-8) 15 A/60 V (3AB-15) 25 A/60 V (3AB-25)
48 V Wide Input 6 A/100 V (3AB-6) 15 A/100 V (3AB-15) 25 A/100 V (3AB-25)
300 V Input 2 A/250 V (3AB-2) 4 A/250 V (3AB-4) 6 A/250 V (3AB-6)

MI Series

Use MIL-F-15160 or MIL-F-23419 equivalents of the commercial fuses listed below.

200 W 400 W 600 W

28 V Input 10 A/250 V (3AB-10) 20 A/250 V (3AB-20) 30 A/125 V (3AB-30)
270 V Input 2 A/250 V (3AB-2) 4 A/250 V (3AB-4) 6 A/250 V (3AB-6)

Grounding

the terminal marked (GND). Use the same wire gauge as that specified for your ComPAC

unit’s input voltage connections, below.

Input Voltage Connections. Connect the line voltage to VIN+ (positive) and VIN– (negative).

For one-up ComPAC models (max. output 200 W), use #16 input wire; for two-up and three-

up models (max. output 400 W and 600 W), use #14 input wire. Be sure to tighten the lead

connections securely—recommended connector screw torque is 3.5 in-lbs (0.4 N-m).

Recommended strip length is 9 mm.

Output Wire Gauge. Use the output wire gauge that corresponds to the output current of

your ComPAC unit, below:

105 A–160 A : #4 26 A–40 A : #10 7 A–10 A : #16

66 A–104 A : #6 16 A–25 A : #12 4 A–6 A : #18

41 A–65 A : #8 11 A–15 A : #14 0 A–3 A : #20

. For safe operation, the ComPAC unit must be grounded. Connect a ground lead to

Output Voltage Trimming. Do not trim the outputs higher than 110% of their nominal

output voltage. When an output is trimmed up, do not exceed its maximum rated output power.

Operating Temperature. Do not allow the ComPAC to exceed its maximum operating

temperature, which is reached when the heat sink/–CC plate is 85°C. (Full power can be

delivered up to this temperature.) Heat sink temperature is a function of the output power

and voltage of the supply, ambient temperature, and airflow across the heat sink. Refer to the

Vicor Applications Manual to determine the maximum ambient temperature for your

application. Always use worst-case conditions when calculating operating temperature.

Note: To ensure proper heat transfer from the internal module(s) to the heat sink, the

mounting holes through the heat sink (2, 3, and 4 holes on one-, two-, and three-up models,

respectively) must contain properly torqued screws at all times during operation, whether or

not the unit is mounted.

EXTERNAL TOOTH

LOCKWASHER

#10 TERMINAL

RETAINING NUT

#10 NUT PLATE

USER OUTPUT

TERMINALS

#10 BRASS STUD

HELICAL

LOCKWASHER

(FITS WITHIN

OPENING PROVIDED)

TERMINAL COVER

NEGATIVE

If the unit is operated unmounted, insert a #6 or metric flathead screw

through each hole from below and secure with a nut on top, torqued to 6 in-

lbs (0.7 N-m). A thermal interface material is recommended for –CC models

– consult factory.

Output Terminal Connections. A hardware kit with parts for output terminal

connections is provided with each ComPAC unit. The following drawing

shows the assembly of those parts for the proper connection of metal power

terminals. Assembly for PCB power terminals is the same except that they do

not require an external tooth lockwasher. Consult the table below for the

recommended torque level for each stud size.

Metal Terminal

7

For More Information

The Vicor Applications Manual and product data sheet contain complete

information about ComPAC DC-DC Switchers. To receive literature or to

consult an applications engineer about installation or operation of this product,

contact your nearest Vicor office. (See page 8.)

“AMP” and “Faston” are registered trademarks of AMP, Incorporated, Harrisburg, PA.

Drawing: P.N. 10894 #1

Terminal and Terminal Recommended

Product Model Style Stud Size Torque

–Output, +Output

LC-, PC-, & PCB 8-32 UNC 10 in-lbs (1.1 N-m)

RC-Series
MC- & NC-Series Metal 10-32 UNC 15 in-lbs (1.7 N-m)
QC-Series PCB 8-32 UNC 10 in-lbs (1.1 N-m)

Metal 10-32 UNC 15 in-lbs (1.7 N-m)

Supervisory Sized to accept AMP Faston®insulated
All models receptacle #2-520184-2

(Bitte lesen Sie die Sicherheits-Vorschriften auf Seite 8.)

8

Sicherheits-Vorschriften

Absicherung am Eingang. Das ComPAC muß mit einer externen

Sicherung am Eingang versehen werden. Die entsprechenden

Sicherungswerte entnehmen Sie bitte der Tabelle auf Seite 6 unter der

Rubrik “Input Line Fusing”.

Erdung. Um den IEC 950 Klasse I Erdungsforderungen zu

entsprechen, muß ein Erdungskabel an den Anschluß (GND)

angeschlossen werden. Für ComPAC Modelle mit einem Modul (max.

Leistung 200 W) benutzen Sie bitte AWG 16- und für Modelle mit 2

und 3 Modulen (max. Leistung 400 W und 600 W) AWG 14-Kabel.

Anschlüsse Eingangsspannung. Vergewissern Sie sich, daß die Kabel

für die Eingangsspannung fest angeschlossen sind und achten Sie auf

die Polarität.

Betriebstemperatur. Die maximale Betriebstemperatur des ComPAC-

Gerätes darf nicht überschritten werden. Dies ist gegeben, wenn der

Kühlkörper eine Temperatur von 85 Grad Celsius erreicht hat.

Weitere Informationen. Das Vicor Applications Manual und

Produkt-Datenblätter enthalten ausführliche Informationen über

ComPAC DC-DC Wandler. Fordern Sie bitte Unterlagen bei Vicor

oder Ihrer nächsten Vicor Vertretung an.

Visit the Vicor website at:

www.vicorpower.com

Vicor Corporation

Andover, MA, U.S.A
Tel: [phone]
Fax: [phone]

Vicor France

Tel: [phone]
Fax: [phone]

Vicor Germany

Tel: [phone]
Fax: [phone]

Printed in U.S.A. Pt. No. 23935 Rev 4.1 11/09

Chicago, IL
Tel: [phone]
Fax: [phone]

Vicor Italy

Tel: [phone]
Fax: [phone]

Vicor U.K.

Tel: [phone]
Fax: [phone]

Sunnyvale, CA
Tel: [phone]
Fax: [phone]

Vicor Hong Kong

Tel: [phone]
Fax: [phone]

Vicor Japan

Tel: [phone]
Fax: [phone]