VICOR PFC Mini User Manual
USER GUIDE | UG:115
PFC Mini™
Power Factor Corrected AC-DC Switcher
Contents Page
Overview 1
Standard Features 2
Optional Features 2
Mechanical Considerations 2
PFC Mini Dos and Don’ts 3
Technical Description 3
PFC Mini™
Configuration Layout 5
Part Numbering 6
PFC MegaPAC Quick Install
Instructions 7
PFC Mini™
Mechanical Drawing 9
Output Connectors for
PFC Mini™ 10
PFC Mini™ Connector Kit
(19-130047) Listing 11
Interface Connections 11
Enable / Disable Control of
Maxi, Mini, Micro Series
Module Arrays 16
Minor Changes for
PFC Mini™ Shipped
October 2005 Onwards 18
PFC Mini™ Output
Power vs. Input Voltage 19
Specifications 20
Current Share Boards –
Optional Feature 23
Low-Leakage Version 26
Low Output Ripple 26
Office Environment Fan 26
Molex Connector Limitation 26
Overview
The PFC Mini is an extremely low-profile 1RU switching power supply that combines the advantages of
power-factor correction and high power density. This guide covers both standard- and rugged-chassis
COTS (MI) versions of the product. The PFC Mini can provide up to six isolated outputs (three slots) and
each slot accommodates the following Vicor DC-DC Converters.
VI/E-200™ and VI/E-J00™ series: one VI/E-200 or two VI/E-J00 converters
Maxi, Mini Micro series: one Maxi, two Mini converters (Micros cannot be used)
The use of these converters give the PFC Mini the inherent power flexibility typical of all Vicor
products. Accepting input voltages of 85 – 264VAC, and 100 – 380VDC, the PFC Mini can provide
up to 1,500 Watts in a package size of 1.72 x 6 x 12.2in [43,6 x 152,4 x 309,9mm]. The PFC Mini is
factory-configured to meet user requirements.
Note: If you have a PFC Mini that shipped from October 2005 onwards, please see Page 18 for more details.
UG:115 Page 1
Standard Features
Power factor correction: 0.99 at 115VAC; 0.95 at 230V
Universal input: 85 – 264VAC, 47 – 500Hz, or 100 – 380V
Power output: 1,500W at 230VAC; 800W at 115V
AC
DC
AC
Up to six isolated outputs (three slots)
Fan cooled
Full power to 45°C; half power at 65°C
Conducted EMI:
VI-200™/VI-J00™ series: Maxi, Mini, Micro series:
FCC Class B FCC Class A
EN55022 Class B EN55022 Class A
(certain configurations meet EN55022 Class B)
Harmonic distortion complies with EN61000-3-2
AC Power OK status signal
Autosense (for more information, see Page 8 and Page 13)
Output overcurrent protection on all outputs
Output overvoltage protection (not applicable when using VI-J00)
Output overtemperature limiting (not applicable when using VI-J00)
Ride-through (hold-up) time: >20ms at 1,200W load (nominal line)
Size: 1.72 x 6 x 12.2in [43,6 x 152,4 x 309,9mm]
Safety agency approvals: CE Mark, cTÜVus, UL
(Note: certain MI chassis may not carry all safety certs.)
Optional Features
Extended temperature range output converters
Current share board - see Page 23
RAM™ modules for low noise applications - see Page 26
Connector kit available (#19-130047)
Low leakage available – see Page 26
Office environment fan – see Page 26
MI-chassis-specific options:
Mil-STD-810 for shock and vibration
Mil-STD-704 and -1399 for overvoltage and transients
–40°C Operation
Conformal coating – contact factory
UG:115 Page 2
Mechanical Considerations
The PFC Mini™ can be mounted on either of two surfaces using standard 8-32 (4 mm) size screws.
Maximum allowable torque is 4.4in.lbs and the maximum penetration is 0.16in [4mm]. When selecting
a mounting location and orientation, the unit should be positioned so airflow is not restricted. Maintain
a 2in [5,1cm] minimum clearance at both ends of the PFC Mini and route all cables so airflow is not
obstructed. The power supply draws air in at the fan-side/AC-input side and exhausts air out the
load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fans move
approximately 20CFM of air.
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 10in.lbs.
Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such
applications, a shock-absorbing mount design is required.
PFC Mini Dos and Don’ts
If sense jumpers are removed, do not leave sense lines open (especially if unit does not have
Autosense). Sense lines must be terminated to their respective outputs. Use twisted pair
20 – 22AWG wire when installing remote sense
NEVER disconnect the +OUT and –OUT load wires while the supply is operating as
disconnecting WILL cause damage to the power supply. Ensure load wires connected before
remote sense connected.
To prevent damage to supply, verify polarity of remote-sense connection before turning supply on.
Always turn the power supply off before disconnecting input or output wires.
Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the
output terminals.
Run the output (+/–) power cables next to each other to minimize inductance.
Do not repair or modify the power supply in any manner. Doing so will void the warranty.
Contact Factory.
Insert proper fault protection at power supply input terminals (i.e., a fuse).
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 UL60950. Appropriate care must be taken in design
implementation of the supply.
UG:115 Page 3
Technical Description
The PFC Mini consists of an offline single-phase, power-factor-corrected front end, EMI filter, cooling
fan, customer interface, associated housekeeping circuits and a selection of Vicor DC-DC converters.
Input AC mains voltage is applied to a terminal block. The input current is passed through an EMI filter
designed to meet conducted noise limit “B” specifications in FCC Part 15 and EN55022, Class B (with
VI-200™/VI-J00™ series modules. If Maxi, Mini, Micro series modules are used, it meets FCC Class A
and EN55022 Class A. (Certain configurations meet Class B).
At start up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after initial
power up by a DC bus voltage sense circuit driving a relay. After rectification, the input voltage is
put through a boost converter that keeps the AC input current sinusoidal and synchronized with the
input AC voltage (in compliance with EN61000-3-2). The boost converter delivers a regulated input
to the hold-up capacitors and a high-voltage backplane. The backplane supplies power to the DC-DC
converters that provide the desired low-voltage regulated outputs.
Voltage conversion is achieved by the Vicor 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, the PFC Mini™ outputs are disabled to limit the inrush current and to allow the DC
bus potential to settle out to the correct operating level. A low-power 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 fans.
The internal housekeeping VCC comes up within two seconds after the application of input power. Once
the high-voltage bus is within operating limits, the AC Power OK signal asserts to a TTL "1," indicating
the input power is OK and enables the power outputs. An auxiliary VCC output of 5VDC sourcing up to
0.3A is provided for peripheral use.
An output enable / disable function is provided by using an optocoupler to control Vicor DC-DC
converters. If the enable / disable control pin is pulled low, the optocoupler turns on and disables the
output. The nominal delay associated for an output to come up when measured from release of the
enable / disable pin is 5 – 10ms. The General Shut Down function controls all outputs simultaneously
and works in a similar manner.
Figure 1
Input
Line Filter
Customer
Current
Sample
Interface
Rectifier
Waveform
Sample
Soft-Start
Circuit
PFC Control
E/D Control
Fan
Boost Converter
Enable/Disable Control
Isolated
Housekeeping
Power
High-Voltage
Bus
Output Card #1
Output Card #2
Output Card #3
Power
Output
Power
Output
Power
Output
UG:115 Page 4
PFC Mini™ Configuration Layout
AC input
Slot 1
Fan
S2-M1S1-M1
Slot 2 Slot 3
Fan
S3-M1
AC input
Slot 1
Fan
S2-M1S1-M1
Slot 2 Slot 3
Fan
S
-
3
S
-
3
M
2
M
1
Shown above are two sample PFC Mini configuration layouts. Due to the configurability nature of
the PFC Mini, various output combinations are possible. See Page 11 for more information about
your output connections. The PFC Mini has three slots, and each slot accommodates either full- or
half-brick modules.
Please note that the maximum output power of the PFC Mini is 1,500W at 230VAC, 800W at 115VAC,
irrespective of the maximum output power of the modules; e.g., if a PFC Mini is configured with
three Maxi modules on the configuration sheet, the maximum output power of the module (600W) is
listed. However, irrespective of the maximum output power of the three Maxi modules (1,800W), the
maximum output power of the PFC Mini is still 1,500W at 230VAC and 800W at 115VAC.
When populated with 12V modules, the maximum output power per slot is 500W (with other modules
it is 600W). Hence, when a 12V Maxi module is used, the maximum output power is limited to 500W. If
a 12V Mini module is used, the maximum output power is limited to 250W.
UG:115 Page 5
Output #2
VI-J63-CW-S
E/D#3
V375A5C400BN4
E/D#2
V375A5C400BN4
E/D#1
Configuration Example:
ModulesWATTSAMPSVOLTSSLOT#
ModulesWATTSAMPSVOLTSSLOT#
V375A5C400BN4*800805.01
V375800805.01
V375A5C400BN4*2
V375A5C402
VI-J60-CY-S*50105.03 (M1)
VI-50105.03 (M1)
VI-J63-CW1004.224.03 (M2)
VI-1004.224.03 (M2)
* Actual module part numbers may vary depending on customer configuration
Output #1
VI-J60-CY
E/D#3
-S*
-S
SLOT#3SLOT#2SLOT #1
E/D = Enable/Disable
Part Numbering
PFC Mini™ PMx1-x2 x (x4)-xxxx(-x5)(-x6)
e.g.: PM4-22-2988
PM1-03B-48
PM3-03-2643-2
PM6-60-2888-2-QF
PM = PM
x1 = number of outputs
x2 = number of VI-200™/VI-J00™
x3 = number of Maxi, Mini
x4 = optional - standard product designator
xxxx = configuration/customer specific # assigned by Vicor
x5 = optional factory assigned note MI = rugged chassis + MC for conformal coated rugged
x6 = additional option codes revised to orginal configuration
QF = quiet fan/office enviornment
LL = low leakage
UG:115 Page 6
NOTE: SET SCREW MAX
Output Return
TORQUE = 4.4 IN. LBS.
115-230 VAC 10A
47 TO 500 Hz
300VDC
---
L2/N
L1
-
+-
+
9
8
SxJ1 Dual Output connector
DO NOT
OPERATE
WITHOUT
EARTH GND
SxJ2
Locking Key
14
15161718
-S+-
T
T
-S
67
M1 Output
M2 Output
13
+S
+S
45
INPUT CONNECTIONS
MBJ1-1 EARTH GROUND
MSJ1-2 L2-NEUTRAL
MBJ1-3 L1
Output
1112
10
++-
-
+
-
3
12
Pin 1 Identifier
PFC MegaPAC™ Quick Install Instructions
(For mechanical drawing, see Page 9)
Mounting the PFC Mini™
Mount the PFC Mini on either of two sides.
Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.16in [4mm].
Maintain 2in [5,1cm] clearance at both ends of power supply for airflow.
Input Connections
Input Power MBJ1
Apply input AC power to terminal block MBJ1 using a pressure screw terminal.
Strip length of AC power conductors to be 0.35 inches.
Maximum torque is 4.4in.lbs.
Place a fuse or circuit breaker in the input line for safety requirements.
The connector manufacturer recommends the wires not be tinned.
A ferrule can be used to prevent fraying.
Output Connections (see Page 10 for more details on output connectors)
Power Connections
Installing bus bars on output studs (when full-size module is used):
The right stud is Positive and the left stud is the Return.
Remove the top nut and place ring lug over output stud.
Do not remove the lower nut next to the PCB.
Replace and tighten the nut to a torque of 10 inch pounds. Do Not over-tighten nuts.
Installing power connectors with 18-pin molex connectors
SxJ1-1, SxJ1-10, SxJ1-11 are Positive for output #1, while pins
SxJ1-2, SxJ1-3, SxJ1-12 are the Return.
SxJ1-7, S3J1-8 and SxJ1-16 are Positive for output #2, while pins
SxJ1-9, SxJ1-17 and SxJ1-18 are the Return.
[b]
Use Molex mating receptacle #39-01-2180 with #44476-3112 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0199.
Current PFC Minis have 18-pin SxJ1 connectors.
Note: Effective January 2001, all PFC Mini units have 18-pin connectors (Molex PN#39-01-2180) vs. the 14-pin
(Molex PN# 39-01-2140). If you already have a 14-pin design in, remove the harness assembly from the 14-pin
connector housing and insert the harness connector pins into the 18-pin connector housing. For further information,
contact an Applications Engineer.
[a]
Outputs with current molex connectors are limited to 9A/pin (27A per output).
[b]
Where x refers to the slot number.
[a]
(when half size module used):
UG:115 Page 7
Remove jumpers for
Trim Connector
Remote Sense
Remove jumpers for
Remote Sense on
Output # 2
Connector J2
Remove jumpers for
Remote Sense on
Output # 1
Sense Connections
Note: PFC Mini™ units built after 12/2000 have been equipped with a feature called Autosense. If no sense
connections are made, the PFC Mini will automatically operate in local-sense mode. If remote-sense connections are
made, the PFC Mini will operate in a remote-sense mode.
For units built before 12/2000 (units without Autosense), Sense connections must ALWAYS be made.
Not connecting Sense Lines to their respective outputs can cause failure to the unit.
Sense connections on output connections with studs
PFC Minis are currently shipped with Autosense installed. Those without the Autosense were shipped
with local sense installed. (See note on Page 13)
If remote sense is desired, remove jumpers MBJ1 and J3, located behind the sense connector.
Connector pin SxJ2-2 is the +SENSE and SxJ2-3 is the –SENSE.
Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
Attach terminals to 20 – 22AWG stranded twisted pair wire using Molex tool #11-01-0208.
Attach opposite end of sense lines to point where regulation is desired.
Verify that sense lines are not cross-connected.
Sense connections on output connection with Molex connectors
PFC Minis are currently shipped with Autosense installed. Those without the Autosense were shipped
with local sense installed. (See note on Page 13)
If remote sense is desired, remove jumpers on MBJ1 and J3, located on either side
of the output connector.
Connector pin SxJ1-4 is the +SENSE and SxJ1-5 is the –SENSE for output #1.
SxJ1-13 is the +SENSE and SxJ1-15 is the –SENSE for output #2.
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded twisted pair wire using Molex tool #11-01-0197.
1
2
3
SxJ2
Locking Key
15161718
-
9
-S+-
+-
T
+
67
8
SxJ1 Dual Output connector
J3 INTERFACE CONNECTION
MATING HDWR:
HOUSING: AMP P/N 205204-4
TERMINALS: AMP P/N 66506-9
SCREW LOCK: AMP P/N 205980-4
CRIMP TOOL: AMP 58448-3
J3 INTERFACE PIN OUT
E/D-1
J3-1
E/D-2
J3-2
E/D-3
J3-3
J3-4
J3-5
J3-6
J3-7
J3-8
J3-9
Pin
Trim Pin Access
+SENSE
–SENSE
14
T
-S
M1 Output
M2 Output
SIGNAL GROUND
VCC +5V 300mA
ACOK AC POWER OK
GSD GENERAL SHUTDOWN
SPARE
SPARE
1112
13
+S
+S
10
++-
-
+
-
3
45
12
Pin 1 Identifier
Trim Connections
Trim connections on outputs with studs:
SxJ2-1 provides trim access.
Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
Attach 20 – 22AWG stranded wire using Molex tool #11-01-0208.
Trim connections on outputs with Molex connectors:
SxJ1-14 provides trim access for output #1, and SxJ1-6 provides trim access for output #2.
Use Molex mating receptacle #39-01-21 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
Interface Connections
J3-1 to 3 are Enable/Disable for cards 1-3, respectively.
J3-4 is Signal Ground, J3-5 is +5V, J3-6 is AC Power OK, and J3-7 is General Shutdown.
Use mating receptacle AMP P/N 205204-4 with terminals AMP P/N 66506-9.
Attach terminals to 18 – 24AWG stranded wire.
UG:115 Page 8
PFC Mini™ Mechanical Drawing
3 4
S3JX
2
SEE PAGE 11 FOR DETAILED OUTPUT
CONNECTION INFORMATION
.34 ±.02 8.64 ±0.51
2
12.03 305.56
12.49 ±.02 317.29 ±0.51
12.16 308.86
4
3
S2JX
6.00 152.40
4
3
S1JX
2.00 50.80
8.00 203.20
.47 11.94
NOTE: FOR INCREASED OUTPUT POWER,
CUSTOMER MOUNTING HOLES:
4X #8-32 X .156 or M4 X 4mm MAX LG.
FROM OUTSIDE OF POWER SUPPLY
CUSTOMER MOUNTING HOLES:
2X #8-32 X .156 or M4 X 4mm MAX LG.
FROM OUTSIDE OF POWER SUPPLY
8.00 203.20 2.00 50.80
CURRENT SHARE BOARDS ARE AVAILABLE.
WITH VI-200/VI-J00 MODULES CSB-01
4.00 101.60
WITH MAXI/MINI MODULES CSB-02
SEE PAGE 21 AND 22 FOR MORE INFORMATION ON
CURRENT SHARE BOARDS.
BOTTOM VIEW
All Westcor power supplies can now be configured online
using VSPOC, the online configurator tool available on vicorpower.com
SCALE: 1:2
1.72 ±.02 43.69 ±0.51
.920 23.37
5 1
.487 12.36
J3 INTERFACE PIN OUT
5.268 133.81
1.600 40.64
9 6
J3-1 E/D-1
J3-2 E/D-2
J3-3 E/D-3
J3-4 SIGNAL GROUND
J3-5 VCC +5V 300mA
J3-6 ACOK AC POWER OK
J3-7 GSD GENERAL SHUTDOWN
J3-8 SPARE
2.210 56.13
DO NOT
WITHOUT
OPERATE
NOTE: SET SCREW MAX
TORQUE = 4.4 IN. LBS.
47 TO 500 Hz
300VDC
115-230 VAC 10A
14 AWG WIRE
CLAMPING SCREWS
J3-9 SPARE
MATING HDWR: (AMP P/N: OR EQUIVALENT)
HOUSING: AMP P/N: 205204-4
TERMINALS: AMP P/N: 66506-9
SCREW LOCK: AMP P/N: 205980-4
J3 INTERFACE CONNECTION
CRIMP TOOL: AMP 58448-3
AIR FLOW
EARTH GND
L2/N
MBJ1-1 EARTH GROUND
MBJ1-2 L2 / NEUTRAL
MBJ1-3 L1
L1
---
MBJ1 INPUT CONNECTIONS
1.00 25.40
NOTES: UNLESS OTHERWISE SPECIFIED
1. INTERPRET DRAWING PER ANSI Y14.5-1994.
WITH OPTIONAL BUSBAR.
A COMPLETE SET OF MATING CONNECTORS CAN
BE PURCHASED FROMWESTCOR BY SPECIFYING
CONNECTOR KIT P/N: 19-130047
REF DESIGNATION LEGEND
MB = MOTHER BOARD
S1 = (SLOT 1) DAUGHTERBOARD MODULES E/D 1.
S2 = (SLOT 2) DAUGHTERBOARD MODULES E/D 2.
S3 = (SLOT 3) DAUGHTERBOARD MODULES E/D 3.
2
3
4
UG:115 Page 9
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