VICOR PFC MegaPAC-EL, PFC MegaPAC-HPEL User Manual

USER GUIDE | UG:119

PFC MegaPAC-EL

TM

PFC MegaPAC-HPELTM
Power Factor Corrected AC-DC Switchers

Contents Page

Overview 1

Standard Features 2

Optional Features 2

Mechanical Considerations 3

MegaPAC Dos and Don’ts 3

Technical Description 4

Configuring and
Reconfiguring MegaPACs 5

ConverterPAC Functional
Description 7

Part Numbering 8

ConverterPAC Output and
Connector Pin Identification 10

PFC MegaPAC-EL and -HPEL
Quick Install Instructions 11

PFC MegaPAC-EL and PFC
MegaPAC-HPEL
Mechanical Drawing 14

Interface Connections 15

Specifications 22

Output Studs 23

Output Power Derating 24

PFC MegaPAC-EL/HPEL
Connector Kit (19-130040)
Listing 24

Connector Kit for
Dual Outputs only ­MegaPAC Family 19-130042 24

Current Share Boards ­Optional Feature 25

Current Share Boards ­Optional Feature Diagram 27

Output Sequencing 28

Overview

The PFC MegaPAC-EL and PFC MegaPAC High Power Low Noise (HPEL) combine power factor
correction (PFC) with the configurability of the MegaPAC family of power supplies. The
PFC MegaPAC-EL and PFC MegaPAC-HPEL provide up to 1,600W and 2,400W of output power
respectively and have power densities of 4.3W/in3 and 6.5W/in3 respectively. The chassis has eight slots
and can provide as many as 16 outputs. The PFC MegaPAC-EL and PFC MegaPAC-HPEL have the same
input and output connections, mounting points and the same dimensions: 3.4 x 6.0 x 15.6in
[85,6 x 152,4 x 396,2mm]. Note that length of older units were 15.5in [393,6mm].

A complete power supply is configured at the factory by selecting and inserting up to eight (four – six
for the PFC MegaPAC-HPEL depending on ConverterPACs used) 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 selection of output voltage and power levels. The net
result is a power supply that offers the advantages of a custom supply, but is assembled from standard
and modular building blocks.

Manufactured at Vicor, the entire family of MegaPAC power supplies is completely user-configurable.
If output requirements change, i.e., more power or a different output voltage is needed, upgrading
is easy: simply unlock a single screw and replace the slide-in ConverterPAC assembly with one that is
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 400V). The driver is to the left of the
boosters when looking at the output end of the supply. A user-friendly interface provides control and
output sequencing capability (see Page 16 for more information about this capability), in addition to
useful status indicators. Please consult our Applications Engineering Department if you have other
special requirements.

Note: This user guide contains references to parts and products that are no longer available for new designs.
They remain included for reference only.

UG:119 Page 1

Standard Features

 Power Factor Correction; 0.99 at 115VAC, 0.95 at 230V
 Universal Input: 85 – 264VAC, 47 – 500Hz, or 100 – 380V

AC

DC

 Power Outputs:

PFC MegaPAC-EL™: 1,600W at 230VAC PFC MegaPAC-HPEL™: 2,400W at 230VAC
1,200W at 115VAC 1,200W at 115V

AC

 Outputs:

PFC MegaPAC-EL and HPEL: Up to 16 outputs

 Output ripple: 10mV

or 0.15% whichever is greater

P-P

 Fan Cooled
 Full-power to 40°C; half power to 60°C
 Soft start for limiting inrush current
 Conducted EMI meets FCC Class A and EN55022 A specifications

(some configurations meet Class B. Contact factory)

 Harmonic Distortion to EN61000-3-2
 RoHS compliant available
 Output Sequencing and General Shutdown

(General Shutdown refer to Page 17. Output sequencing refer to Page 28.
Consult Applications Engineering for automatic sequencing circuitry.)

 Overcurrent protection on all outputs
 Overvoltage protection on all ConverterPAC outputs

(not applicable with VI-J00 modules)

 Overtemperature limiting on all ConverterPAC outputs

(not applicable with VI-J00 modules)

 Size: 3.4 x 6.0 x 15.6in [85,6 x 152,4 x 396,2mm]
 Safety Agency Approvals: CE Mark, cTÜVus, UL

Optional Features

 DC OK status signal
 Current Share Boards - see Pages 25 – 27
 Output voltage adjustment range with built-in potentiometer

UG:119 Page 2

Mechanical Considerations

The PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ 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 20lb.in. The maximum penetration is 0.15in [3.8 mm].

When selecting a mounting location and orientation, the unit should be positioned so air flow is
not restricted. Maintain a 2in minimum clearance at both ends of the PFC MegaPAC-EL and PFC
MegaPAC-HPEL 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 PFC MegaPAC-EL and PFC MegaPAC-HPEL. The fan
moves approximately 30CFM of air.

Avoid excessive bending of output power cables after they are connected to the PFC MegaPAC-EL
and PFC MegaPAC-HPEL. 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 PFC MegaPAC-EL and PFC MegaPAC-HPEL units are 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 45lb.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™ Dos and Don’ts

 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 22-24AWG wire. If ConverterPAC has
Autosense, no local-sense connection is required. See Pages 11 and 12 for more information
on Autosense.

 If needed, use Connector Kit # 19-130040 for the PFC MegaPAC-EL and PFC MegaPAC-HPEL.
 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.

 Always turn the power supply off before disconnecting input or output wires.
 NEVER disconnect the +Out and –Out load wires while the supply is operating, as disconnecting WILL

cause damage to the power supply.

 Do not unplug ConverterPACs while input power is applied. They are not designed for

hot-plug applications.

 Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the

output power terminals.

UG:119 Page 3

 For power expansion, use booster ConverterPACs™. Viewing the unit from the output terminal side,

always insert boosters to the right side of the driver.

 Do not use boosters as independent outputs. Disconnecting bus bars will damage

booster ConverterPACs.

 For booster arrays, do not remove bus bars.
 Always ensure that output hex-nuts are properly torqued before applying power to supply.
 Run the output (+/–) power cables next to each other to minimize inductance.
 Wait five minutes after shutting off power before inserting or removing ConverterPACs.
 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 unit. Do not attempt
to repair or modify the power supply in any manner other than the exchange of ConverterPACs as
described in this Design Guide.

 Insert proper fault protection at power supply input terminals (i.e., a fuse).
 Use proper size wires to avoid overheating and excessive voltage drop.
 Never loosen the inner nut on a ConverterPAC.
 Verify output nuts are tight before powering up.
 FinQPACs™ require two slots each because of the larger heat sink attached to dissipate the extra

heat generated by the higher-power Maxi module. Refer to Page 8 for more information on which
ConverterPACs can be used.

Technical Description

The PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ chassis consists of an offline single phase,
power-factor-corrected front end, EMI filter, cooling fan, low-noise filters, customer interface and
associated housekeeping circuits. Input AC mains voltage (L1, L2 and GND) is applied to a terminal
block. The input current is passed through an EMI filter designed to meet conducted noise limit A
specifications of FCC Part 15, VDE 0871 and EN55022 Class A. 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 AC input voltage (in compliance with EN61000).
The boost converter delivers regulated high voltage DC to the hold-up capacitors and backplane.
The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired
regulated outputs.

Voltage conversion in the output assemblies 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 emissions and high efficiencies.

At initial power up, the PFC MegaPAC-EL and PFC MegaPAC-HPEL 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 fan. The
internal housekeeping VCC comes up within two seconds after the application of input power. Once the
high-voltage bus is within its limits, the AC 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.

UG:119 Page 4

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 ConverterPAC output. The nominal delay for an
output to come up when measured from release of the Enable / Disable pin is 10 – 15ms. 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 after the loss of input power. Detecting the loss of input power takes a finite time period
after which the AC Power OK signal goes from a TTL “1” to “0." This signal is available for use within

1.2s after initial power up and can be used to indicate an impending loss of power. At least 3ms of
warning time is given. Following the loss of input power, the outputs are disabled when the bus voltage
drops below its operating threshold.

Figure 1

PFC MegaPAC-EL™ and

PFC MegaPAC-HPEL™

low-noise architecture

Input

Line Filter

Customer

Current

Sample

Interface

Rectifier

Fan

Waveform

Sample

Current
Monitor

Soft Start

Circuit

PFC Control

E/D Control

Boost Converter

Enable/Disable Control

Housekeeping

Power

High Voltage
DC Bus

QPAC #1

QPAC #2

QPAC #3

QPAC #8

Power
Output

Power
Output

Power
Output

Power
Output

Configuring and Reconfiguring MegaPACs

Most ConverterPACs of the same length can be inserted into any available slot of a MegaPAC chassis.
They can also be easily added, replaced or moved by sliding the assemblies in or out of a MegaPAC
chassis. For outputs greater than 200W, a driver QPAC™ and one or more booster ConverterPACs will
be used. For outputs greater than 600W, a driver FinQPAC™ 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 left
empty, it will provide an airflow escape and cause failure to the power supply.

UG:119 Page 5

Figure 2

Paralleling ConverterPACs

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. Torque the retaining screw to 0.23N.m (2lb.in); do not overtighten. Power and
interface connections can be made after 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 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 – 4. After 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 400V. For a detailed guideline on how outputs should be
placed in series, please refer to: AN:204 Creating High-Voltge Outputs.

Bus Bars for Paralleling

Loosen screw to

remove ConverterPAC

12

Driver

Boosters

4

3

5

6

8

7

UG:119 Page 6

+

_

VI-J00

M1

M2

+

_

M2

VI-200

VI-J00

M1

QPAC

DualPAC

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 or between different
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
whichever is greater. The following Extended-Length ConverterPACs can be used in the

PFC MegaPAC/EL - Low Noise.

QPAC™ (L)

The QPAC output assembly consists of a VI-200™ DC-DC converter that converts the unregulated
high-voltage bus to the desired regulated output voltage. Each QPAC (L) can provide up to 200W of
output power, and booster QPACs can be added in parallel for more power. Power and slave QPACs
can be added in parallel for more power. QPACs are fused with a PC-Tron, DC-rated, fast-acting fuse.
An active preload ensures the DC-DC converter operates in its highest-noise performance range.
As the load on the module increases, the preload removes itself from the circuit. QPACs, using the
VI-200 module, have an optional DC OK TTL signal. All QPACs have overcurrent protection with
automatic recovery when the overcurrent condition is removed. Overvoltage Protection (OVP) and
Overtemperature Limiting (OTL) are available. Please note that for the QPAC (L), the output voltage

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

DualQPAC™ (LD)

The DualQPAC output assembly consists of two VI-J00 DC-DC converters that provide two isolated
output voltages. DualQPACs can provide up to 100W of output power from each output. The
DualQPACs are fused with a PC-Tron, DC-rated, fast-acting fuse. An active preload ensures the DC-DC
converter operates in its highest noise performance range. OVP and OTL is not available. Please note

that for the QPAC (L) the output voltage from either output terminal to chassis should not
exceed 400VDC, or peak. For detailed pinout description, refer to Page 10.

or 0.15%,

P-P

VI-J00

Maxi

JuniorQPAC

FinQPAC

JuniorQPAC™ (LJ)

The JuniorQPAC output assembly consists of a VI-J00 Vicor DC-DC converter that converts the
unregulated high-voltage bus to the desired regulated output voltage. OVP and OTL is not available.

Please note that for the QPAC (L) the output voltage from either output terminal to chassis
should not exceed 400VDC, or peak.

FinQPAC™ (PZL)

The FinQPAC output assembly consists of a Maxi DC-DC converter that converts the unregulated
high-voltage bus to the desired regulated output voltage. Each Maxi module can provide up to 600W
of output power. Each FinQPAC occupies two slots because it has an extra large heat sink attached
to dissipate the heat generated by this more powerful Maxi converter. It cannot be used in any other
member of the MegaPAC Family. FinQPACs have overcurrent protection with automatic recovery when
the overcurrent condition is removed. Overvoltage Protection (OVP) and Overtemperature Limiting (OTL)
are available. Please note that for the FinQPAC (PZL) the output voltage from either output

terminal to chassis should not exceed 400VDC, or peak.

UG:119 Page 7

List of ConverterPACs™ used in the PFC MegaPAC-EL™ and

PFC MegaPAC-HPEL™ Low Noise and their features

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

QPAC (L) Std Std Std AS

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

JuniorQPAC(LJ) N/A Std N/A AS

FinQPAC(PZL)+ Std Std Std AS

[a]

AS

[a]

[a]

[a]

AS

AS

AS

[a]

[a]

[a]

[a]

Opt Opt

Opt N/A

Opt Opt

Opt Opt

OVP Overvoltage Protection (latching) RS Remote Sense

OCP Overcurrent Protection (auto-recovery) LS Local Sense

OTL Overtemperature Limiting AS Autosense

PG Power Good (DC OK TTL Signal) + Maxi OTL is non-latching

[a]

See Pages 11 and 12 for more information on Autosense.

Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualQPAC and JuniorQPAC.

Part Numbering

PFC MegaPAC-EL MPxA-7xBxxxx-xC-x

D

eg. MP5-782560-G-EL

PFC MegaPAC-HPEL MXxA-7xBxxxx-xC-x

D

eg. MX4-742543-2-EL

MP = MegaPAC™ prefix

xA = number of outputs

7 = power factor corrected

xC = optional code ex. G = RoHS

MX = PFC MegaPAC-HPEL prefix

X = PFC chassis that can use Maxi

xB = Number of modules

xxxx = assigned by Vicor

xD = optional code e.g., EL = Extended Length

ConverterPAC XxDV/xEAx

F

eg. L15V/10A

X = ConverterPAC type (For RoHS, add G to current prefix)

xD = Voltage out

xE = Current out (rounded to one decimal point)

xF = Can be multiple options (see Page 9)

UG:119 Page 8

ConverterPAC™ options

B

Booster module

D

DC OK or Power Good

F

Full 50 – 110% output adjustment

[b]

M

Military Grade module

R

RAM external

[c]

S

Trimpot removed for external

[d]

BatPAC™ adjustment

OUT

[e]

OUT

≤ 15V

OUT

F1

50 – 107.5% output adjustment

F2

50 – 105% output adjustment

F3

50 – 102.5% output adjustment

F4

50 – 100% output adjustment

F5

60 – 110% output adjustment

F6

70 – 110% output adjustment

F7

80 – 110% output adjustment

F8

90 – 110% output adjustment

F9

100 – 110% output adjustment

I

Industrial Grade module

K

Custom SRF module used

P

Preload

[b]

D option: Optional for all ConverterPACs used in this power supply.

[c]

T & F options: Optional for all ConverterPACs used in this power supply EXCEPT the DualQPAC™.

[d]

R option: N/A to any ConverterPACs used in the PFC MegaPAC-EL™ / PFC MegaPAC-HPEL™.

[e]

V options: N/A to any ConverterPACs used in the PFC MegaPAC-EL / PFC MegaPAC-HPEL.

T

90 – 110% output adjustment

T1

90 – 107.5% output adjustment

T2

90 – 105% output adjustment

T3

90 – 102.5% output adjustment

T4

90 – 100% output adjustment

T5

98 – 105% output adjustment

T6

100 – 110% output adjustment

V1

"VXI" low noise (150mV) 15V < V

V2

"VXI" low noise (50mV) V

V3

“VXI” low noise (1% ripple) V

≤ 24V outputs

DC

> 24V

[e]

UG:119 Page 9

ConverterPAC™ Output and Connector Pin Identification

QPAC VI-200 MODULE

DUAL QPAC

(M2)

FinQPAC

QPAC™

JuniorQPAC™

DualQPAC™

+VOUT

OUTPUT ADJUST

–VOUT

J2-PIN1

J2 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-PIN1(M1)

J1-B

J2-PIN1

TRIM TOP

7

TRIM BOT

6

N/C

5

4

VCC IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

J1-A-PIN1

(OUTPUT CONNECTORS)

1 AND 4 +VOUT

1

4

2 AND 5 –VOUT

2

5

6

3

3 +R/SENSE 6 –R/SENSE

J1-A

(OUTPUT CONNECTORS)

1 AND 4 +VOUT

4

1

2 AND 5 –VOUT

5

2

6

3

3 +R/SENSE 6 –R/SENSE

DUALQPAC - COMPONENT SIDE VIEW

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

FinQPAC™

M2

Output A
48V/2.1A

M1

Output B
12V/8.3A

Example: LD12V/8.3A-48V/2.1A

+OUT

OUTPUT ADJUST

–OUT

P2-PIN1

Notes:

1. All ConverterPACs except the FinPAC™ occupy one slot. The FinPAC occupies two slots.

2. New output studs were installed on the ConverterPACs and are 1/8th inch longer.

Refer to Pages 14 and 23 for more information.

P2 REMOTE SENSE TRIM/SC & POWER GOOD

+SENSE

7

6

–SENSE

5

TRIM

4

VCC IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

MATING HDWR:

HOUSING- MOLEX P/N: 39-01-0073

TERMINALS- MOLEX P/N: 39-00-0031

CRIMP TOOL MOLEX P/N: 57005-5000

(J1-B)

(J1-A)

J1-B (M1)

J1-A (M2)

UG:119 Page 10

PFC MegaPAC-EL™ and -HPEL Quick Install Instructions

QPAC (L)

J1B (M1)

J1A (M2)

(For Mechanical Drawing, see Page 14)

Mounting the PFC MegaPAC-EL and PFC MegaPAC-HPEL™

 Mount the power supply on any of its four sides.
 Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15in [3,8 mm].

The maximum allowable torque is 20lb.in.

 Maintain 2in [5,1cm] clearance at either end for airflow.

L2

L1

INPUTS
115/230 VAC

47 TO 500 Hz

300VDC

NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS

LABEL NO: 94-00046 REV B

INPUT CONNECTIONS

J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1

DO NOT

OPERATE

WITHOUT

EARTH

GROUND

Input Panel Connectors

+VOUT

OUTPUT ADJUST

–VOUT

J2-PIN1

Single Output QPAC™

5

–

–RS

–

+RS

321

46

+

+

5

–RS

–

+RS

321

+46–

+

DualQPAC™ Output Con-

nector

Input Connections

Input Power J9

 Apply input AC power to terminal block J9 using a pressure screw terminal.
 Strip length of AC power conductors to be 0.35in.
 Maximum torque is 4.4lb.in.
 Place a fuse or circuit breaker in the input line for safety reasons.
 Use a maximum wire size of 14AWG with soldered terminals.
 The connector manufacturer recommends the wires not be tinned.

A ferrule (Phoenix P/N 32-00-58-0, purchased from other sources) can be used to prevent fraying.

Output Connections

Power Connections

Installing ring lugs and / or bus bars on output studs:

 The upper stud is Positive and the lower stud is the Return.
 Newer outputs studs are 1/8th inch longer. See Pages 14 and 23 for more information.
 Remove nut.
 Place ring lug over output stud.
 Replace and tighten outer nut to a maximum torque of 45lb.in. Do Not Over-Tighten Nuts.
 Verify all output nuts are properly installed before turning on supply.

Installing power connectors on DualQPACs - J1A (M2) and J1B (M1):

 Use Molex mating receptacle #39-01-2060 with #39-00-0039 terminals provided.
 Pins 1 and 4 are Positive, while pins 2 and 5 are the Return.
 Attach terminals to 18-24AWG stranded wire using Molex tool #11-01-0197.

Sense Connections

Newer power supplies have the Autosense feature. For these units, if Remote Sense connections are
not made or needed, no Local Sense selection is necessary - simply connect the output to the load and
the unit will automatically operate in Local Sense. If Remote Sense connections are made, the unit will
operate in a Remote Sense mode. Remote Sense terminals should be terminated to their respective
output i.e., –RS to –Output and +RS to +Output. See Page 12 for more information on Autosense. For

units without Autosense, sense connections must ALWAYS be made. Not connecting sense
lines to their respective output can cause failure to the unit. WARNING: NEVER disconnect

the +Out and –Out load wires while the supply is operating as disconnecting WILL cause damage to
the power supply.

UG:119 Page 11

TRIM TOP

J2-PIN1

(OUTPUT CONNECTORS)

POWER GOOD INVERTED

J2-PIN1

J2-PIN1

7

6

TRIM BOT

5

N/C

4

VCC IN

POWER GOOD

3

2

POWER GOOD INVERTED

1

SIGNAL GROUND

J2/P2 Sense Connectors

J1-B (M1)

1 AND 4 +VOUT

1

4

2 AND 5 –VOUT

2

5

6

3

3 +R/SENSE 6 –R/SENSE

J1-A (M2)

1 AND 4 +VOUT

1

4

2 AND 5 –VOUT

5

2

6

3

3 +R/SENSE 6 –R/SENSE

DualQPAC Sense Connector

TRIM TOP

7

6

TRIM BOT

5

N/C

4

VCC IN

POWER GOOD

3

2

1

SIGNAL GROUND

Sense Connector J2 (and P2 for the FinQPAC™):

 Sense connections do not have to be made if either the Local Sense option was ordered (older units)

or if Autosense is present (see previous note on Autosense).

 Attach opposite ends of Sense lines to point where regulation is desired.
 Verify that Sense lines are not cross-connected before applying input power.
 For the QPAC™, J2-7 is the +Sense and J2-6 is the –Sense.
 For the FinQPAC, P2-7 is the +Sense and P2-6 is the –Sense.
 Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG stranded wire using Molex tool #57005-5000.

Sense Connections on DualQPACs™:

 Sense connections do not have to be made either if the Local Sense option has been ordered or

Autosense is present (refer to note on Autosense).

 Sense connections are available on the J2 connector (P2 for the FinQPAC) or the J1A (M2)

and J1B (M1) connectors.

 If using J2 or P2 connector, see pin description on Page 10.
 On J1A and J1B, Pin 3 is the +Sense and Pin 6 is the –Sense.
 Use Molex mating receptacle #39-01-2060 with #39-00-0039 terminals provided.
 Attach terminals to 18-24AWG twisted pair wire using Molex tool #11-01-0197.
 Verify that Sense lines are not cross connected before applying input power.

Trim Pin Connection J2 for QPACs (and P2 for FinQPAC)

 The Trim J2 connection should only be made if the Trim option has not been installed.

(A “T” or an “F” in the ConverterPAC™ part number means the Trim option is installed; eg. M5V/40AT).

 For the QPAC™, refer to J2 Connector. J2-5 provides Trim Access.
 For the FinQPAC, refer to P2 Connector. P2-5 provides Trim Access.
 Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG stranded wire using Molex tool #57005-5000.

Trim Pin Connection on the

J2 /P2 Connector

TRIM TOP B

7

6

TRIM BOT A

5

N/C

4

VCC IN

POWER GOOD

3

2

POWER GOOD INVERTED

1

SIGNAL GROUND

Trim Pin Connection J2 for DualQPACs

 The Trim J2 connection should only be made if the Trim option has not been installed.
 J2-7 is Trim B and J2-6 is Trim A.
 Use Molex mating receptacle #39-01-0073 and #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG twisted pair wire using Molex tool #57005-5000.

UG:119 Page 12

+SENSE

7

J10

6

–SENSE

5

TRIM

4

VCC IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

DC OK/Power Good

Connection on

the J2 /P2 Connector

65

43

2

1

8

9

1110

J10-7
J10-8
J10-9
J10-10
J10-11

12

E/D-7
E/D-8

VCC +5V, 0.3A

SIGNAL GROUND

AC POWER OK

J10-1
J10-2
J10-3
J10-4
J10-5

7

J10 INTERFACE

E/D-1
E/D-2
E/D-3
E/D-4
E/D-5

Interface Connections J10

DC OK (Power Good) Connection J2 (and P2 for FinQPAC™)

 DC OK is only available as an option and is not present unless requested.
 For the QPAC™, refer to the J2 connector. J2-3 is Power Good.
 For the FinQPAC, refer to the P2 connector. P2-3 is Power Good.
 Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG stranded wire using Molex tool #57005-5000.

Interface Connections J10

 Use Molex mating receptacle #39-01-2120 with #39-00-0039 terminals.
 J10-1 through 8 are Enable / Disable for slots 1 – 8.
 J10-9 is VCC, J10-10 is Signal Ground, J10-11 is AC Power OK and J10-12 is General Shutdown.
 Attach terminals to 18-24AWG stranded wire using Molex tool #11-01-0122.

UG:119 Page 13

PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ Mechanical Drawing

J10-1O

J10-11

J10-12

J10 INTERFACE

MAY BE PRESENT. THE NEW OUTPUT PANEL HAS A BRASS INSERT AND THE

NOTE: EITHER THE ORIGINAL OR RE-DESIGNED OUTPUT STUD AND PANEL COMBINATION

OUTPUT PANEL AND STUDS

[18.5mm]

7 SP. @ .7285

5.10 [129.5mm]

.47 [11.94]

15.18 [385.69]

10.01 [254.25]

15.62 [396.81]

3.28 [83.19]

.53 [13.39]

RE-DESIGNED STUD

AND PANEL

(RE-DESIGNED LENGTH)

1.46 [37.03]

.41 [10.35]

ORIGINAL STUD

AND PANEL

.73 [18.52]

2.77 [70.23]

1.40 [35.56]

1/4 - 20 SERRATED FLANGED

10.01 [254.25]

15.50 [393.63]

NUT ZINC PLATED STEEL

WITH OPTIONAL BUSS BARS

10.01 [254.25]

(ORIGINAL LENGTH)

CUSTOMER MOUNTING HOLES (16X)

M4 OR #8-32 THREAD MAXIMUM

SCREW PENETRATION .150 [4.00mm]

FROM OUTSIDE SURFACE.

.21 [5.33]

E/D-1

J10-1

E/D-2

E/D-3

J10-2

J10-3

2.92 [74.17]

E/D-4

E/D-5

J10-4

J10-5

2.75 [69.85]

(T0P AND BOTH SIDES)

STUD IS 1/8 INCH LONGER.

.25 [6.35]

5.100 [129.54]

.470 [11.94]

FAN

(DIRECTION OF AIR

FLOW OPTIONAL)

3.37 [85.60]

HOUSING-MOLEX P/N: 39-01-2120.

MATING HDWR:

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

CRIMP TOOL-MOLEX P/N: 11-01-0122

L1

INPUTS
115/230 VAC

47 TO 500 Hz

300VDC

NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS

LABEL NO: 94-00046 REV B

L2

DO NOT

OPERATE

WITHOUT
EARTH
GROUND

14AWG WIRE

EARTH

GROUND

DO NOT

WITHOUT

OPERATE

L2

AC

DC

47 – 500Hz

300V

INPUTS

115/230 V

L1

NOTE: SET SCREW MAXIMUM

TORQUE = 4.4INLBS

CLAMPING SCREWS

65

E/D-6

E/D-7

J10-6

J10-7

VCC +5V, 0.3A

SIGNAL GROUND

E/D-8

J10-9

J10-8

AC POWER OK

GEN SHUTDOWN

43

J10

2

1

12

1110

9

8

7

6.04 [153.42]

J9-1 EARTH GROUND

J9-2 L2-NEUTRAL

J9-3 L1

INPUT CONNECTIONS

UG:119 Page 14

2.92 [74.17]

INSERT

BRASS

.21 [5.33]

LABEL NO: 94-00046 REV B

NUT

FLANGED

RE-DESIGNEDORIGINAL

Figure 3

Input panel connectors

Interface Connections

Chassis Input Power Terminals (J9)

Input AC power is applied to terminal block J9 using a pressure screw terminal that accepts a maximum
wire size of 14AWG. The insulation should be stripped 0.35in and the maximum torque applied to the
screws should not exceed 4.4lb.in.
The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N 32-00-58-0,
purchased from other sources) can be used to prevent fraying. J9-1 (GND) is Earth Ground for safety;
J9-2 (L2) and J9-3 (L1) are the other Hot connections. For Input DC power, L2 is (+) and L1 is (–).

A fault clearing device, such as a fuse or circuit breaker with a maximum 15A rating at the power supply
input is required for safety agency compliance. It should be sized to handle the start-up inrush current of
25APK at 115 V

Output Power Connections (+P, – P for Single Output, or J1A/J1B for Dual Outputs)

For single output ConverterPACs, these terminals are two 1/4-20 plated steel studs. The upper stud
is positive with respect to the lower stud. For dual output ConverterPACs, there is a six-pin Molex
connector for each output. J1A (M2) pins 1 and 4 are the +Output, and J1A pins 2 and 5 are the
–Output. Pins 3 and 6 are duplicates of the Remote Sense terminals present on J2A and J2B. Use
appropriate wire size rated to handle the full output current, including short-circuit levels. Avoid large
current loops in output cables; run power and return cables next to one another to minimize inductive
effects. All outputs are isolated and can provide positive or negative outputs.

and 230V

RMS

J10

RMS

.

L2

L2

L1

INPUTS
115/230V

AC

47 – 500Hz

300V

DC

NOTE: SET SCREW MAXIMUM
TORQUE = 4.4IN.LBS

LABEL NO: 94-00046 REV B

DO NOT
OPERATE
WITHOUT

EARTH

GROUND

L1

DO NOT

INPUTS

OPERATE

115/230V

AC

47 – 500 Hz

WITHOUT

300V

DC

EARTH

NOTE: SET SCREW MAXIMUM
TORQUE = 4.4IN.LBS

INPUT CONNECTIONS

J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1

GROUND

LABEL NO: 94-00046 REV B

Output +/–Sense Connections –J2 for Single Output, or J1A/J1B for Dual Outputs

Newer power supplies may have some outputs configured with the Autosense feature that automatically
locally senses the output if remote sense is not used. To check if an output has the Autosense feature,
measure the impedance from the + Out to +Sense and –Out to –Sense pins. If the impedance is 5Ω,
then the output has Autosense and does not require local-sense jumpers.

If units do not have Autosense, sense connections must be made. When making sense connections,
keep in mind that although all outputs are open-Sense protected, the +/–Sense terminals MUST
be connected to their respective outputs before the PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™
are powered up. (NEVER disconnect the +Out and – Out load wires while the supply is operating as
disconnecting WILL cause damage to the power supply). Regardless of the output polarity configured,
the +Sense should always connect to the +Power output. The –Sense connects to the –Power output.
Sense connections are not required on booster ConverterPACs™ or if the Local Sense option is specified
(old units). Local Sense mode means that the Remote Sense lines are not connected. Sense pins can be
accessed on J1A/J1B or J2A/J2B on dual output units.

UG:119 Page 15

Figure 4

Interface connector

Signal Ground (J10-10)

Signal Ground (see Figure 4 and Connector Pin Identification) is an isolated ground reference for all J10
interfacing signals and can be used for ConverterPAC™ output status signals such as Power Good. This
is not the same as Earth Ground on input power connector J9.

J10 INTERFACE

J10

65

43

2

1

8

9

7

1110

12

J10-1
J10-2
J10-3
J10-4
J10-5
J10-6

E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6

J10-7
J10-8

J10-9
J10-10
J10-11
J10-12

E/D-7
E/D-8

VCC +5V, 0.3A

SIGNAL GROUND

AC POWER OK

GEN SHUTDOWN

Enable/Disable (J10-1 to J10-8)

The Enable / Disable control pins allow ConverterPAC outputs to be set either on or off. J10-1 through
J10-8 are the control pins for output positions 1 – 8, respectively (see Figure 5 and Connector Pin
Identification above). For DualQPACs™, both outputs are set on or off by the same control pin. In
parallel arrays, only the driver ConverterPAC need be controlled. The Enable / Disable pins must be
pulled low to less than 0.7V with respect to Signal Ground to disable the outputs. They will sink 10mA
maximum. These pins should be open circuited or allowed to exceed 4.5V when enabled. Do not
apply more than 6V to these inputs at any time. If driven from an electromechanical switch or relay, a
capacitor should be connected to eliminate the effects of switch bounce.

Figure 5

Enable / disable and

general shutdown

Using external transistors to
drive enable/diable logic

TTL "1" (OFF)
TTL "0" (ON)

1
0

Enable/Disable Output 1

General Shutdown

Signal Ground

J10

12

10

PFC MegaPAC-EL™

9

VCC

1

UG:119 Page 16

Figure 6

MegaPAC

Enable / disable control

of Maxi Arrays

Enable / Disable control of Maxi Module Arrays

When using the Enable / Disable function on an output that consists of two or more Maxi modules, it
is necessary to connect the E/D pins of the corresponding module locations together such that both
modules are commanded to turn ON or OFF simultaneously.

Example:

Slots 2, 4 and 6 have been configured as a single-output parallel array (see Figure 6).

In order to disable the 48V output, E/D 2, E/D 4 and E/D 6 should be shorted together as shown in
Figure 6. With E/Ds connected together, a single switch can then be used to remotely enable and
disable the output.

Note: For single output power supply configurations, the simplest method of remotely enabling and disabling the
output is to use the General Shutdown (GSD) function.

Slot# 8

Slot# 7

Slot# 6

Slot# 5

Slot# 4

Slot# 3

Slot# 2

Slot# 1

L3.3V/40A

L5V/40A

PZL48V/12.5AJS1

PZL48V/12.5AJS1

PZL48V/12.5AN

J10

2
4

6

10

123

J1

Power Factor Corrected

General Shutdown / GSD (J10-12)

The GSD control pin on J10-12 allows simultaneous shutdown of all ConverterPAC™ outputs (see
Connector Pin Identification on Page 16, Figure 4). This pin must be pulled down to less than 0.7V and
will sink 13mA maximum to shut down all outputs. The GSD pin should be open circuited or allowed
to exceed 4.5V when not in use or when the outputs are to be enabled. Do not apply more than 6V to
this input at any time. Normal open circuit voltage is 1.5 – 3V with respect to Signal Ground. If driven
from an electromechanical switch or relay, a capacitor should be connected to eliminate the effects
of switch bounce.

AC OK / Power Fail (J10-11)

This is an active high TTL compatible signal and provides a status indication of the AC input power
(see Figure 7 and Connector Pin Identification on Page 16, Figure 4). It is capable of sourcing 0.5mA at
>3.2V and sink 16mA at <0.5V. This signal switches to a TTL “1” when the high-voltage bus exceeds
low-line condition during turn-on and switches to a TTL “0” 3ms (minimum) before loss of output
regulation due to the loss of input AC power. This signal can be used to warn external control circuits
of an impending
loss of power.

UG:119 Page 17

Figure 7

AC OK Power Fail

Figure 8

Auxiliary VCC

J10

+5V

2.49K

10kΩ

AC Power OK

PN2222

11

10

Signal Ground

Auxiliary VCC +5V / 0.3A (J10-9)

The VCC on J10-9 is an auxiliary 5V regulated power source (see Figure 8 and Connector Pin
Identification on Page 16). It is +5VDC ±5% with respect to Signal Ground and can supply 300mA
maximum. It is short-circuit-proof, but if shorted all outputs will shut down through the Enable / Disable
circuitry. The Auxiliary VCC typically powers user circuitry or is used with the Power Good circuitry to
provide a pull-up reference for the outputs of the DC Power Good circuit on a ConverterPAC™. If used
for this purpose, the Signal Ground on J10-10 must also be connected to the J3-1 Signal Ground pin of
the ConverterPAC.

J10

78M05

+5V/300mA

9

Auxiliary VCC

Figure 9

Power Good and VCC

0.1µF

Signal Ground

10

Power Good (J2-3 / P2-3)

The optional Power Good signal on J2-3 / P2-3 is referenced to Signal Ground on J2-1 / P2-1 and
indicates the status of the output voltage. This signal is asserted a TTL “1” when the output voltage
is above 95% of nominal. It is a TTL “0” when the output voltage is below 85% of nominal. If the
Trim option is also used, the Power Good trip points DO NOT track with the trimmed voltage. It is
possible to trim the output below the fixed set points of the Power Good circuit and cause a negative
Power Good signal.

J2/P2

4

2N2222

2.49kΩ

2.49kΩ

10kΩ

3

2

1

VCC IN

Power Good

Power Good Inverted

Signal Ground

UG:119 Page 18

Power Good Inverted (J2-2 / P2-2)

This is the inverse of the Power Good signal and is referenced to Signal Ground on J2-1 / P2-1.

Signal Ground (J1-1 / P2-1)

Signal Ground on J2-1/P2-1 is an isolated secondary ground reference for J2/P2 status signals. It is used
to provide a reference point for the Power Good circuitry and is not the same as Earth Ground on input
power connector J9.

VCC IN (J2-4 / P2-4)

The VCC IN on J2-4/P2-4 is an input that requires +5V either from the J10 Auxiliary VCC, or from
another source. Input current to this pin is limited by an internal resistor to 3mA. If the J10 Auxiliary
VCC is connected to VCC IN on J2-4/P2-4, then the J10 Signal Ground must be connected to Signal
Ground on J2-1/P2-1.

+Sense / –Sense - J2-6 and J2-7 (See Pages 11 and 12 for information on Autosense)

The +Sense on J2-7 should be connected to the +Power Out, and the –Sense on J2-7 to the
–Power Out terminal. Do not reverse or leave the Sense pins open. Sense pins can be terminated locally
at the output of the power supply, in which case the power supply will provide regulation at the output
terminals. The voltage appearing at the load may drop slightly due to voltage drop in the power cables.
If it is necessary to compensate for voltage drop along the output power cables, this termination should
be made close to the output load. Compensation of up to 0.5V (0.25V per lead) can be obtained. Use
twisted pair 22-24AWG wire for this purpose.

For DualQPACs™, the +Sense pins are available on connectors designated as J2A-2 and J2B-2 for
outputs A and B, respectively. –Sense pins are on J1A-3 and J1B-3, respectively. These pins are also
duplicated on the power connectors J1A and J1B.

Reminder: Only units with Autosense will automatically operate in Local Sense mode if no Sense
connections are made. It will operate in Remote Sense mode if Remote Sense connections are made.
Units without Autosense MUST have sense connections (Local or Remote) terminated to their respective
output for the unit to operate properly. Further, NEVER disconnect the +Out and –Out load wires while
the supply is operating as disconnecting WILL cause damage to the power supply.

Figure 10

Sense Leads

+P +Out

P2-7 +Sense

P2-6 –Sense

-P –Out

(Local Sense)

(Remote Sense)

Use 22-24AWG

Load

Twisted Pair Wires

UG:119 Page 19

Use 22-24AWG

Table 1

Module internal

reference voltages and

Thevenin resistances

External Trim (J2-5/P2-5)

Output voltage can be trimmed using an optional factory-installed Trim potentiometer or with the Trim
pin (see Figure 11). The Trim potentiometer is located on the ConverterPAC™. If the Trim potentiometer
has not been ordered, the Trim pin must be used. When using the Trim pin, the Trim limits are
determined by the DC-DC converter used on the ConverterPAC. Maximum Trim ranges are 10% above
the nominal converter voltage and 50% below the nominal converter voltage (except 10, 12 and 15V
outputs which are 10% below nominal) as measured from the output studs or output connector of
the power supply.

Note: The combined effects of module trim up, remote sense and dynamic-load step may cause the module to trip
OVP. (Tripping OVP will require cycling input power to the supply off, then on).

The Trim pin on J2/P2 can be used to control the output voltage. It is referenced to the –Sense pin on J2
and can be controlled by either a resistor network or an external voltage source. To increase an output
voltage above its nominal, it is necessary to increase the voltage at the Trim pin above the internal
reference voltage (V

Note: Converters are sometimes pretrimmed at the factory if a nonstandard output voltage is requested. If using a
nonstandard voltage or if a ConverterPAC is ordered with a Trim option, the resistor calculations will differ from those
on Page 21. Please consult the factory for assistance.

). The reverse is true to decrease an output voltage.

REF

Output Module V

VI-200™ / VI-J00™ ≥3.3V 2.50V 10.0kW

VI-200 / VI-J00 < 3.3V 0.97V 3.88kW

Maxi (Pre-Defined) 1.23V 1.0kW

Maxi (User-Defined) 1.23V Consult Factory

REF

R

TH

Figure 11

External trim

To Error
Amplifier

+

R

TH

V

1

–

Twisted Pair Wires

+P +Out

(Remote Sense)

R1

P2-7 +Sense

R2

P2-5

R5

R3

R6

P2-6 –Sense

V

REF

R4

R8

R7

+
V

2

Load

–

–P –Out

Use 22-24AWG Twisted Pair Wires

UG:119 Page 20

Example:

±10% Trim adjust on a 12V nominal output.

Figure 11 shows a typical variable Trim circuit. Using a 10kΩ trimpot (R7), the resistor values for R6 and
R8 can be calculated as follows:

V1 = V

IR5 = (2.75V – V

+ 10% = 2.75V Given: V

REF

)/RTH = (2.75V – 2.5V)/10kW = 25mA

REF

= 2.5V (see Table 1)

REF

Setting the bottom limit:

VR6 = 2.5V – 10% = 2.25V

And since IR5 = IR6 = 25mA,

R6 = VR6 / IR6 = 2.25V / 25mA = 90kW

V2 = V1 + VR6 = 2.75V + 2.25V = 5V

IR7 = V2 / R7 = 5V / 10kW = 500mA

IR8 = IR7 + IR6 = 525mA

VR8 = (V

+ 10%) – V2 = 13.2V – 5V = 8.2V Given: V

NOM

NOM

= 12V

R8 = VR8 / IR8 = 8.2V / 525mA = 15.62kW

Using the above resistor combination, a 12V output can be trimmed externally up to 13.2V and down to

10.8V. For further information on external trimming, refer to Chapter 5 of the VI-200™ / VI-J00 Design
Guide and Applications Manual or consult the factory for assistance.

CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS BELOW 5V.

UG:119 Page 21

Specifications

Input Characterisitcs

Input Voltage 85 – 264VAC, 47 – 500Hz 100 – 380V

Power Factor 0.99 at 115VAC ; 0.95 at 230V

Inrush Current 25APK at 115VAC and 230V

AC

Ride-Through Time >20ms at nominal line, full load

Power Fail >3ms warning

Conducted EMI EN55022 Class A; FCC Class A (Certain configurations meet B. Contact factory)

Surge Immunity

EN 61000-4-5 Installation Class 3, Performance Criteria B
(Temporary loss of output power may occur which is self recoverable)

Primary to Chassis GND = 2,121V

Dielectric Withstand

Primary to Secondary = 4,242V
Secondary to Chassis GND = 750V

Ouput Characterisitcs

Line/Load Regulation

Line Regulation

Load Regulation

[f]

[f]

VI-200/VI-J00
Set Point Accuracy

[f]

Maxi Setpoint Accuracy

Ripple and Noise 0.15% or 10mV

Output Trim Range

VI-200™ / VI-J00™: ±0.2% max.10% to full load
±0.5% max. No load to 10% load

Maxi: ±0.20% max. to 0.3% max LL to HL, Full Load

Maxi: ±0.1% No load to full load

1% for standard voltages; 2% for special or adjustable voltages

1% for standard voltages;
2% for special, adjustable voltages and 48VDC outputs

, whichever is greater, 75% min. load

P-P

10 – 110% of nominal voltage Maxi modules
50 – 110% of nominal voltage VI-200 / VI-J00 modules
90 – 110% of nominal voltage VI-200 / VI-J00 modules 10 – 15V

Overcurrent Trip Point

105 – 125% of full load capability of VI-200 / VI-J00 modules
115% typical of full load capability of Maxi modules

Overvoltage Protection 115 – 135% on VI-200 on QPAC™ and FinQPAC™

Efficiency 80% typical

PFC MegaPAC-EL™ PFC MegaPAC-HPEL™

Output Power

1,600W at 230V

AC

1,200W at 115VAC

[f]

DC

AC

DC

DC

DC

2,400W at 230V

1,200W at 115VAC

AC

[f]

[f]

Not to exceed an input current of 15A.

UG:119 Page 22

Environmental Characteristics

Storage Temperature –40 to 85°C

Altitude

Operating Temperature

Humidity 0 – 95% non-condensing

Safety Agency Approvals

Product Weights
(fully configured)

Warranty

[g]

De-rate 2.6% total output power for each 1,000ft to a maximum operating
altitude of 15,000ft. Non-operating storage maximum altitude is 40,000ft.

–20 to 40°C full power; –20 to 60°C half power

cURus – UL 60950-1, CSA 60950-1
cTUVus – EN 60950-1, UL 60950-1, CSA 60950-1
CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC

PFC MegaPAC-EL™ PFC MegaPAC-HPEL™

12.8lbs [5,8 kgs] 13.1lbs [6 kgs]

2 years limited warranty.
See www.vicorpower.com for complete warranty statement.

See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of
normal output voltage.

[g]

The maximum operating temperature is 40°C. If using a VI-200 with output voltage less than 12V and more than

150W, the operating temperature decreases to 35°C. This also applies when using a FinQPAC™ with output voltage
less than 24V and more than 500W.

Output Studs

New, more robust output studs (with a 3:1 safety margin at 45lbs.in) were installed in ConverterPACs™,
the slide-in assemblies used in the MegaPAC™ Family. These new outputs studs are 1/8" longer to
allow for multiple lugs. They are fully compatible with the original flanged nut ConverterPACs for use in
parallel arrays.

Other advantages include:

 Inner nut (that might become loose) replaced by a brass insert
 Stronger connection to the PCB
 Improved conductivity (less voltage drop and heating)
 Both the stud and panel are less likely to break due to over torqueing

Shown below are the original and redesigned studs.

Original Redesigned

Refer to Page 14 for dimensional data.

UG:119 Page 23

Output Power De-Rating

z)

Output Power vs Input Voltage (VAC) (47 – 500H

2,400W @ 200V

2400

2200

oe eee

De-Rate at 12W/Volt

2000

1800

1600

1400

Output Power(Watts)

1200

Safe Operating Area

1000

85 95 105125 145 165 185 200 215 235 255265

Input Voltage (V

(For VDC, 100V

applies)

MIN

or VDC)

AC

PFC MegaPAC-EL™ and -HPEL Connector Kit (19-130040) Listing

Item Qty Description Vendor #1 Part #

1 1 HOUSING 12 POS.165 CTR W/LATCH MOLEX 39-01-2120

2 12 TERMINAL FEM CRIMP 18-24AWG TIN MOLEX 39-00-0039

** CRIMP TOOL FOR ITEM 2 MOLEX 11-01-0197

3 8 HOUSING 7 POS.098 CTR L/PROFILE MOLEX 39-01-0073

4 8 HOUSING 4 POS.098 CTR L/PROFILE MOLEX 39-01-0043

5 94 TERMINAL FEM CRIMP 22 – 18AWG PH/BRNZ MOLEX 39-01-0031

** CRIMP TOOL FOR ITEMS 3 & 4 MOLEX 00-01-0197

6 8 HOUSING 3 POS.1 CTRS W/LATCH MOLEX 50-57-9403

7 27 TERMINAL FEM CRIMP 22-24AWG SEL/GLD MOLEX 16-02-0103

** CRIMP TOOL FOR ITEM 7 MOLEX 11-01-0118

** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT)

AC

Connector Kit for Dual Outputs only - MegaPAC™ Family 19-130042

Item Qty Description Vendor #1 Part #

1 1 HOUSING 3 POS.100 CTR W/LATCH MOLEX 50-57-9403

2 6 TERMINAL FEM CRIMP 22-24AWG SEL GOLD MOLEX 16-02-0103

** CRIMP TOOL FOR ITEM 2 MOLEX 11-01-0118

3 2 HOUSING 6 POS.165 CTR W/LATCH MOLEX 39-01-2060

4 12 TERMINAL FEM CRIMP 18-24AWG TIN MOLEX 39-01-0039

** CRIMP TOOL FOR ITEM 4 MOLEX 11-01-0197

** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT)

UG:119 Page 24

Current Share Boards - Optional Feature

"Current Sharing" also known as Load Sharing, is the ability to divide the output current evenly across
all active power supplies. This greatly reduces stresses on each power supply and allows them to
run cooler, resulting in higher reliability. Standard "current sharing" techniques typically utilize shunt
resistors or Hall-Effect devices to measure the current from each power supply. Power shunt resistors
continually dissipate power and require cooling especially when dealing with high-output currents of
>100A. Hall-Effect devices measure magnetic fields generated by current flowing through a conductor
and although they dissipate no power, they tend to be large and expensive.

First developed by Vicor Engineering for paralleling MegaPAC™ supplies, the box-to-Box Current Share
Board or CSB allows two or more Vicor power supplies to current share by utilizing the inherent voltage
drop produced in the negative output return cable. This eliminates the need for additional shunt
resistors or expensive Hall-Effect devices and provides a simple five-wire connection method to achieve
a ±1mV accuracy between the Negative Output power rails. This accuracy translates to a 1% current
sharing if there is a total of 100mV conductional voltage drop in the negative return path.

Constructed as a current source to drive the Trim pin of a Vicor module, the design uses an accurate
comparator circuit to monitor the power returns. In addition, the circuit is unidirectional and can only
trim an output voltage up. The benefit is that only the supply that is supporting less current is adjusted
up. This action balances the currents to the load by matching the output voltages of the supplies. In
the case of one supply failing, the circuit will attempt to trim the failed supply only. This will leave the
remaining functional supply alone to provide power to the load at its nominal voltage. Thus the circuit
also offers simple redundancy. In addition, because CSB functions as a current source, the Trim outputs
(T1 and T2) of the CSB can be placed in parallel to create a summing node. This allows current sharing
between more than two supplies by paralleling the T2 output of one CSB circuit with the T1 output
of the next CSB.

Please note: The CSB is not intended for use in hot-swap Applications.

Figure 12

CSB interconnect example

Power Supply 1

24V@1kW

Power Supply 2

24V@1kW

(Requirements on Page 26).

+OUT

+S

TRIM

–S

–OUT

+OUT

+S

TRIM

–S

–OUT

Yellow

Brown

White

Black

D*

T1

–V1

T2

D*

–V2

Power

Red

C SB02

+V

–V

OUT

OUT

UG:119 Page 25

Requirements:

1. For proper operation, the power supplies being paralleled should be enabled at the same time.

2. –Out conductors must be of equal length and wire gauge.

Separate –Out conductors must be used from each supply to the load or the use of a "Y"
connection to a common point must be used as shown in Figure 12. Each leg of the "Y"must
have a minimum of a few millivolts of drop in order for proper operation. 50 – 100mV of drop will
provide from 5 to 1% accuracy.

3. –V1 and –V2 for all box-to-box circuits must be connected directly at the negative output power
studs or terminals to achieve accurate current sharing.

4. D* can be added if redundancy is needed. If redundancy is not required, D* can be replaced with
direct wire connections.

5. When using D*, the Power input should be connected on the cathode side of the paralleling diodes
as shown in Figure 12.

6. Terminate Sense Leads either locally or remotely as shown in Figure 12.

7. For paralleling more than two supplies consult factory for assistance.

UG:119 Page 26

12

34

56

1.74"

[44.2mm]

0.12"

[3.0mm]

1.500"

[38.1mm]

0.12"

[3.0mm]

0.900"

[22.9mm]

1.14"

[29.0mm]

0.13in [3.3mm] Dia Non
Plated thru hole four
places

Molex CT43045F surface-mountable
connector. 0.390in height above board.

Pin Description

1 P ower

2T1

3 –V1

4T2

5 –V2

6

No Connection

J1 Pinout

Figure 13

Mechanical drawing

Figure 14

Cable drawing

Current Share Boards - Optional Feature Diagram

1.74"

1.500"

[44.2mm]

[38.1mm]

J1 Pinout

Pin Description

P ower

1

2T1

3 –V1

4T2

5

–V2

No Connection

6

0.12"

[3.0mm]

0.12"

[3.0mm]

24.0" +/– 1.0"

0.900"

[22.9mm]

1.14"

[29.0mm]

0.13in [3.3mm] Dia Non
Plated thru hole four
places

12

34

56

Molex CT43045F surface-mountable
connector. 0.390in height above board.

Specifications:

P1

Red, 22AWG

Yellow, 22AWG

Brown, 22AWG

White, 22AWG

Black, 22AWG

Power

T1

–V1

T2

–V2

1. Power: 2 – 50VDC at 5mA maximum.

2. Accuracy: ±1mV between –VOUT connections.

3. Output current when not trimming up: ±1µA (VI-200 / J00),

±5µA (Maxi).

4. Use four, non-plated through holes with standoffs for mounting.

5. CSB01 MUST be used for current sharing VI-200™ / VI-J00™ converters (VI-200 / J00).

6. CSB02 MUST be used for current sharing Maxi converters (Maxi, Mini and Micros).

PLEASE NOTE, THE CSB IS NOT INTENDED FOR HOTSWAP APPLICATIONS

Contact your Regional Applications Engineer a: [e-mail] for additional information.

UG:119 Page 27

Output Sequencing

Using the MegaPAC's™ standard Input Interface Connector (J10) along with the ConverterPAC's™
optional DC OK Option, it is possible to implement unique output voltage power-up and power-down
sequences. Below is an example showing how this may be done.

Requirement: 5V must start before the 3.3V output. If the 5V output is lost, the 3.3V
output must turn off.

The first step in meeting this requirement is to configure the 5V QPAC™ with the DC OK Option,
which is indicated by a "D" designator in the QPAC's part number, located on the top surface of each
QPAC above the +V
connector installed. To order a QPAC with the DC OK option, please contact the Vicor customer service
department for assistance. The DC OK option monitors the output voltage of a given ConverterPAC and
provides a TTL logic signal depending on its output voltage.

Figure 17 shows the correct wiring connections between the Power Good Connector (J3) of a 5V QPAC
and the Input Interface Connector (J10) of a typical PFC MegaPAC-EL configuration. In this example, the

3.3V QPAC is located in the slot #7 and the 5V QPAC (with the DC OK option) is located in slot #8. In

order for the Power Good option to properly function, it requires a 5V source to provide the necessary
VCC pull up. This 5V source is conveniently available using the +5V aux source from the Input Interface
Connector (J10-9 and J10-10). With a VCC voltage properly applied to the 5V QPAC's Power Good
Connector (J3-1 and J3-4), the Power Good signal (J3-3) can now be connected to the Enable / Disable
control pin for slot #7 (J10-7). The 5V QPAC's Power Good signal will remain low until its output has
reached approximately 95% of its nominal output voltage. This will keep the 3.3V output in disabled
mode, allowing the 5V output to reach regulation first. In addition, should the 5V output drop below
85% the Power Good signal will drop low and disable the 3.3V output. Figures 18 and 19 show the
startup and shutdown waveforms for the circuit shown in Figure 17.

. Any QPAC that has the DC OK option will also have the four-Pin J3 DC OK

OUT

Figure 15

QPAC pinout

+V

OUT

J2 Pin 1

V

Pot Adjust (Option)

TRIM

–V

OUT

J3 pin 1 (DC OK Option)

UG:119 Page 28

Figure 16

)

J3 DC OK connector

Figure 17

Output sequencing

wire interconnect

DC OK (Power Good)

J3

Pin

J3-4 VCC

4
3

J3-3 Power Good

2

J3-2 Power Good Inverted

1

J3-1 Signal Ground

12345678

3.3V Output

5V with "D" option (DC OK

6

12

5

11

4

10

3

9

2

8

1

7

L1L

2

UG:119 Page 29

Channel #1: 5V Output

5V Output

5V DC OK

3.3V Out

p

ut

Channel #2: 3.3V Output

Channel #3: 5V DC OK signal

Figure 18

Start-up waveforms

5V Output

3.3V Output

5V DC OK

Figure 19

Shut-down waveforms

5V Output

3.3V Output

5V DC OK

UG:119 Page 30

For more information about this or other Vicor products, or for assistance with component-based power
system design, contact the Vicor office nearest you. The Vicor comprehensive line of power solutions
includes modular, high-density DC-DC converters and accessory components, configurable power
supplies and custom power systems. Vicor designs and builds configurable power supplies incorporating
its high-density DC-DC converters and accessory components.

This product line includes:

LoPAC™ FAMILY:

 PFC MicroS
 PFC Micro
 PFC Mini

MegaPAC™ FAMILY:

 PFC MegaPAC™
 4kW MegaPAC
 PFC MegaPAC (High Power)
 PFC MegaPAC (Low Noise/High Power)
 PFC MegaPAC-EL™ (Low Noise)
 Mini MegaPAC™
 ConverterPACs™

OTHERS:

 FlatPAC-EN™

Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini and PFC MegaPAC.

UG:119 Page 31

Limitation of Warranties

Information in this document is believed to be accurate and reliable. HOWEVER, THIS INFORMATION
IS PROVIDED “AS IS” AND WITHOUT ANY WARRANTIES, EXPRESSED OR IMPLIED, AS TO THE
ACCURACY OR COMPLETENESS OF SUCH INFORMATION. VICOR SHALL HAVE NO LIABILITY FOR THE
CONSEQUENCES OF USE OF SUCH INFORMATION. IN NO EVENT SHALL VICOR BE LIABLE FOR ANY
INDIRECT, INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, WITHOUT
LIMITATION, LOST PROFITS OR SAVINGS, BUSINESS INTERRUPTION, COSTS RELATED TO THE REMOVAL
OR REPLACEMENT OF ANY PRODUCTS OR REWORK CHARGES).

Vicor reserves the right to make changes to information published in this document, at any time
and without notice. You should verify that this document and information is current. This document
supersedes and replaces all prior versions of this publication.

All guidance and content herein are for illustrative purposes only. Vicor makes no representation or
warranty that the products and/or services described herein will be suitable for the specified use without
further testing or modification. You are responsible for the design and operation of your applications
and products using Vicor products, and Vicor accepts no liability for any assistance with applications or
customer product design. It is your sole responsibility to determine whether the Vicor product is suitable
and fit for your applications and products, and to implement adequate design, testing and operating
safeguards for your planned application(s) and use(s).

VICOR PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR WARRANTED FOR USE IN LIFE SUPPORT,
LIFE-CRITICAL OR SAFETY-CRITICAL SYSTEMS OR EQUIPMENT. VICOR PRODUCTS ARE NOT CERTIFIED
TO MEET ISO 13485 FOR USE IN MEDICAL EQUIPMENT NOR ISO/TS16949 FOR USE IN AUTOMOTIVE
APPLICATIONS OR OTHER SIMILAR MEDICAL AND AUTOMOTIVE STANDARDS. VICOR DISCLAIMS
ANY AND ALL LIABILITY FOR INCLUSION AND/OR USE OF VICOR PRODUCTS IN SUCH EQUIPMENT OR
APPLICATIONS AND THEREFORE SUCH INCLUSION AND/OR USE IS AT YOUR OWN RISK.

Terms of Sale

The purchase and sale of Vicor products is subject to the Vicor Corporation Terms and Conditions of Sale
which are available at: (http://www.vicorpower.com/termsconditionswarranty)

Export Control

This document as well as the item(s) described herein may be subject to export control regulations.
Export may require a prior authorization from U.S. export authorities.

Contact Us: http://www.vicorpower.com/contact-us

Vicor Corporation

25 Frontage Road

Andover, MA, USA 01810

Tel: [phone]
Fax: [phone]

www.vicorpower.com

email

Customer Service: [e-mail]

Technical Support: [e-mail]

©2018 Vicor Corporation. All rights reserved. The Vicor name is a registered trademark of Vicor Corporation.

All other trademarks, product names, logos and brands are property of their respective owners.

03/18 P/N 07-130265-01 Rev 1.2 Page 32

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