Vicor Mini MegaPAC AC-DC Switcher User Manual

USER GUIDE | UG:110
Mini MegaPACTM AC-DC Switcher
November 2013
Contents Page
Overview 1 of Product
Mechanical 2 Considerations
MegaPAC 3 Do’s and Don’ts
Technical Description 3
Configuring and 5 Reconfiguring MegaPACs
ConverterPAC 6 Description
Part Numbering 8
ConverterPAC Output 9 and Connector Pin Identification
Quick Install 10 Instructions
Mechanical Drawings 13
Interface Connections 14
Specifications 20
Output Studs 21
Connector Kit Contents 21
Current Share Boards 22
Low Leakage Version 25
Overview
A complete power supply is configured at the factory by selecting and inserting up to five same length slide-in output assemblies called ConverterPACs. ConverterPACs incorporate one or two VI-200/VI-J00 and/or Maxi Vicor DC-DC converters and are available in a wide array of output voltages 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 the ConverterPACs, refer to the ConverterPAC data sheets. The ConverterPACs used in the Mini MegaPAC use VE­2xx and VE-Jxx modules. In addition, there is a four output model called a FlexPAC that uses discrete circuits to support low power needs.
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 assembly with one of the same length and has the desired voltage power rating. For additional flexibility, 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 user­friendly 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. Using the VSPOC configurator tool available on
vicorpower.com, anybody can now configure a Mini MegaPAC (and other Westcor
power supplies) online.
UG:110 vicorpower.com Applications Engineering: 800 927.9474 Page 1
Standard Features
n Input voltage: 90-132 or 180-264 Vac, 47-500 Hz, or 260-380 Vdc
n Output power: 1,000 W @ 115 Vac or 230 Vac
n Outputs: 5 slots (up to 10 outputs)
n Full power output to 45°C; half power to 65°C
n Fan cooled
n Conducted EMI meets EN55022 Class A and B
n AC Power OK status signal
n RoHS compliant available
n Output Sequencing and General Shutdown (Consult Applications Engineering
for automatic sequencing circuitry)
n Autosense (Refer to Page 10 and Page 14 for more information on Autosense)
n Overcurrent protection standard on all outputs
n Output overvoltage protection on all ConverterPAC outputs with VI-200 module
n Output overtemperature limiting on all ConverterPAC outputs with VI-200 module
n Size: 3.4"H x 6.0"W x 9.5”L (85,8 x 153,4 x 241,3 mm)
n Safety Agency Approvals: CE Mark, cTÜVus
Optional Features
n DC OK status signal
n Reversed fan airflow direction
n Extended temperature range DC-DC converters
n Current share boards - see Pages 22-24
n Low leakage version - see Page 25
Mechanical Considerations
The Mini 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" (5,1 cm) minimum clearance at both ends of the Mini MegaPAC and route all cables so airflow is not obstructed. The standard unit draws air in at the fan side and exhausts air out the load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fan moves approximately 30 CFM of air.
Avoid excessive bending of output power cables aer they are connected to the Mini MegaPAC. For high-current outputs, use cable-ties to support heavy cables and minimize mechanical stress on output studs. Be careful not to short-out to neighboring output studs. The Mini MegaPAC is supplied with serrated, flanged hex-nuts on all output studs. 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.
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MegaPAC Do’s and Don’ts
n For units without Autosense, do not leave ConverterPAC Sense lines open. Always
terminate them to their respective output locally or at the load. Use twisted pair 22-24 AWG wire. If ConverterPAC has Autosense, no local sense connection is required. See Page 10 and Page 14 for more information on Autosense.
n If needed, use Connector Kit # 19-130040 for the Mini MegaPAC.
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 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. The fan draws air into the unit and forces it out at
the output power terminals.
n Single output ConverterPACs should NOT be paralleled directly together.
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. For booster arrays, do not power up with bus bars removed.
n Always ensure that output hex-nuts are properly torqued before applying
power to supply.
n Do not use boosters as independent outputs. Disconnecting bus bars will damage
booster ConverterPACs.
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 do 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. Verify output nuts are tight
before powering up.
n Output voltages over 60 Vdc, whether from individual modules or series arrays, are
considered as hazardous secondary outputs under UL60950. Appropriate care must be taken in design implementation of the supply.
n Only use the regular length ConverterPACs in the Mini MegaPAC. One cannot use any
of the Extended Length ConverterPACS in the Mini MegaPAC. The ELs are only used in the EL (Low Noise) products.
Technical Description
The Mini MegaPAC chassis consists of an o-line single phase AC front end, EMI filter, cooling fan, customer interface and associated housekeeping circuits. Input AC mains voltage (L1/N, L2 and GND) is applied to a terminal block. The input current is passed through an EMI filter designed to meet EN55022 Class A and B. At start-up, inrush current is limited by an NTC thermistor prior to being passed to the power rectifiers. The power rectifiers and filter capacitors are arranged in a conventional full wave bridge
UG:110 vicorpower.com Applications Engineering: 800 927.9474 Page 3
rectifier/voltage doubler configuration. This operates as a full wave bridge rectifier on 230 Vac, or can be manually strapped for operation as a voltage doubler on 115 Vac, delivering unregulated 300 Vdc to a high voltage backplane. The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired low voltage, regulated outputs.
Voltage conversion in the output assemblies is achieved by Vicor's 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 eciencies.
At initial power-up, the Mini MegaPAC outputs are disabled to limit the inrush current and to allow the DC bus potential to settle out to the correct operating level. A low­power flyback converter operating with PWM current-mode control converts the high voltage DC bus into regulated low voltage to power the internal housekeeping circuits and DC cooling fan. When operating on 115 Vac, the internal housekeeping Vcc comes up within two seconds aer the application of input power. On 230 Vac, it comes up within 500 ms. Once the bus potential is within operating parameters, the AC Power OK signal asserts to a TTL "1" indicating that the input power is OK, and allows the power outputs to come up within <50 ms later. An auxiliary Vcc output of 5 Vdc sourcing up to
0.3 A is provided for peripheral use on interface connector J10-9.
An output Enable/Disable function is provided by using an optocoupler to control the Gate In pins of the ConverterPAC assemblies. If the Enable/Disable control pin is pulled low, the optocoupler turns on, pulling the Gate In pin low and disabling the output. The typical delay associated for an output to come up when measured from release of the Enable/Disable pin is 5-10 ms. The General Shutdown function controls all outputs simultaneously and works in a similar manner.
The ride-through (hold-up) time is the amount of time the load can be supported before loss of output regulation aer the loss of input power. Detecting the loss of input power takes a finite time period aer which the AC Power OK signal goes from a TTL “1” to “0.” This signal is available for use within 1.2 seconds aer initial power-up and can be used to indicate an impending loss of power. A minimum of 3 ms of warning time is given. Following the loss of input power, the outputs are disabled when the bus voltage falls below its operating threshold.
Figure 1.
Mini MegaPAC Architecture
High Voltage Unregulated Bus
Power Input
EMI Filter
DC Fan
AC/DC Power Rectification, Input Voltage Strapping, Inrush Current Limiting
Housekeeping Circuits
Customer Interface (Optoisolators)
Logic Power Supply
DC Bus Sense
Control
DC/DC Output ConverterPAC #1
DC/DC Output ConverterPAC #2
DC/DC Output ConverterPAC #3
DC/DC Output ConverterPAC #4
DC/DC Output ConverterPAC #5
Power Output
Power Output
Power Output
Power Output
Power Output
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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. (Currently, the exceptions are the FinPACs which can only be used in the PFC MegaPAC-High Power and the UniPACs which can only be used in the 4 kW MegaPAC). 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. 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 five 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 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
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 when 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. 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 8). 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 (Creating High Voltage Outputs) available on the website at www.vicorpower.com.
Figure 2.
Paralleling ConverterPACs
Bus Bars for Paralleling
Loosen screw to
remove ConverterPAC
123
Driver
Boosters
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4
5
Remote Sense
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
VI-J00
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
VI-200
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 and between AC input MegaPAC chassis. They can be added, moved, or changed as necessary. The following ConverterPACs are used in the Mini MegaPAC.
ModuPAC
The ModuPAC output assembly consists of a VI-200 DC-DC converter that converts the 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. ModuPACs are fused with a PC-Tron, DC-rated,
+
fast-acting fuse. A passive LC filter is used to reduce output ripple/noise down to 1%
_
typical, and 2% maximum peak-to-peak from 10% to 100% of rated load. An optional DC Power Good signal, or output voltage Trim potentiometer can be specified. The ModuPAC contains overvoltage protection (OVP), overcurrent protection (OCP) and overtemperature limiting (OTL). The OCP has automatic recovery when the overcurrent condition is removed. The OVP and OTL are latching functions and require recycling of the AC input power to restart.
JuniorPAC
The JuniorPAC consists of a VI-J00 DC-DC converter that converts the high voltage
+
bus to the desired regulated output voltage. JuniorPACs can provide up to 100 Watts of output power and are fused with a single PC-Tron, DC-rated, fast-acting fuse. A passive
_
LC filter is used to reduce output ripple/noise down to 1% typical, and 2% maximum peak-to-peak from 10% to 100% of rated load. An optional DC Power Good signal or output voltage Trim potentiometer can be specified. The JuniorPAC contains output overcurrent protection, which recovers automatically when the overcurrent condition is removed. Overvoltage protection and overtemperature limiting are not available.
VI-J00 VI-J00
M2
VI-J00 RAM
M1
VI-200/BatMOD
DualPAC
RamPAC
BatPAC
DualPAC
M1
This output assembly consists of two VI-J00 DC-DC converters that convert the high voltage bus to the desired regulated output voltages as noted above. The outputs
M2
are electrically isolated. Enabling and disabling the slot will control both outputs simultaneously.
RamPAC
+
This output assembly consists of a VI-J00 DC-DC converter with a Ripple Attenuator Module (RAM) and is designed for applications requiring low output ripple/noise.
_
The RamPAC can attenuate the ripple/noise down to 10 mV peak-to-peak or 0.15% whichever is greater over a 20 MHz bandwidth from 10% to 100% of rated load of the converter. RamPACs can only operate between 5–50 V and is limited to 100 W (20 A).
BatPAC
The BatPAC output assembly consists of a VI-200 BatMod current source that converts
+
the high voltage bus to the desired regulated output voltage. The converter is fused with a PC-Tron, DC-rated, fast-acting fuse. The BatPAC is a 200 Watts programmable current
_
source that can be configured as a battery charger. Maximum current and voltage settings are controlled using potentiometers that come as a standard feature, or through Trim pin access as an option. BatPACs are available for 12 V, 24 V and 48 V battery systems.
UG:110 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 two to four discrete outputs that convert the high voltage bus to the desired output voltage. Each FlexPAC output can be manually trimmed from 2 V to 25 V and supports up to 5 Amps with a maximum output power of 50 W per output. All outputs maintain less than 50 mV 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 Autoranging MegaPAC and their features
ConverterPAC OVP OCP OTL RS/AS* LS/AS* PG TrimPot
ModuPAC Std Std Std AS* AS* Opt Opt
DualPAC N/A Std N/A AS* AS* N/A Opt
JuniorPAC N/A Std N/A AS* AS* Opt Opt
RamPAC N/A Std N/A AS* AS* Opt Opt
BatPAC N/A Std N/A N/A N/A N/A Opt
FlexPAC Std Std Std N/A LS N/A Std
* See Page 10 and 14 for more information on Autosense.
OVP Overvoltage Protection (latching) OCP Overcurrent Protection
OTL Overtemperature Limiting (latching) RS Remote Sense
PG Power Good (DC OK TTL Signal) LS Local Sense (replaced by Autosense)
AS Autosense
Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC, JuniorPAC, RamPAC and FlexPAC.
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Part Numbering
Mini MegaPAC MMxA-1xBxxxx
eg. MM4-143605
MM = Mini MegaPAC Prefix
xA = number of outputs
1 = Mini MegaPAC Chassis
xB = number of modules + FlexPACs
xxxx = assigned by Westcor
ConverterPAC XxDV/xEAx
F
eg. M15V/10A eg. M15V/10ADFI eg. D15V/6.7A-12V/8.3AT
X = ConverterPAC type (For RoHS, add G to current prefix) M = ModuPAC D = DualPAC R = RamPAC J = JuniorPAC B = BatPAC (RoHS = GM) (RoHS = GD) (RoHS = GR) (RoHS = GJ) (RoHS = GB) xD = Voltage out
x
= Current out (rounded to 1 decimal point)
E
xF = Can be multiple options* (see below)
FlexPAC Fxxaaa-bbb-ccc-ddd
F = FlexPAC xx = pack chassis variations
aaa = voltage setting for output 1 with implicit factor of 10 (103 = 10.3 V)
bbb = output 2 ccc = output 3 ddd = output 4
* ConverterPAC options
Booster module
B
D DC OK or Power Good
F Full 50-110% output adjustment
50-107.5% output adjustment
F1
50-105% output adjustment
F2
50-102.5% output adjustment
F3
50-100% output adjustment
F4
60-110% output adjustment
F5
70-110% output adjustment
F6
80-110% output adjustment
F7
90-110% output adjustment
F8
100-110% output adjustment
F9
Industrial Grade module
I
Custom SRF module used
K
[1]
[2]
Military Grade module
M
Preload
P
R RAM external
Trimpot removed for external BatPAC adjustment
S
T 90-110% output adjustment
90-107.5% output adjustment
T1
90-105% output adjustment
T2
90-102.5% output adjustment
T3
90-100% output adjustment
T4
98-105% output adjustment
T5
100-110% output adjustment
T6
V1 "VXI" low noise (150 mV)15 V < V
"VXI" low noise (50 mV) V
V2
"VXI" low noise (1% ripple) for outputs >24 V
V3
[3]
[4]
< 24 V output
OUT
< 15 Vdc
OUT
5
[1]
D option: Optional for all ConverterPACs EXCEPT the DualPAC, BatPAC, and FlexPAC
[2]
F option: Optional for all ConverterPACs EXCEPT the BatPAC, DualPAC and FlexPAC.
Trim Range based on module type and voltage.
[3]
R option: When using an external RAM, components such as Autosense resistors and Local Sense jumpers must be removed before turning on the supply. In addition, in order to insure proper operation, sense pins must be connected either locally or remotely after the RAM's output. For further information, contact Applications Engineering.
[4]
T option: Optional for all ConverterPACs EXCEPT the BatPAC, DualPAC and FlexPAC. Trim range determined based on module type and voltage.
[5]
V option: Optional ONLY on the ModuPAC, DualPAC and JuniorPAC. N/A on all other ConverterPACs.
UG:110 vicorpower.com Applications Engineering: 800 927.9474 Page 8
ConverterPAC Output and Connector Pin Identification for the Mini MegaPAC
DUALPAC
BATPAC
ModuPAC JuniorPAC
RAMPAC
DualPAC
+ V0UT
J2-PIN1
0UTPUT ADJUST
- VOUT
J3-PIN1
J1-B-PIN1
J2-B-PIN1
OUTPUT ADJUST
J1-A-PIN1
J2-A-PIN1
OUTPUT ADJUST
(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
J1
(OUTPUT CONNECTORS)
1 AND 4 +V OUT
1
4
2 AND 5 -V OUT
2
5
6
3 +R/SENSE 6 -R/SENSE
3
J2
(REMOTE SENSE)
TRIM PIN ACCESS
1
2
+ SENSE
3
- SENSE
MATING HDWR:
HOUSING- MOLEX P/N: 50-57-9403
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 11-01-0118
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0043
TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
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: 11-01-0118
BatPAC
FlexPAC
+ V0UT
CURRENT LIMIT ADJUST
VOLTAGE LIMIT ADJUST
- VOUT
J2-PIN1
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
J2 (BATPAC REMOTE INTERFACE)
CURRENT LIMIT ADJUST
4
3
VOLTAGE LIMIT ADJUST
2
CURRENT MONITOR
1
- VOUT
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-0043
TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
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: New output studs have been installed on the ConverterPACs and are 1/8 inch longer. Refer to Page 21 for more information.
UG:110 vicorpower.com Applications Engineering: 800 927.9474 Page 9
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