VICOR PFC MegaPAC, PFC MegaPAC MI, Westcor PFC MegaPAC High Power, Westcor PFC MegaPAC High Power MI User Manual

USER GUIDE | UG:105

Westcor PFC MegaPACTM
Power Factor Corrected AC-DC Switchers

May 2013

Contents Page

Overview 1
of Product

Mechanical 3
Considerations

MegaPAC 3
Do’s and Don’ts

Technical Description 4

Configuring and 5
Reconfiguring
MegaPACs

ConverterPAC 6
Description

ConverterPAC 10
Output and Connector
Pin Identification

Overview

The PFC MegaPAC family of supplies combine power factor correction (PFC) with the
inherent configurability of all Westcor MegaPAC products. This design guide covers 4
model variations:

1. PFC MegaPAC 1600 W max, standard chassis

2. PFC MegaPAC MI 1600 W max, rugged COTS chassis

3. PFC MegaPAC High Power 2400 W max, standard chassis

4. PFC MegaPAC High Power MI 2400 W max, rugged COTS chassis

Quick Install 12
Instructions

Mechanical Drawings 15

Interface Connections 16

Specifications 23

Power Derating 25

Connector Kit Listing 25

Current Share Boards 26

Low Leakage Version 29

Output Sequencing 30

All PFC MegaPACs have the same input and output connections, mounting points, and
the same dimensions:

The extended length (-EL) chassis is covered in a dierent design guide

A complete power supply is configured at the factory by selecting and inserting up to
eight same length slide-in output assemblies called ConverterPACs. ConverterPACs
incorporate one (or more) VI-200/VI-J00), Maxi Vicor DC to DC converters and/or
FlexPACs and are available in a wide selection of output voltage 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. Currently, the standard power
chassis uses only FlexPACs and ConverterPACs with VI-200/VI-J00 Vicor DC to DC
converters while the high power chassis accepts FlexPACs and ConverterPACs with
both VI-200/VI-J00 and/or Maxi module. (Refer to page 6 for a brief overview of the
ConverterPACs used.) Using the PowerBench configurator tool available on

www.vicorpower.com, anybody can now configure a PFC MegaPAC (and other Westcor
power supplies) online.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 1

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 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
400 V). The driver is to the le of the boosters when looking at the output end of the
supply. A user-friendly interface provides control and output sequencing capability
(see page 30 for more information about this capability), in addition to useful status
indicators. Please consult our Applications Engineering Department if you have other
special requirements.

Standard Features

n Power Factor Correction; 0.99 at 115 Vac, 0.95 at 230 Vac - both at full load (47-63Hz)

n Universal Input: 85-264 Vac, 47-500 Hz, or 100-380 Vdc

nPower Outputs:

Standard Chassis: 1,600W at 230 Vac High Power Chassis: 2,400W at 230 Vac

1,200W at 115 Vac 1,200W at 115 Vac

nOutputs:

Standard Chassis: Up to 32 outputs High Power Chassis: Up to 32 outputs

n Fan Cooled

n Full power to 40°C; half power to 60°C

n So start for limiting inrush current

n Conducted EMI meets FCC class A and EN 55022 class A

Some configurations meet Class B. Consult Factory

n Harmonic Distortion to EN61000-3-2

n RoHS compliant available

n Output Sequencing and General Shutdown

(Refer pg. 25. Consult Applications Engineering for automatic sequencing circuitry.)

n Overcurrent protection on all outputs

n Overvoltage protection and Overtemperature limiting on all ConverterPAC outputs

(not applicable with VI-J00)

n Size: 3.4”H x 6.0”W x 12.4”L (313,9mm x 152,4mm x 309,mm)

n Safety Agency Approvals: cURus, cTUVus, CE Mark

Optional Features

n DC OK status signal

n Current Share Boards - see pages 26 - 28

n Output voltage adjustment range with built-in potentiometer

n Low Leakage Version available upon request - see page 29

n -40C operation

n Conformal Coating (contact factory)

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 2

Mechanical Considerations

The PFC MegaPAC 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 5.5 lb-in. The maximum penetration is 0.15 in. (3.8mm).

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

Avoid excessive bending of output power cables aer they are connected to the PFC
MegaPAC . 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 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 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.

MegaPAC Do’s and Don’ts

n Remote sense should be used:

- To improve poor output regulation.

- When using older ConverterPACs that do not have the autosense feature.

n NEVER connect the remote sense wires in reverse.To avoid failures, always terminate

the +Sense to the +Out and the -Sense to the -Out.

n If needed, compatible connector kits can be ordered separately. Refer to page 25 for

additional information regarding connector kits.

n To avoid overheating, NEVER operate the supply with an open output slot. Open slots

should always be filled with a ConverterPAC or a plastic airblock designed for
the PFC MegaPAC.

n Always turn the power supply OFF before disconnecting any input or output wires.

Failure to do so may lead to an electrical shock hazard and or damage to
the power supply.

n Do not insert or remove a ConverterPAC while the power supply is running.

They are not designed for hot insertion or extraction.

n Wait 5 minutes aer shutting o the power supply before inserting or

removing a ConverterPAC.

n Do not restrict airflow to or from the supply as this can cause overheating damage.

n Booster ConverterPACs are available for power expansion. Refer to page 6 for

additional information.

n Do Not use boosters as independent outputs. Operating boosters with disconnected

bus bars will cause failures.

n Before turning on the unit ensure all input and output wire are properly connected

and all hex nuts properly tightened.

n Keep output wires as short as possible and run the output (+/-) power cables next to

each other. Use twisted pair wiring whenever possible.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 3

n Avoid running input and output wiring in close proximity as this may cause noise

related problems.

n PFC MegaPACs are NOT user serviceable. Please contact our customer service

department at 1-800-735-6200 for repair assistance. Please be advised that attempts
to repair or modify the power supply will void the warranty.

n A proper fault protection device (fuse or breaker) should be used in series with

the input terminals.

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

n NEVER loosen the inner nut on a ConverterPAC.

n FinPAC ConverterPACs can only be used with a high power chassis. A high power

chassis is identified by an “MX” prefix code in the specific model number.

n Output voltages over 60 Vdc, whether from individual modules or series arrays, are

considered as hazardous secondary outputs under UL 60950. Appropriate care must
be taken in design implementation of the supply.

Technical Description

The PFC MegaPAC chassis consists of an o-line single phase, power-factor-corrected
front end, EMI filter, cooling fan, 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 “B”
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 aer initial power-up by
a DC bus voltage Sense circuit driving a relay. Aer 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 Vicor’s family of
Zero-Current-Switching (ZCS) DC to 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 eciencies.

At initial power-up the PFC 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. The internal housekeeping Vcc comes up within 2 s aer
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 5 Vdc sourcing up to 0.3 A is provided for
peripheral use.

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 10-15 ms. The General Shutdown function
controls all outputs simultaneously and works in a similar manner.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 4

The ride-through (holdup) 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. At least 3 ms 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 and PFC

MegaPAC-High Power

Architecture

Input

Line Filter

Current

Sample

Customer

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

ConverterPAC #1

ConverterPAC #2

ConverterPAC #3

ConverterPAC #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. (Currently, two exceptions are the FinPACs
which can only be used in the high power chassis and the UniPACs which can only be
used in the 4 kW MegaPAC.) For outputs greater than 200 Watts, a driver ModuPAC
and one or more booster ConverterPACs will be used. For outputs greater than
600 Watts, a driver FinPAC 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 5 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.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 5

Figure 2.

Remote Sense

Output Adjust

- Vout

+ Vout

DC OK (Power Good)

Paralleling ConverterPACs

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 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.

Bus Bars for Paralleling

Loosen screw to
remove ConverterPAC

VI-200

ModuPAC

12

Driver

Boosters

4

3

5

6

8

7

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 dierent AC input MegaPAC chassis (Exceptions are the FinPAC
and UniPAC). They can be added, moved, or changed as necessary. The following
ConverterPACs can be used in the PFC MegaPAC and/or PFC MegaPAC-High Power.

Spec sheets for ConverterPACs are available at www.vicorpower.com

ModuPAC

The ModuPAC output assembly consists of a VI-200 DC to 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.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 6

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

Remote Sense
Output Adjust

- Vout

+ Vout

DC OK (Power Good)

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

VI-J00 VI-J00

M2

VI-J00 RAM

M1

JuniorPAC

DualPAC

RAMPAC

JuniorPAC

The JuniorPAC consists of a VI-J00 DC to 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.

M1

DualPAC

This output assembly consists of two VI-J00 DC to DC converters that convert the high

M2

voltage bus to the desired regulated output voltages as noted above. The outputs are
electrically isolated. For detailed pin out description, refer to page 10.

RAMPAC

This output assembly consists of a VI-J00 DC to 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 over a 20 MHz
bandwidth from 10% to 100% of rated load of the converter.
Outputs from 5 V to 50 V are available.

VI-200/BatMOD

Maxi

BatPAC

ModuPAC

FlexPAC

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.

FINPAC

The FinPAC output assembly consists of a Maxi DC to DC converter that converts the
unregulated high voltage bus to the desired regulated output voltage. Each Maxi module

+

can provide up to 600 Watts of output power. Each FinPAC occupies 2 slots because

_

it has an extra large heatsink attached to dissipate the heat generated by this more
powerful Maxi converter. Currently, the FinPAC is ONLY used in the high power (MX)
chassis. It cannot be used in any other member of the MegaPAC Family.
Contact Westcor for future updates.

FlexPAC

The FlexPAC output assembly consists of from 2 to 4 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.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 7

List of ConverterPACs used in the PFC MegaPAC and

PFC MegaPAC-High Power and their features

ConverterPAC OVP OCP OTL RS/AS LS/AS PG TrimPot

ModuPAC Std Std Std AS* AS* Opt Opt

JuniorPAC N/A Std N/A AS* AS* Opt Opt

DualPAC N/A Std N/A AS* AS* N/A Opt

RAMPAC N/A Std N/A AS* AS* Opt Opt

BatPAC N/A Std N/A N/A N/A N/A Std

FinPAC** Std Std N/A AS* AS* Opt Opt

FlexPAC Std Std Std LS LS N/A Std

* See pages 12 and 13 for more information on Autosense.

** All the above mentioned ConverterPACs can be used in both the PFC MegaPAC and PFC MegaPAC-
High Power except the FinPAC which currently can only be used in the PFC MegaPAC-High Power.
(The UniPAC - not listed above - cannot be used either in the PFC MegaPAC or the PFC MegaPAC-
High Power. Currently, the UniPAC is only used in the 4 kW MegaPAC.)

Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC,
JuniorPAC and RamPAC.

Part Numbering

PFC MegaPAC Mpaa-7bcccc-v-xx

p = P for standard chassis p = X for high power chassis

aa = number of outputs

b = number of DC-DC modules and FlexPACs

cccc = customer specific configuration code

v = optional revision code and may be blank (note: v = G for RoHS compatible

product)

xx = additional option codes
Note: xx = MI for rugged chassis, = MC for rugged chassis with conformal coating

ConverterPAC XxDV/xEAx

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

F

xD = Voltage out

x

= Current out (rounded to 1 decimal point)

E

= Can be multiple options* (see page 9)

x

F

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 8

Part Numbering (Cont.)

* 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

Industrial Grade module

I

Custom SRF module used

K

Preload V

P

Military Grade module

M

R RAM external

3

1

2

Examples:

M15V/10A, M15V/10ADFI, D15V/6.7A-12V/8.3AT

S

T 90-110% output adjustment

T1

T2

T3

T4

T5

T6

V1

V2

V3

Trimpot removed for external

BatPAC adjustment

4

90-107.5% output adjustment

90-105% output adjustment

90-102.5% output adjustment

90-100% output adjustment

98-105% output adjustment

100-110% output adjustment

"VXI" low noise (150 mV or less)

15V< V

OUT

"VXI" low noise (50 mV or less)

≤ 15 Vdc

OUT

“VXI” low noise (1% ripple or less)

V

> 24 V

OUT

≤ 24 V

5

M = ModuPAC (RoHS =GM) R = RAMPAC (RoHS = GR)
D = DualPAC (RoHS = GD) B = BatPAC (RoHS = GB)
J = JuniorPAC (RoHS = GJ) PZ = PZ - FinPAC (RoHS = GPZ)

[1]

D option: Optional for all ConverterPACs EXCEPT the DualPAC, BatPAC and RamPAC

[2]

F options: Optional for all ConverterPACs EXCEPT the BatPAC, DualQPAC, and FlexPAC. Trim range

dependent 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 options: Optional for all ConverterPACs EXCEPT the BatPAC, DualQPAC, and FlexPAC. Trim Range
dependent on module type and voltage

[5]

V options: Optional ONLY on the ModuPAC, DualPAC and JuniorPAC. N/A on all other
ConverterPACs. Requires 15% minimum load.

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

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 9

ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC

MODUPAC/JR.PAC/RAMPAC

DUALPAC

20-130182-TAB

ModuPAC
JuniorPAC

RAMPAC

DualPAC

+ V0UT

J2-PIN1

OUTPUT ADJUST

- VOUT

J3-PIN1

J1-B-PIN1

J2-B-PIN1

OUTPUT ADJ. #1

J1-A-PIN1

J2-A-PIN1

OUTPUT ADJ. #2

(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

3 +R/SENSE 6 -R/SENSE

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: 11-01-0208

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: 11-01-0208

Note:

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 page 24
for more information.

DUALPAC - COMPONENT SIDE VIEW

M2

Output A
48V/2.1A

M1

Output B
12V/8.3A

Example: D12V/8.3A-48V/2.1A

J1-B (M1)

J1-A (M2)

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 10

ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC

BatPAC

FinPAC

+ V0UT

CURRENT LIMIT ADJUST

VOLTAGE LIMIT ADJUST

- VOUT

J3-PIN1

+ 0UT

OUTPUT ADJUST

- OUT

P2-PIN1

J2 (BATPAC REMOTE INTERFACE)

CURRENT LIMIT ADJUST

4

3

VOLTAGE LIMIT ADJUST

2

CURRENT MONITOR

1

- VOUT

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

MATING HDWR:

HOUSING- MOLEX P/N: 39-01-0043

TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000

FlexPAC

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

7

–

89 10 11 12

––

n/a n/a

++++

n/a

n/a

12 4356

M1

M2

M3

M4

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:

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 page 24
for more information.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 11

PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 15)

MODUPAC/JR.PAC/RAMPAC

Mounting the PFC MegaPAC and PFC MegaPAC-High Power

n Mount the power supply on any of its four sides.

n Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15"

(3,8mm). The maximum allowable torque is 5.5 lb-in.

n Maintain 2" (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

DO NOT
OPERATE
WITHOUT

EARTH

GROUND

Input Panel Connectors

+ Vout

J2 Pin 1

Vtrim Pot Adjust (Option)

- Vout

J3 pin 1 (DC OK Option)

Single Output ModuPAC

Input Connections

Input Power J9

n Apply input AC power to terminal block J9 using a pressure screw terminal.

n Strip length of AC power conductors to be 0.35 inches.

n Maximum torque is 4.4 lb-in.

n Place a fuse or circuit breaker in the input line for safety reasons.

n Use a maximum wire size of 14 AWG with soldered terminals.

n 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:

n The upper stud is Positive and the lower stud is the Return.

n Newer outputs studs are 1/8th inch longer. See page 24 for more information.

n Remove nut.

n Place ring lug over output stud.

n Replace and tighten outer nut to a maximum torque of 45 lb-in.

Do Not Over-Tighten Nuts.

n Verify all output nuts are properly installed before turning on supply.

J1A

46

5

+

-

-RS

+

-

+RS

321

J1B

5

-RS

-

+RS

321

DualPAC Output Connector

Installing power connectors on DualPACs (J1A and J1B):

n Use Molex mating receptacle #39-01-2060 with #39-00-0039 terminals provided.

+46-

n Pins 1 and 4 are Positive, while pins 2 and 5 are the Return.

+

n Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197.

Sense Connections

Note: 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 13 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.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 12

J2 Sense Connector

J2

Pin

1

J2-1 Trim Pin Access

2

J2-2 +Sense

3

J3-3 -Sense

P2 Sense Connector

+SENSE

7

6

-SENSE

5

TRIM

4

Vcc IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

Sense Connector J2 (and P2 for the FinPAC):

n Sense connections do not have to be made if the Local Sense option was ordered or if

Autosense is present (see above note on Autosense.)

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

n J2-2 is the +Sense and J2-3 is the -Sense.

n Attach terminals to 22-24 AWG twisted pair wire using Molex tool #11-01-0208.

n Attach opposite ends of Sense lines to point where regulation is desired.

n Verify that Sense lines are not cross-connected before applying input power.

n For the FinPAC, P2-7 is the + Sense and P2-6 is the -Sense.

n Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided

n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.

J1A

5

+

-

-RS

+

-

+RS

321

1 and 4 +V OUT

2 and 5 -V OUT

3 +REMOTE SENSE

6 -REMOTE SENSE

J1B

PIN

5

-RS

-

+RS

321

+46-

+

46

DualPAC Output Connector

J2 Trim Pin Connector

J2

Pin

1

J2-1 Trim Pin Access

2

J2-2 +Sense

3

J3-3 -Sense

P2 Trim Pin Connector

+SENSE

7

6

-SENSE

5

TRIM

4

Vcc IN

3

POWER GOOD

2

POWER GOOD INVERTED

1

SIGNAL GROUND

Sense Connections on DualPACs:

n 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).

n Sense connections are available on the J2 connector (P2 for the FinPAC)

or the J1A and J1B connectors.

n If using J2 or P2 connector, see instructions on page 10.

n On J1A and J1B, Pin 3 is the +Sense and Pin 6 is the -Sense.

n Use Molex mating receptacle #39-01-2060 with #39-00-0039

terminals provided.

n Attach terminals to 18-24 AWG twisted pair wire using

Molex tool #11-01-0197.

n Verify that Sense lines are not cross-connected before applying input power.

Trim Pin Connection J2 (and P2 for FinPAC)

n 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; e.g. M5V/40AT.)

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

n Attach terminals to 22-24 AWG stranded wire using Molex tool #11-01-0208.

n J2-1 provides Trim access.

n For the FinPAC, refer to P2 Connector. P2-5 provides Trim Access.

n Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.

n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 13

g

DC OK (Power Good)

D

35

J3

Pin

J3-4 Vcc

4
3

J3-3 Power Good

2

J3-2 Power Good Inverted

1

J3-1 Si

nal Gro

P2 DC OK Connector

+SENSE

7

6

-SENSE

5

TRIM

4

Vcc IN

3

POWER GOOD

2

POWER GOOD INVERTE

1

SIGNAL GROUND

und

DC OK (Power Good) Connection J3 (and P2 for FinPAC)

n DC OK is only available as an option and is not always present.

n J3-4 is Vcc In, J3-3 is Power Good, J3-2 is Power Good inverted, and J3-1

is Signal Ground.

n Use Molex mating receptacle #39-01-0043 with #39-00-0031

terminals provided.

n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.

n For the FinPAC, refer to the P2 Connector. P2-3 is Power Good.

n Use Molex mating receptacle #39-01-0073 with #39-00-0031

terminals provided.

n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.

2

1

8

7

J10 INTERFACE

E/D-1

J10-1

E/D-2

J10-2

E/D-3

J10-3

E/D-4

J10-4

E/D-5

J10-5

E/D-6

J10-6

J10

9

43

J10-7
J10-8
J10-9
J10-10
J10-11
J10-12

65

1110

12

E/D-7
E/D-8

Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK

GEN SHUTDOWN

Interface Connections J10

n Use Molex mating receptacle #39-01-2120 with #39-00-0039 terminals provided.

n J10-1 to 8 are Enable/Disable for slots 1-8.

n J10-9 is Vcc, J10-10 is Signal Ground, J10-11 is AC Power OK, and J10-12

is General Shutdown.

n Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197.

FlexPAC Connections J1

n Use Molex mating receptacle #39-01-2120 with #39-00-0039 terminals provided.

n Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197.

n J1 pins 11, 5, 12 and 6 are for special trim options. Contact factory for use.

n Local Sense only.

–

7

–

89 10 11 12

––

n/a n/a

++++

n/a

n/a

12 4

6

7 –V

M1

8 –V

M2

9 –V

M3

10 –V

M4

11 DO NOT USE
12 DO NOT USE

OUT

OUT

OUT

OUT

M1
M2
M3
M4

1 +V

M1

OUT

2 +V

M2

OUT

3 +V

M3

OUT

4 +V

M4

OUT

5 DO NOT USE
6 DO NOT USE

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 14

PFC MegaPAC Mechanical Drawing

3.28 [83.19]

.53 [13.39]

RE-DESIGNED STUD AND PANEL

(18.5 MM)

7 SP. @ .7285

5.10 (129.5 MM)

1.46 [37.03]

.41 [10.35]

ORIGINAL STUD AND PANEL

.47 [11.94]

.73 [18.52]

2.77 [70.23]

1.40 [35.56]

OUTPUT PANEL AND STUDS

NUT ZINC PLATED STEEL

1/4 - 20 SERRATED FLANGED

WITH OPTIONAL BUSS BARS

BRASS

INSERT

FLANGED

NUT

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

STUD IS 1/8 INCH LONGER. (SEE SHEET ONE FOR DIMENSIONAL DATA).

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

ORIGINAL RE-DESIGNED

11.93 [302.90]

.21 [5.33]

2.92 [74.17]

MATING HDWR:

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

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

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

E/D-1

E/D-2

J10 INTERFACE

J10-1

J10-2

E/D-3

J10-3

6.75 [171.45]

E/D-4

E/D-5

J10-4

J10-5

E/D-6

J10-6

E/D-7

J10-7

E/D-8

J10-8

12.36 [313.87]

(RE-DESIGNED LENGTH)

Vcc +5V, 0.3A

SIGNAL GROUND

AC POWER OK

J10-9

J10-1O

J10-11

.25 [6.35]

3.37 [85.60]

GEN SHUTDOWN

J10-12

65

12

1110

43

J10

9

2

8

1

7

FAN

(DIRECTION OF AIR

5.10 [129.54]

FLOW OPTIONAL)

6.04 [153.42]

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

EARTH

GROUND

DO NOT

WITHOUT

OPERATE

47 TO 500 Hz

300VDC

INPUTS

115/230 VAC

J9-1 EARTH GROUND

J9-2 L2-NEUTRAL

J9-3 L1

6.75 [171.45]

LABEL NO: 94-00046 REV B

NOTE: SET SCREW MAXIMUM

TORQUE = 4.4 INCH POUNDS

2.92 [74.17]

M4 OR #8-32 THREAD MAXIMUM

SCREW PENETRATION .150 [4.00 MM]

CUSTOMER MOUNTING HOLES (16X)

FROM OUTSIDE SURFACE.

.21 [5.33]

12.24 [310.83]

(ORIGINAL LENGTH)

2.75 [69.85] 6.75 [171.45]

(T0P AND BOTH SIDES)

.47 [11.94]

L2

DO NOT
OPERATE
WITHOUT

EARTH

GROUND

L2

L1

14 AWG WIRE

CLAMPING SCREWS

INPUT CONNECTIONS

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 15

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 14 AWG. The insulation should be stripped .35 inches
and the maximum torque applied to the screws should not exceed 4.4 lb-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 25A pk at 115 Vrms and 230 Vrms.

L2

L1

DO NOT

INPUTS

OPERATE

115/230 VAC

47 TO 500 Hz

WITHOUT

300VDC

EARTH

GROUND

NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS

LABEL NO: 94-00046 REV B

u

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

DO NOT
OPERATE
WITHOUT

EARTH

GROUND

INPUT CONNECTIONS

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

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 6-pin Molex connector for each output. J1A 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 eects. All
outputs are isolated and can provide positive or negative outputs.

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 5 ohms, then the output has Autosense and
does not require local sense jumpers. FlexPAC is local sense only.

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 and PFC MegaPAC-High Power are powered up. 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, BatPACs, or if the Local Sense option is specified. 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:105 vicorpower.com Applications Engineering: 800 927.9474 Page 16

Figure 4.

Interface Connector

Signal Ground (J10-10)

Signal Ground (see Figure 4 and Connector Pin Identification on page 14) 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.

E/D-1

65

12

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

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

J10

2

1

8

7

43

9

1110

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 sequenced either
on or o. J10-1 through J10-8 are the control pins for output positions 1 through 8,
respectively (see Figure 5 and Connector Pin Identification on page 14). For DualPACs
and FlexPACs, all outputs are sequenced. In parallel array using VI/VE modules only
the driver ConverterPAC need be controlled. The Enable/Disable pins should be pulled
low to less than 0.7 V with respect to Signal Ground to disable the outputs. They will
sink 10 mA maximum. These pins should be open circuited or allowed to exceed 4.5 V
when enabled. Do not apply more than 6 V to these inputs at any time. If driven from
an electromechanical switch or relay, a capacitor should be connected to eliminate the
eects of switch bounce.

Figure 5.

Enable/Disable and
General Shutdown

A TTL "1" applied to the base of the transistor turns
output OFF. Pin 1 (or Pin 12 for GSD) is pulled Low
with respect to Signal Ground.

Enable/Disable Output 1

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

1
0

General Shutdown

Signal Ground

J10

12

10

PFC MegaPAC

9

1

Vcc

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 17

Figure 6.

Enable/Disable Control

of Maxi Arrays

Enable/Disable control of Maxi/Mini/Micro 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 48 V 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

M3.3V/40A

M5V/40A

PZ48V/12.5AJS1

PZ48V/12.5AJS1

PZ48V/12.5AN

J10

2
4

6

10

123

J1

MegaPAC

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 9). This pin must be pulled down
to less than 0.7 V, and will sink 13 mA maximum to shut down all outputs. The GSD
pin should be open circuited or allowed to exceed 4.5 V when not in use, or when
the outputs are to be enabled. Do not apply more than 6 V to this input at any time.
Normal open circuit voltage is 1.5 to 3 V with respect to Signal Ground. If driven from
an electromechanical switch or relay, a capacitor should be connected to eliminate the
eects of switch bounce.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 18

Figure 7.

AC OK Power Fail

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 14). It is capable
of sourcing 0.5 mA at >3.2 V and sink 16mA at < 0.5 V. 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” 3 ms (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.

J10

+5V

2.49K

10K

AC Power OK

PN2222

11

10

Signal Ground

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

The Vcc on J10-9 is an auxiliary 5 V regulated power source (see Figure 8 and Connector
Pin Identification on page 14). It is +5 Vdc +/–5% with respect to Signal Ground and can
supply 300 mA 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.

Figure 8.

Auxiliary Vcc

78M05

+5V/300 mA

0.1 µF

J10

9

Auxiliary Vcc

Signal Ground

10

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 19

Figure 9.

od Inverte

d

Power Good and Vcc

Power Good (J3-3)

The optional Power Good signal on J3-3 is referenced to Signal Ground on J3-1, 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
setpoints of the Power Good circuit and cause a negative Power Good signal.

2N2222

ConverterPAC

2.49K

2.49K

10K

J3

4

3

2

1

Vcc In

Power Good

Power Go

Signal Ground

Power Good Inverted (J3-2)

This is the inverse of the Power Good signal and is referenced to Signal Ground on J3-1.

Signal Ground (J3-1)

Signal Ground on J3-1 is an isolated secondary ground reference for J3 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 (J3-4)

The Vcc In on J3-4 is an input that requires +5 V either from the J10 Auxiliary Vcc, or
from another source. Input current to this pin is limited by an internal resistor to 3 mA.
If the J10 Auxiliary Vcc is connected to Vcc In on J3-4, then the J10 Signal Ground must
be connected to Signal Ground on J3-1.

+Sense/ –Sense - J2-2 and J2-3 (See page 10 and 13 for information on Autosense)

The +Sense on J2-2 should be connected to the +Power Out, and the –Sense on J2-3 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 0.5 V (0.25 V per lead) can be obtained. Use
twisted pair 22-24 AWG wire for this purpose.

For DualPACs, the +Sense pins are available on connectors designated as J2A-2 and
J2B-2 for outputs A and B, respectively. –Sense pins are on J2A-3 and J2B-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.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 20

Figure 10.

Sense Leads

+P +Out

+Sense

(Local Sense)

(Remote Sense)

Load

-Sense

-P -Out

Use 22-24 AWG
Twisted Pair Wires

External Trim (J2-1)

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 V, 12 V and
15 V outputs which are 10% below nominal) as measured from the output studs or
output connector of the power supply.

Note: The combined eects of module trim up, remote sense and dynamic load step may
cause the module to trip OVP. (See page 6 for information on restart).

The Trim pin on J2 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 (Vref). The
reverse is true to decrease an output voltage.

Note: Converters are sometimes pre-trimmed at the factory if a nonstandard output voltage is
requested. Standard voltages include 2 V, 3.3 V, 5 V, 10 V, 12 V, 15 V, 24 V, 28 V, and 48 V. If using a
nonstandard voltage, or if a ConverterPAC is ordered with a Trim option, the resistor calculations will

differ from those on page 22. Please consult the factory for assistance.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 21

Use 22-24 AWG Twisted Pair Wires

Table 1.

Module Internal

Reference Voltages and

Thevenin Resistances.

Figure 11.

External Trim

Output Module Vref RTH

VI-200/VI-J00 ³3.3 V 2.50 V 10.0 kW

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

Maxi/Mini/Micro (Pre-Defined) 1.23 V 1.0 kW

Maxi/Mini/Micro (User Defined) 1.23 V Consult Factory

Use 22-24 AWG

To Error
Amplifier

Twisted Pair Wires

+P +Out

R1

J2-2 +Sense

R2

J2-1

+

RTH

R5

V1

V

-

Ref

R3

R4

R6

J2-3 -Sense

-P -Out

R8

R7

(Remote Sense)

+
V

2

-

Load

Example:

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

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

V1= V

IR5 = (2.75 V - V

+ 10% = 2.75 V Given: V

ref

)/RTH = (2.75 V - 2.5 V)/10 kW = 25 mA

ref

= 2.5 V (see Table 1)

ref

Setting the bottom limit:

VR6 = 2.5 V - 10% = 2.25 V

And since IR5 = IR6 = 25 mA,

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

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

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

IR8 = IR7 + IR6 = 525 mA

VR8 = (V

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

nom

nom

= 12 V

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

Using the above resistor combination, a 12 V output can be trimmed externally up
to 13.2 V and down to 10.8 V. For further information on external trimming, refer to
Chapter 5 of the Applications Design Guide or consult the factory for assistance.

CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS BELOW 5 V.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 22

Specifications

Input Characterisitcs

Input Voltage 85-264 Vac, 47-500 Hz 100-380 Vdc

Power Factor 0.99 @ 115 Vac ; 0.95 @ 230 Vac - both at full load (47-63 Hz)

Inrush Current 25A pk @ 115 Vrms and 230 Vrms

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

Power Fail >3 ms warning

Conducted EMI

Surge Immunity

Dielectric Withstand

Overvoltage and Transients Per Mil-STD 704 and 1399 (MI rugged chassis only

Ouput Characterisitcs

Line/Load Regulation

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

Load Regulation* Maxi: ± 0.1% No load to full load

VI-200/VI-J00 Setpoint

Accuracy*

Maxi Setpoint Accuracy

Ripple and Noise

External Output Trim Range

(Using Trim/Sc pin)

Overcurrent Trip Point

Overvoltage Protection 115-135% on VI-200 and Maxi modules only

Efficiency 80% typical

Output Power

FCC Class A; EN55022 Class A (Certain configurations meet B. Contact Factory)

Mil-STD 461 CE 101 and 102 require external filtering

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 = 2,121 Vdc

Primary to Secondary = 4,242 Vdc

Secondary to Chassis GND = 750 Vdc

Ist Gen: ± 0.2% max.10% to full load

± 0.5% max. No load to 10% load

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

1% for standard voltages;

2% for special, adjustable voltages and 48 Vdc outputs

Std. outputs: 2% or 100 mV p-p, whichever is greater, 75% min. load;

VXI options: V1 = (150 mVp-p or less) 15 V < Vout < 24 V outputs

V2 = (50 mVp-p or less) Vout < 15 Vdc

V3 = (1% ripple or less) Vout > 24 V

(VXI options require 15% minimum load)

RAMPAC: 10 mVp-p or 0.15% whichever is greater

FlexPAC 50 mV 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 10-15 V

2-25 V FlexPAC

105-125% of full load capability of VI-200/VI-J00 modules

115% typical of full load capability of Maxi modules

135% FlexPAC

MP Prefix MX Prefix

1,600 W at 230 Vac 2,400 W at 230 Vac

1,200 W at 115 Vac

+

1,200 W at 115 Vac

+

*Note: Not to exceed an input current of 15 A.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 23

Specifications (Cont.)

Environmental Characteristics

Storage Temperature -40°C to 85°C

Altitude

Operating Temperature**

Shock and Vibration Mil-STD 810 (MI rugged chassis ONLY)

Humidity 0 to 95% non-condensing

Safety Agency Approvals

Product Weights

(fully configured)

Warranty

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

**The maximum operating temperature is 40°C. If using a VI-200 with output voltage less than 12 V
and more than 150 Watts, the operating temperature decreases to 35°C. This also applies when using
a FinPAC with output voltage less than 24 V and more than 500 Watts.

Derate 2.6% total output power for each 1,000 ft to a maximum operating

altitude of 15,000 ft. Non-operating storage maximum altitude is 40 K.

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

-40°C optional with rugged chassis (-MI or -MC suffix)

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

Note: some MI chassis will not carry all safety approvals

MP Chassis MX Chassis

9.75 lbs (4,42 kgs) 10 lbs (4,54 kgs)

2 years limited warranty.

See www.vicorpower.com for complete warranty statement.

Output Studs

New, more robust output studs (with a 3 to 1 safety margin @ 45 in. lbs.) 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:

n Inner nut (that might become loose) replaced by a brass insert

n Stronger connection to the PCB

n Improved conductivity (less voltage drop and heating)

n Both the stud and panel are less likely to break due to over torqueing

Shown below are the original and re-designed studs.

Original Redesigned

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 24

PFC MegaPAC Output Power Derating

Output Power vs Input Voltage (Vac) (47-500 HZ)

2400

2,400W @ 200 Vac

2200

Power Exceeded

Derate at 12W/volt

2000

1800

1600

1400

Output Power (Watts)

1200

Safe Operating Area

1000

85 95 105 125 145 165 185 200 215 235 255 265

nput Voltage (Vac or Vdc)

(For VDC, 100V min applies)

PFC MegaPAC 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 - 24 AWG 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 - 18 AWG 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 - 24 AWG SEL/GLD MOLEX 16-02-0103

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

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

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 25

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 Eect 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 >100 Amps.
Hall Eect 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 Westcor Engineering for paralleling MegaPAC supplies, the Box-to­Box 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 Eect
devices and provides a simple 5 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 oers 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 Hotswap Applications.

Figure 12.

CSB Interconnect Expample

+OUT

+S

Power Supply 1

24V@1kW

Power Supply 2

24V@1kW

TRIM

-OUT

+OUT

TRIM

-OUT

Yellow

-S

Brown

+S

White
Black

-S

(Requirements on page 27.)

D*

D*

T1

-V1
T2

-V2

Power

C SB02

+VOUT

Red

-VOUT

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 26

Current Share Boards - Optional Feature (Cont.)

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 mV to 100 mV 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 above.

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

7. For paralleling more than 2 supplies consult factory for assistance.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 27

Current Share Boards - Optional Feature (Cont.)

1.74"

1.500"

(38.1mm)

0.12"

(3.0mm)

0.12"

(3.0mm)

Figure 13. Mechanical Drawing

J1 Pinout

Pin Description

1 P ower

2T1

3 -V1

4T2

-V2

5

No Connection

6

(44.2mm)

12

34

56

0.900"

(22.9mm)

1.14"

(29.0mm)

0.13" (3.3mm) Dia Non
Plated thru hole 4
places

Molex CT43045F surface mountable
connector. .390" height above board.

24.0" +/- 1.0"

P1

Red, 22 AWG

Yellow, 22 AWG

Brown, 22 AWG

White, 22 AWG

Black, 22 AWG

Figure 14. Cable Drawing

P ower

T1

-V1

T2

-V2

Specifications:

1. Power: 2-50 Vdc at 5 mA maximum.

2. Accuracy: +/- 1 mV between -Vout connections.

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

+/-5 uA (Maxi/Mini/Micro).

4. Use 4 non-plated through holes with standos 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/Mini/Micro converters

(Maxi, Mini and Micros).

PLEASE NOTE, THE CSB IS NOT INTENDED FOR HOTSWAP APPLICATIONS

Contact your Regional Applications Engineer at 1-800-927-9474
for additional information.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 28

Low Leakage Version

If Low Leakage is required, the MegaPAC Family of Power Supplies has a model
variant (must be requested). This model enables the user to meet various additional
specifications. Presently, the PFC MegaPAC, Mini MegaPAC and Autoranging MegaPAC
are available in Low Leakage versions. Other models can be made available.
The MegaPAC Family of Power Supplies consist of:

n PFC MegaPAC

n PFC MegaPAC-High Power

n PFC MegaPAC-EL (Low Noise)

n Mini MegaPAC

n Autoranging MegaPAC

n 4 kW MegaPAC

n 4 kW MegaPAC-EL (Low Noise)

The advantage of the Low Leakage MegaPAC power supply is in multiple power supply
systems that have one AC input. This option will lower the input leakage current for
these products to 500 µA or less. An additional external EMI filter may be required.

How Low Leakage is obtained

Low Leakage for the MegaPAC Family of power supplies is obtained with the removal of
the "Y" capacitors from within the EMI filter of the MegaPAC as well as the "Y" capacitors
on the input of the ConverterPACs. This reduces the leakage current from the AC input
to AC ground (chassis) to below 500 µA. At the same time, since the "Y" capacitors are a
vital component of the EMI filter, without them, the EMI will go up. When this happens,
the unit may no longer meet Westcor’s published specifications for conducted EMI.
In order to reduce the EMI to within an acceptable limit, an additional external EMI
filter maybe required. All safety agency certifications for the MegaPAC Power Supplies
remain intact. Contact Applications Engineering for more information.

Westcor currently has the following ConverterPACs (See ConverterPAC information
sheet and/or Design Guide for more information):

VI-200/VI-J00 Maxi/Mini/Micro Other

ModuPAC (M) FinPAC (PZ) FlexPAC (FSS)

JuniorPAC (J) UniPAC (XU)

DualPAC (D) QPAC (XQ)

RamPAC (R) FinQPAC (PZL)

BatPAC (B)

QPAC (L)

DualQPAC (LD)

Junior QPAC (LJ)

Please note: The MegaPACs (including Low Leakage versions) are not UL 2601 or EN60601 compliant.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 29

Figure 15.

g

ModuPAC Pinout

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.

* DC OK Option is not available for VI-J00 dual output DualPACs

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

The first step in meeting this requirement is to configure the 5 V ModuPAC with the
DC OK Option, which is indicated by a "D" designator in the M oduPAC's part number,
located on the top surface of each ModuPAC above the +Vout. Any ModuPAC that
has the DC OK option will also have the 4 pin J3 DC OK connector installed. To
order a ModuPAC with the DC OK option, please contact Westcor's 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.

+ Vout

J2 Pin 1

Vtrim Pot Adjust (Option)

Figure 16.

J3 DC OK Connector

- Vout

J3 pin 1 (DC OK Option)

DC OK (Power Good)

J3

Pin

J3-4 Vcc

4
3

J3-3 Power Good

2

J3-2 Power Good Inverted

1

J3-1 Si

nal Gro

und

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 30

Figure 17.

Output Sequencing

Wire Interconnect

12345678

6

12

5

11

4

10

3

9

2

8

1

7

L1L

2

3.3V Output

5V with "D" option (DC OK)

Figure 17 shows the correct wiring connections between the Power Good Connector (J3)
of a 5 V ModuPAC and the Input Interface Connector (J10) of a typical PFC MegaPAC
configuration. In this example, the 3.3 V ModuPAC is located in the slot #7 and the
5 V ModuPAC (with the DC OK option) is located in slot #8. In order for the Power
Good option to properly function, it requires a 5 V source to provide the necessary Vcc
pull up. This 5 V source is conveniently available using the +5 V aux source from the
Input Interface Connector (J10-9 and J10-10). With a Vcc voltage properly applied
to the 5 V ModuPAC'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 5 V ModuPAC's Power Good signal will remain low until its output has reached
approximately 95% of its nominal output voltage. This will keep the 3.3 V output in
disabled mode, allowing the 5 V output to reach regulation first. In addition, should
the 5 V output drop below 85% the Power Good signal will drop low and disable the 3.3
V output. Figures 18 and 19 show the startup and shutdown waveforms for the circuit
shown in Figure 17.

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 31

Output Sequencing (Cont.)

Channel #1: 5 V Output

Channel #2: 3.3 V Output

Channel #3: 5 V DC OK signal

Figure 18.

Startup Waveforms

5V Output

3.3V Output

5V DC OK

Figure 18. Startup Waveforms

Figure 19.

Shutdown Waveforms

5V Output

3.3V Output

5V DC OK

Figure 19. Shutdown Waveforms

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 32

NOTES:

UG:105 vicorpower.com Applications Engineering: 800 927.9474 Page 33

For Vicor Global Office Locations, please go to: http://www.vicorpower.com/contact-us
or call 800-735-6200.

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

Westcor’s product line includes:

LOPAC FAMILY:

• PFC MicroS

• PFC Micro

• PFC Mini

MEGAPAC FAMILY:

• PFC MegaPAC

• 4kW MegaPAC

• 4kW MegaPAC-EL (Low Noise)

• PFC MegaPAC (High Power)

• PFC MegaPAC (Low Noise/High Power)

• PFC MegaPAC-EL (Low Noise)

• Mini MegaPAC

• Autoranging MegaPAC

• ConverterPACs

OTHERS:

• FlatPAC-EN

• PFC FrontEnd

• MicroPAC

• Conduction Cooled MicroPAC

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

INFORMATION FURNISHED By VICOR IS BELIEVED TO BE ACCURATE AND RELIABLE. HOWEVER, NO RESPON­SIBILITy IS ASSUMED By VICOR FOR ITS USE. NO LICENSE IS GRANTED By IMPLICATION OR OTHERWISE
UNDER ANy PATENT OR PATENT RIGHTS OF VICOR. VICOR COMPONENTS ARE NOT DESIGNED TO BE USED
IN APPLICATIONS, SUCH AS LIFE SUPPORT SySTEMS, WHEREIN A FAILURE OR MALFUNCTION COULD RESULT
IN INJURy OR DEATH. ALL SALES ARE SUBJECT TO VICOR'S TERMS AND CONDITIONS OF SALE, WHICH ARE
AVAILABLE UPON REqUEST.

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. THE LATEST DATA IS AVAILABLE ON THE
VICOR WEBSITE AT VICORPOWER.COM

The Power Behind Performance

Rev 1.2 01/2014 P/N 07-130243-01A vicorpower.com Applications Engineering: 800 927.9474 Page 34