Vicor FlatPAC-EN MI EN Compliant Autoranging Switchers User Manual

FlatPAC-EN™ and FlatPAC-EN MI EN Compliant Autoranging Switchers

FlatPAC-EN/EN MI Design Guide

Design Guide

and

“Quick Install” Instructions

www.vicorpower.com

03-000050 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474

TABLE OF CONTENT

Overview of Product...........................................................................................................................3

Part Numbering...................................................................................................................................3

Mechanical Considerations.................................................................................................................4

FlatPAC-EN/EN MI Do’s and Don’ts................................................................................................4

Technical Description.........................................................................................................................5

Configuration Layout drawing...........................................................................................................6

Quick Install Instructions....................................................................................................................7

Mechanical Drawings.........................................................................................................................10

Output connector information............................................................................................................11

Connector Kit listing..........................................................................................................................12

Interface Connections.........................................................................................................................13

RS 232 Microcontroller......................................................................................................................14

Specifications.......................................................................................................................... ..........18

Output vs. AC & DC Voltage Graphs . .............................................................................................20

Thermal Curves..................................................................................................................................22

Current Share Boards.........................................................................................................................26

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FlatPAC-EN/EN MI Design Guide

FlatPAC-EN™ and FlatPAC-EN MI EN Compliant Autoranging Switcher

Overview

The FlatPAC-EN/EN MI is an ultra low profile switching power supply that provides up to 500 Watts from up to 4 isolated outputs. It operates on either 115 or 230 Vac nominal (47-63 Hz), or 250-380 Vdc. It can be populated with either VI-200/VI-J00 or Maxi/Mini/Micro Vicor converters. The use of these converters gives the FlatPACEN/EN MI the inherent power flexibility typical of all Vicor products. With dimensions of 1.4" H (35,6mm) x 5.0" W (127mm) x 9.2" L (233,7mm), the FlatPAC-EN/EN MI provides a power density greater than 7W/in

. It is facto-

ry configured to meet user output requirements. Note: The FlatPAC-EN/EN MI does not have an internal fan. The MI version is a rugged chassis designed specifically for COTS and harsh environment applications

Using the PowerBench configurator tool available on vicorpower.com, anybody can now configure a FlatPAC-EN

(and other Westcor power supplies) online.

Standard Features

• Power Factor Correction (passive): Power Factor (Typical) 0.70 (>75% Load)

• Input Voltage: 90-132/180-264 Vac1, 47-63 Hz, or 250-380 Vdc

• Maximum Power Output: 500W (105/190Vac min.) 425W for EN61000-3-2 compliance

• Up to 4 isolated user specifiable outputs

• Conducted EMI: FCC Class A EN 55022 Class A

FCC Class B EN 55022 Class B Mil-STD 461 may require external filter

• Harmonic Attenuation to EN61000-3-2/A14

• Compliant to EN61000-4-4 (Electrical Fast Transient/Burst) and EN61000-4-5 (Surge Immunity)

• MI version meets Mil-STD 810 for Shock and Vibration with extended temp range

• MI version also available with -40C temp rating

• Efficiency (typical) > 70%

• Autosense

• RS-232 microcontroller interface

• Output overcurrent protection on all outputs

• Size: 1.4" H (35,6mm) x 5.0" W (127,0mm) x 9.2" L (233,7mm)

• Safety Agency Approvals: cURus, cTUVus, CE Mark

Derates to 260W@90Vac, 400W @ 180 Vac.

For output power ≤ 425W, not to exceed an input current of 3.33 A rms at 230 Vac, 50 Hz.

3 This feature is implemented in all converter slots (except with Micro modules). Autosense allows automatic local sensing

when remote sense connections are not made. The FlatPAC-EN/EN MI will operate in remote sense mode when remote sense connections are made. Refer to page 16 for more information on Autosense.

Optional Features

• Current Share Board for unit to unit power sharing - See page 26 and page 27

• Connector kits (# 19-130044)

• Conformal coating available on select MI models - contact factory

• -40oC Operation, Mil-STD 810 Shock and Vibration (MI rugged chassis only)

Part Numbering

FlatPAC-EN/EN MI FLx1-x2 x3 -xxxx (-x4)(-x5)x

Number of outputs

e.g. FL4-13-6544 x

Number of VI-200/VI-J00 modules

Number of Maxi/Mini/Micro modules

xxxx Sequential number assigned by Westcor (-x4) Optional Factory assigned: G - RoHS

(-x5) Optional versions

Note: x5= MI for rugged chassis, = MC for rugged chassis with conformal coating

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FlatPAC-EN/EN MI Design Guide

Mechanical Considerations

The FlatPAC-EN/EN MI is mounted on the bottom surface using standard 8-32 or 4 mm screws (cannot be mounted from the front.)

Maximum allowable torque is 5 in. lbs.,. The maximum penetration for mounting holes A1, A2, A3 and A4 is

0.125 in. (3mm) and for mounting holes B1, B2, C1 and C2 is 0.250 in. (6mm). The minimum recommended mounting holes are as follows:

1. For standard mounting (forced air cooling), use A1, A2, A3, A4 mounting holes.

2. For standard mounting (conduction cooling), use A1, A2, A3, A4, B1 and B2 mounting holes.

3. For a Vicor 2 Up FlatPAC retrofit replacement, use C1 and C2 as these two are identical to the recommended mounting holes on the FlatPAC.

For increased ruggedness, additional mounting holes can be used to secure the power supply.

The FlatPAC-EN/EN MI does not have an internal fan. It can be either conduction or convection cooled (same model).

Avoid excessive bending of output power cables after they are connected to the output terminals. For high-current outputs, use cable ties to support heavy cables and minimize mechanical stress on connectors. Be careful not to short-out to neighboring outputs. The maximum torque recommended on output nuts is 10 in. lbs.

For applications that require vibration levels above MIL-STD-810E, minimum integrity test, a shock absorbing mount design is required.

FlatPAC-EN/EN MI Do’s and Don’ts

• Do not exceed an operating case temperature of 90oC. To prevent an overtemperature condition, an external fan may be required.

• Run the output (+/–) power cables next to each other to minimize inductance.

• Always turn the power supply off before disconnecting input or output wires.

• When using the remote sense feature, the +Out and -Out load wires should never be disconnected while the supply is operating. Failing to do so could damage the power supply.

• Do not attempt to repair or modify the power supply in any manner as this action will void the warranty. In the event of problems, contact Customer Service at 1-800-735-6200.

• Insert proper fault protection at power supply input terminals (i.e., a fuse). Refer pg 13 for more information.

• Use proper size wires to avoid overheating and excessive voltage drop.

• Output voltages over 60Vdc, whether from individual modules or series arrays, are considered as hazardous secondary outputs under UL 60950. Appropriate care must be taken in design implementation of the supply.

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FlatPAC-EN/EN MI Design Guide

Identical mounting holes (C1 & C2) to Vicor's 2 UP FlatPAC

Technical Description

The FlatPAC-EN/EN MI consists of an off-line single phase autoranging front end, EMI filter, customer interface, power supply control circuit, associated housekeeping circuits, a MiniHAM module and a selection of Vicor’s VI200/VI-J00 and/or Maxi/Mini/Micro DC-DC converters.

The MiniHAM was specifically designed for EN compliance using passive filtering. Unlike active PFC solutions, the MiniHAM generates no EMI, greatly simplifying and reducing system noise filtering requirements. It is also considerably smaller and more efficient than active alternatives and improves the unit’s MTBF. It will provide harmonic current compliance at 230Vac input up to 425W of output power. Input AC mains voltage is applied to input connector MBJ1 (see page 7) and the input current is passed through an EMI filter designed to meet conducted noise limit of EN 55022, Classes A and B specifications (certain configurations meet EN55022 Class B. Consult Factory.)

At start-up, the microcontroller verifies that the input voltage is within the specified operating range. Once this occurs, the microcontroller closes the safety relay and puts the autoranging front-end in the correct mode (closing or opening the Doubler relay). The autoranging front-end has two modes, the doubler mode (90Vac - 132Vac) or bridge rectifier mode (180Vac-264Vac, 250Vdc-380Vdc). Inrush current is limited by a PTC thermistor. The PTC is shunted out (by closing the Inrush relay) when the output voltage has charged up the bus capacitors within the specified range (205Vdc-390Vdc). Approximately 1 second after the application of the input voltage, the bus voltage is within operating limits and the AC OK signal asserts to a TTL "1", indicating the input power is OK. After AC OK is asserted high, the user can now control the power outputs.

Output voltage conversion is achieved by Vicor’s 300Vin family of Zero-Current-Switching (ZCS) DC-DC converters. These are forward converters in which the main switching element switches at zero current. This patented topology has a number of unique attributes: low switching losses; high frequency operation, resulting in reduced size for magnetics and capacitors; excellent line and load regulation; wide adjustment range for output; low EMI/RFI emission and high efficiencies.

At initial power-up, all outputs are disabled to limit the inrush current and to allow the DC bus potential to settle to the correct operating level. A low-power transformer flyback circuit converts the high voltage DC bus into regulated low voltage to power the internal housekeeping circuits as well as the auxiliary +5Vs located in the interface connector.

An output Enable/Disable function is provided to control Vicor’s DC-DC converters. If the Enable/Disable control pin is pulled low, the modules output is disabled. The nominal delay associated for an output to come up when measured from release of the Enable/Disable pin is 9-12 ms. The General Shutdown function controls all outputs simultaneously and works in a similar manner.

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FlatPAC-EN/EN MI Design Guide

FlatPAC-EN/EN MI Configuration Layout

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FlatPAC-EN/EN MI Design Guide

CBJ1

Interface Conn.

VI-200

Maxi

VI-J00

Mini

MBJ1

Input Conn.

MiniHAM

CBJ1

Interface Conn.

MBJ1

Input Conn.

Micro

MiniHAM

VI-J00

Mini

CBJ1

Interface Conn.

VI-J00

Mini

MBJ1

Input Conn.

MiniHAM

VI-J00

Mini

VI-J00

Mini

Single or Dual Outputs

(Stud Connectors)

Single, Dual orTriple Outputs

(Two 18 pin Molex Connectors)

Single, Dual, Triple or Quadruple Outputs

(Two 18 pin Molex Connectors)

For a single output configuration,

either M1or M2 is used

(assumes either a full brick

and/or half brick is used)

(assumes only half bricks are used)

Note: The type of output connector a FlatPAC-EN has depends on which modules are used. E.g. if a two output configuration uses

two half bricks (instead of a full brick and half brick) this two output configuration will have the 18 pin molex connectors,

not stud connectors.

(assumes only half and/or

quarter bricks are used)

FlatPAC-EN/EN MI “Quick Install” Instructions (For mechanical drawings, see page 10)

Mounting the FlatPAC-EN/EN MI

• Mount the FlatPAC-EN on the bottom (cannot be mounted from the front).

• For standard mounting (forced air cooling), use A1, A2, A3, A4 mounting holes. For standard mounting (conduction cooling), use A1, A2, A3, A4, B and B2 mounting holes.

• For a Vicor 2 Up FlatPAC retrofit replacement, use C1 and C2 as these two are identical to the mounting holes on the FlatPAC.

• For increased ruggedness, use additional mounting holes to secure the power supply.

• Use #8-32 or 4mm mounting screws. For mounting holes A1, A2, A3 and A4, the maximum penetration should not exceed 0.125 in. (3mm). For mounting holes B1, B2, C1 and C2, do not exceed maximum penetration of 0.250 in. (6 mm).

* The maximum allowable torque is 5 in. lbs.,

Input Connections

Input Power MBJ1

• Apply input AC power connector MBJ1 using a maximum torque of 5 in. lbs

• Place a fuse or circuit breaker in the input line for safety requirements

(9A).

• Use Molex mating receptacle 39-01-4051, terminals 39-00-0090 and crimp

tool Molex # 11-01-0199.

Output Connections (Refer to page 6 for more information on configuration layout and output connector type)

Note: The type of output connector a FlatPAC-EN has depends on which modules are used. Also, outputs with molex connectors are limited to 9A/pin (27A per output).

Power Connections

Installing power connectors on outputs with 10-32 stud connectors (only full and/or half bricks used):

• Install #10 ring lugs on output studs * The right stud is positive and the left stud is the return when viewed from the output end.

• Remove the nut and place ring lug over output stud.

• Replace and tighten the nut to a torque of 10 inch pounds. Do Not Over-

Tighten Nuts.

Installing power connectors on outputs with 18 pin Molex connectors (only half bricks used):

• The output M1 slot accepts either a Mini or a Junior module. J2-7, J2-8, J216 are positive, while pins J2-9, J2-17 and J2-18 are the returns.

• J2-1, J2-2, J2-3, J2-4, J2-5, J2-10, J2-11, J2-12 and J2-14 are not connected.

• The output M2 slot accepts either a Mini or a Junior module. J3-7, J3-8, and J3-16 are positive while pins J3-9, J3-17 and J3-18 are the returns.

• The output M3 slot accepts either a Mini or a Junior module. J3-1, J3-10, J11 are positive while pins J3-2, J3-3, J3-12 are the returns.

• For this 18 pin housing, use Molex mating receptacle #39-01-2180 with #3900-0039 terminals.

• Attach 18-24 AWG stranded wire using Molex tool #11-01-0197.

• Note: The molex connectors are limited to 9A/pin (27A per output)

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FlatPAC-EN/EN MI Design Guide

MBJ1

N/C

L2/N

GND

OUTPUTS M2 & M3

OUTPUT M1

18 PIN MOLEX OUTPUT CONNECTOR

PIN DESCRIPTION

1 N/C 2 N/C 3 N/C 4 N/C 5 N/C 6 TRIM M1 7 +V OUT M1 8 +V OUT M1 9 -V OUT M1

PIN DESCRIPTION

10 N/C 11 N/C 12 N/C 13 + SENSE M1 14 N/C 15 - SENSE M1 16 +V OUT M1 17 - V OUT M1 18 - V OUT M1

PIN DESCRIPTION

1 +V OUT M3 2 -V OUT M3 3 -V OUT M3 4 + SENSE M3 5 - SENSE M3 6 TRIM M2 7 +V OUT M2 8 +V OUT M2 9 -V OUT M2

PIN DESCRIPTION

10 +V OUT M3 11 +V OUT M3 12 -V OUT M3 13 + SENSE M2 14 TRIM M3 15 - SENSE M2 16 +V OUT M2 17 - V OUT M2 18 - V OUT M2

Identical mounting holes (CI & C2) to Vicor's 2 UP FlatPAC

STUD OUTPUT CONNECTORS

OUTPUT M1

10-32 STUDS

OUTPUT M2

Installing power connectors on outputs with 18 pin Molex connectors

(only half and/or quarter bricks used):

• The output M1 slot only accepts a Micro module. J2-7, J2-8, J2-13 and J2-16 are positive, while pins J2-9, J2-15, J2-17 and J2-18 are the returns.

• The output M2 slot only accepts a Micro module. J2-1, J2-4, J2-10, J211 are positive, while pins J2-2, J2-3, J2-5 and J2-12 are the returns.

• The output M3 slot only accepts a Micro module. J3-7, J3-8, J3-13 and J3-16 are positive, while pins J3-9, J3-15, J3-17 and J3-18 are the returns.

• The output M4 slot only accepts either a Mini or a Junior module. J3-1, J3-10 and J3-11 are positive while pins J3-2, J3-3, and J3-12 are the returns.

• For this 18 pin housing, use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.

• Attach 18-24 AWG stranded wire using Molex tool #11-01-0197

• Note: The molex connectors are limited to 9A/pin (27A per output)

See page 11 for detailed diagrams of output connections.

Sense Connections

The FlatPAC-EN/EN MI is shipped with Autosense installed (For more informa-

tion on Autosense, refer to page 16)

Sense Connections for stud outputs (only full and/or half bricks used):

• For Remote Sense, connect Remote Sense wires to Remote Sense/Trim Pin Access Connector J1 or J2 for single output and J1/J2 for dual outputs.

* Connector pins J1-2 and J2-2 are the + Senses and J1-3 and J2-3 are

the -Senses.

• Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.

• Attach terminals to 24-30 AWG stranded twisted pair wire using Molex tool # 11-01-0208.

• Attach opposite end of sense lines to their respective outputs to point where regulation is desired. Verify that sense lines are not cross-connected.

Sense Connections on 18 pin molex output connectors (only half bricks used):

• If Remote Sense is desired, connect Remote Sense wires to the sense lines of Connector J2 for output 1 and J3 for outputs 2 and 3.

* For Output M1, J2- 13 is the +Sense and J2-15 is the -Sense. * For Output M2, J3-13 is the +Sense and J3-15 is the -Sense. * For Output M3, J3-4 is the +Sense and J3-5 is the -Sense.

• Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.

• Attach 18-24 AWG stranded twisted pair wire using Molex tool #11-01-

0197.

Sense Connections on 18 pin output connectors (only half and/or quarter bricks used):

• If Remote Sense is desired (available only on output M4), connect Remote Sense wires to sense lines of Connector J3

* Remote Sense is NOT available for Micro modules and hence is not

available on outputs M1, M2 and M3.

* On output M4, J3- 4 is the +Sense and J3-5 is the -Sense.

• Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.

• Attach 18-24 AWG stranded twisted pair wire using Molex tool #11-01-0197

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FlatPAC-EN/EN MI Design Guide

OUTPUTS M1 & M2

OUTPUTS M3 & M4

18 PIN MOLEX OUTPUT CONNECTORS

PIN DESCRIPTION

1 +V OUT M2 2 -V OUT M2 3 -V OUT M2 4 +V OUT M2 5 - VOUT M2 6 TRIM M1 7 +V OUT M1 8 +V OUT M1 9 -V OUT M1

PIN DESCRIPTION

10 +V OUT M2 11 +V OUT M2 12 -V OUT M2 13 + VOUT M1 14 TRIM M2 15 - VOUT M1 16 +V OUT M1 17 - V OUT M1 18 - V OUT M1

PIN DESCRIPTION

1 +V OUT M4 2 -V OUT M4 3 -V OUT M4 4 + SENSE M4 5 - SENSE M4 6 TRIM M3 7 +V OUT M3 8 +V OUT M3 9 -V OUT M3

PIN DESCRIPTION

10 +V OUT M4 11 +V OUT M4 12 -V OUT M4 13 + VOUT M3 14 TRIM M4 15 - VOUT M3 16 +V OUT M3 17 - V OUT M3 18 - V OUT M3

OUTPUT M1

OUTPUT M2

10-32 STUDS

STUD OUTPUT CONNECTORS

1 Trim Pin 2 + Remote Sense

3 - Remote Sense

OUTPUTS M2 & M3

OUTPUT M1

18 PIN MOLEX OUTPUT CONNECTORS

J2-13 + SENSE M1 J2-15 - SENSE M1

J3-4 + SENSE M3 J3-5 - SENSE M3

J3-13 + SENSE M2 J3-15 - SENSE M2

18 9

-S

OUTPUTS M1 & M2

OUTPUTS M3 & M4

18 PIN OUTPUT CONNECTORS

M4 accepts 1 Mini or 1 Junior J3-4 + SENSE M4 J3-5 - SENSE M4

M1, M2, M3 accept Micro modules No sense connections are available for Micro modules

-S

Trim Connections

Trim Connections on stud output connectors (when full and/or half brick used) :

• For output M1, J1-1 provides Trim Access

• For output M2, J2-2 provides Trim Access

• Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.

• Attach 24-30 AWG stranded wire using Molex tool #11-01-0208.

Trim Connections for 18 pin Molex output connectors (when half bricks used):

• For output M1, J2-6 provides Trim access

• For output M2 and M3, J3-6 and J3-14 provides Trim access respectively.

• Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.

• Attach 18-24 AWG stranded wire using Molex tool #11-01-0197.

Trim Connections for 18 pin Molex output connectors (when half and/or quarter bricks used):

• For outputs M1 and M2, J2-6 and J2-14 provide Trim access respectively.

• For outputs M3 and M4, J3-6 and J3-14 provide Trim access respectively.

• Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.

• Attach 18-24 AWG stranded wire using Molex tool #11-01-0197.

Interface Connections

• CBJ1-1 is Signal Ground and CBJ1-3 is AC OK.

• CBJ1-4 is the Transmit and CBJ1-5 is the Receive functions for the RS-232 command protocol.

• CBJ1-4 thru 9 are Enable/Disable,CBJ1-10 is General Shutdown and CBJ312 is +5VS.

• For the FlatPAC-EN, CBJ1-2 and CBJ1-11 are not connected.

• Use Molex mating receptacle #50-57-9412 with #16-02-0097 cinch pins.

• Attach 24-30 AWG stranded wire using Molex tool #11-01-0209.

These functions are part of the RS-232 Command Protocols. See page 14 for

detailed information .

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FlatPAC-EN/EN MI Design Guide

1 Trim Pin 2 + Remote Sense 3 - Remote Sense

OUTPUT M1

OUTPUT M2

10-32 STUDS

TRIM: STUD OUTPUT CONNECTORS

OUTPUTS M2 & M3

OUTPUT M1

18 PIN MOLEX OUTPUT CONNECTORS

J2-6 TRIM M1

J3-6 TRIM M2

J3-14 TRIM M3

18 9

OUTPUTS M1 & M2

OUTPUTS M3 & M4

18 PIN MOLEX OUTPUT CONNECTORS

J2-6 TRIM M1

J2-14 TRIM M2

J3-6 TRIM M3

J3-14 TRIM M4

PIN DESCRIPTION

CBJ1-1 SGND CBJ1-2 N/C CBJ1-3 ACOK CBJ1-4 TX CBJ1-5 RX CBJ1-6 E/D-4 CBJ1-7 E/D-3 CBJ1-8 E/D-2 CBJ1-9 E/D-1 CBJ1-10 GSD CBJ1-11 N/C CBJ1-12 +5VS

+ 20 hidden pages