VICOR PFC Micro User Manual
USER GUIDE | UG:121
PFC Micro™
Power Factor Corrected AC-DC Switcher
Contents Page
Overview 1
Standard Features 2
Optional Features 2
Part Numbering 3
Mechanical Considerations 3
PFC Micro Dos and Don’ts 3
Technical Description 4
PFC Micro™ Quick
Install Instructions 5
PFC Micro™
Mechanical Drawings 7
Output Connections
for the PFC Micro™ 8
Output Connectors
for PFC Micro™ 9
Power Connections 9
User Interface Connections 11
Module Power Good
Status Mode 11
Single-Output
Power Supplies (Arrays) 15
Specifications 16
Output Power De-Rating 19
Current Share Boards –
Optional Feature 21
Overview
The PFC Micro is a low-profile switching power supply that combines the advantages of power factor
correction (PFC) and high power density. This guide covers both standard and rugged COTS (MI)
versions of the supply. A PFC Micro provides up to six isolated outputs (from two slots) and each slot
may accommodate the following Vicor DC-DC Converters:
VE-200™/VE-J00™ Series: 1 VE-200 or 2 VE-J00
Maxi/Mini/ Micro Series: 1 Maxi, 2 Minis, or 3 Micros
The use of these converters gives the PFC Micro the inherent power flexibility typical of all Vicor
products. Accepting input voltages of 85 – 264VAC, and 100 – 300VDC, the PFC Micro can provide
up to 800W in a package size of 1.86 x 5.06 x 10.40in [47,3 x 128,5 x 264,1mm]. The PFC Micro is
factory-configured to meet user output requirements.
UG:121 Page 1
Standard Features
Power Factor Correction: Typically 0.98 (>75% Load)
Universal Input: 85 – 264VAC, 47 – 500Hz, or 120 – 300V
Power Output: 800W at 230VAC (200VAC minimum input); 500W at 115VAC (100VAC minimum input)
Up to six isolated outputs (two slots)
Fan cooled
Full power to 45°C; half power at 65°C
Soft start for limiting inrush current
Conducted EMI: FCC Class A; EN55022 Class A (consult factory)
Harmonic Distortion to EN61000-3-2
AC Power OK status signal
RoHS compliant available
Output Sequencing and General Shut Down
Autosense (Refer to pages 6 and 14 for more information on Autosense)
Output overcurrent protection on all outputs
Output overvoltage protection and output overtemperature limiting
(not applicable when using VI-J00)
Ride-through (hold-up) time: >20ms at 500W load
Size: 1.86 x 5.06 x 10.4in [47,3 x 128,5 x 264,1mm]
Safety Agency Approvals: CE Marking, TÜV CUE (certain models may not have all listed approvals)
Uses 300VDC input VI-200™/VI-J00™ modules and/or 375VDC input Maxi/Mini/Micro modules
Power good status signal when Maxi, Mini, or Micro modules used
DC
Optional Features
I/T/H-Grade output converters
Current Share Board for unit to unit power sharing - see pages 22 – 23
Connector kits (# 19-130044)
MI Chassis Specific
Mil-STD 810 for Shock and Vibration
Mil-STD 704 and 1399 for overvoltage and transients
–40°C operation
Conformal coating - contact factory
UG:121 Page 2
Part Numbering
PFC Micro PCx1-x2 x3 (-x4)-xxxx-x
ex: PC6-06-5012-G
x1 = number of outputs
x2 = number of VI-200™/VI-J00™ modules
x3 = number of Maxi/Mini/Micro modules
(-x4 ) = optional Factory assigned
xxxx = sequential number assigned by Vicor
x5 = optional versions
Note: x5 = MI for rugged chassis, = MC for rugged chassis with conformal coating
5
Mechanical Considerations
The PFC Micro™ can be mounted on one of three surfaces using standard 8-32 or 4mm screws.
Maximum allowable torque is 5in.lbs and the maximum penetration of 0.25in [6mm] on the sides and
0.125in [3mm] on the bottom.
When selecting a mounting location and orientation, the unit should be positioned so air flow is not
restricted. Maintain a 2in [5,1cm] minimum clearance at both ends of the PFC Micro and route all cables
so air flow is not obstructed. The power supply draws air in at the fan side/AC input side and exhausts
air out the load side. If air-flow ducting is used, avoid sharp turns that could create back pressure. The
fan moves approximately 10CFM of air.
Avoid excessive bending of output power cables after they are connected to the output terminals.
For high-current outputs, use cable ties to support heavy cables and minimize mechanical stress on
connectors. Be careful not to short-out to neighboring outputs. The maximum torque recommended on
output nuts is 10in.lbs.
Avoid applications in which the unit is exposed to excessive shock or vibration levels as the unit
is designed primarily for office type equipment. In such applications, a shock-absorbing mount
design is required.
PFC Micro Dos and Don’ts
Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at
the output power terminals. A minimum of two inches in front and behind the supply should be
maintained in order to prevent air obstructions.
Run the output (+/–) power cables next to each other to minimize inductance.
Do not attempt to repair or modify the power supply in any manner. In the event of problems,
contact Customer Service at 1-800-735-6200.
Insert proper fault protection at power supply input terminals (i.e., a fuse).
Use proper size wires to avoid overheating and excessive voltage drop.
Output voltages over 60VDC, whether from individual modules or series arrays, are considered
as hazardous secondary outputs under UL 60950. Appropriate care must be taken in design
implementation of the supply.
UG:121 Page 3
Technical Description
The PFC Micro™ consists of an off-line single-phase, power-factor-corrected front end, EMI filter,
cooling fan, customer interface, power supply control circuit, associated housekeeping circuits and a
selection of Vicor VI-200™/VI-J00™ and/or Maxi DC-DC converters.
Input AC mains voltage is applied to input connector MB1J1. The input current is passed through an
EMI filter designed to meet conducted noise limit "A" specifications of FCC Part 15.
At start up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after initial
power up by a DC bus voltage sense circuit driving a relay. After rectification, the input voltage is put
through a boost converter that keeps the AC input current sinusoidal and synchronized with the input
AC voltage (in compliance with EN61000). The boost converter delivers a regulated input to the hold-up
capacitors and a high-voltage backplane. The backplane supplies power to the DC-DC converters that
provide the desired low voltage regulated outputs.
Output voltage conversion is achieved by the Vicor family of Zero-Current Switching (ZCS) DC-DC
converters. These are forward converters in which the main switching element switches at zero current.
This patented topology has a number of unique attributes: low switching losses; high-frequency
operation, resulting in reduced size for magnetics and capacitors; excellent line and load regulation;
wide adjustment range for output; low EMI/RFI emission and high efficiencies.
At initial power up, the PFC Micro 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 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 1s after the application of input power. Once the
high-voltage bus is within operating limits, the AC Power OK signal asserts to a TTL "1," indicating the
input power is OK, and the power outputs will come up 250ms later.
An output enable / disable function is provided to control Vicor DC-DC converters. If the Enable/Disable
control pin is pulled low, the modules output is disabled. The nominal delay associated for an output to
come up when measured from release of the Enable/Disable pin is 9 – 12ms. The General Shut Down
function controls all outputs simultaneously and works in a similar manner.
Figure 1
PFC Micro architecture
Input
Line Filter
Customer
Interface
Bridge
Rectifier
Soft Start
Circuit
Power Supply
Control
Fan
Boost Converter
PFC Control
Enable/Disable -Power Good Read
Isolated
Housekeeping
Power Supply
Output Card #1
Output Card #2
Power
Output
Power
Output
UG:121 Page 4
MBJ1-5 PIN
L1
Not Connected
Not Connected
GND
MAXI MODULE
(2 ISOLATED OUTPUTS)
-
S1
+
10-32 STUDS
-
S2
+
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
S1/S2 J1 (18 Pin)
- - + - T + - + +
- + + T - + - - +
S1/S2J1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
S1/S2J1 (16 Pin)
- + T - +
- + T - + T - +
N/C - +
PFC Micro™ Quick Install Instructions
(For Mechanical Drawing, see page 7)
Mounting the PFC Micro
The PFC Micro can be mounted on either of three sides.
Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.25in [6 mm]
on the side and 0.125in [3mm] on the bottom.
Maintain 2in [5,1cm] clearance at both ends of power supply for air flow.
Input Connections
Input Power MBJ1
Apply input AC power connector MBJ1.
Maximum torque is 5in.lbs.
L2/N
A fuse or circuit breaker in the input line is necessary for safety requirements (10A).
Molex mating receptacle 39-01-4051, terminals 39-00-0090, crimp tool Molex # 11-01-0199.
Output Connections
Note: Outputs with current molex connectors are limited to 9A/pin (27A per output).
A PFC Micro with DIFFERENT Molex connectors capable of 40A is available. Contact factory.
Power Connections
Installing bus bars on output studs (when full-size module is used):
The right stud is Positive and the left stud is the Return on single output cards.
Remove the nut and place ring lug over output stud.
Replace and tighten the nut to a torque of 10 inch pounds.
Do Not over-tighten nuts.
Installing power connectors with 18-pin Molex connectors (when half-size module used):
S1/S2 J1-7, S1/S2 J1-8 and S1/S2 J1-16 are Positive for output #1, while pins
S1/S2 J1-9, S1/S2 J1-17 and S1/S2 J1-18 are the Returns.
S1/S2 J1-1, S1/S2 J1-10 and S1/S2 J1-11 are Positive for output #2, while pins
S1/S2 J1-2, S1/S2 J1-3 and S1/S2 J1-12 are the Returns.
For this 18-pin housing, use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
Installing power connectors with 16-pin Molex connectors (when quarter-size modules used):
S1/S2 J1-7 and S1/S2 J1- 15 are Positive for output #1, while pins
S1/S2 J1-8 and S1/S2 J1- 16 are the Return.
S1/S2 J1-4 and S1/S2 J1-12 are Positive for output #2, while pins
S1/S2 J1-5 and S1/S2 J1- 13 are the Return.
S1/S2 J1-1 and S1/S2 J1-9 are Positive for output # 3, while pins
S1/S2 J1-2, and S1/S2 J1-10 are the Returns.
For this 16-pin housing, use Molex mating receptacle #39-01-2160 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
UG:121 Page 5
1
2
3
Sense Connections
Trim Pin
+REMOTE SENSE
–REMOTE SENSE
Pin
S1/S2 J2
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
S1/S2 J1 (18 Pin)
- - + - T + - + +
- + + T - + - - +
Sense Connections
Sense connections on output connections with studs:
The PFC Micro™ is shipped with Autosense installed
(For more information on Autosense, refer to page 14)
For remote sense, connect remote-sense wires to remote-sense/trim-pin access connector S1/S2 J2.
Connector pin S1/S2 J2-2 is the +SENSE and
S1/S2 J2-3 is the –SENSE.
Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
Attach terminals to 24 – 30AWG stranded twisted pair wire using Molex tool #11-01-0208.
Attach opposite end of sense lines to their respective outputs to point where regulation is desired.
Verify that sense lines are not cross-connected.
Sense connections on output connections with 18-pin Molex connectors:
The PFC Micro is shipped with Autosense installed
(For more information on Autosense, refer to page 14)
If remote sense is desired, connect remote sense wires to sense lines of Connector S1/S2 J1.
Connector pin S1/S2 J1- 13 is the +SENSE and
S1/S2 J1-15 is the –SENSE for output #1.
S1/S2 J1-4 is the +SENSE and
S1/S2 J1-5 is the –SENSE for output #2.
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded twisted pair wire using Molex tool #11-01-0197.
Note: Remote sense is NOT available for triple-output slots.
Trim Connection with Batmod
Pin
1
Current Trim Access
2
3
S1/S2 J2
Voltage Trim
Current Monitor
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
S1/S2 J1 (18 Pin)
- - + - T + - + +
- + + T - + - - +
S1/S2J1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
S1/S2J1 (16 Pin)
- + T - +
N/C - +
- + T - + T - +
CBJ3 E/D INTERFACE CONNECTOR
MATING CONNECTOR: (WESTCOR KIT P/N: 19-130044)
HOUSING: MOLEX (50-57-9412)
SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0097)
CRIMP TOOL: MOLEX (11-01-0209)
PIN DESCRIPTION
CBJ3-1 SGND
CBJ3-2 PGR
CBJ3-3 ACOK
CBJ3-4 ED6
CBJ3-5 ED5
CBJ3-6 ED4
CBJ3-7 ED3
CB3-8 ED2
CBJ3-9 ED1
CBJ3-10 GSD
CBJ3-11 PGDV
CBJ3-12 +5 VS
Trim Connections
Trim connections on output with studs:
S1/S2 J2-1 provides trim access.
Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0208.
Trim connections on connector with 18-pin molex connectors:
S1/S2 J1-6 provides trim access for output #1, and
S1/S2 J1-14 provides trim access for output #2.
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
Trim connections on connectors with 16-pin Molex connectors:
S1/S2 J1-14 provides trim access for output #1, and
S1/S2 J1-6 provides trim access for output #2, and
S1/S2 J1-3 provides trim access for output #3.
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
Interface Connections
CBJ3-1 is Signal Ground,
CBJ3-2 is Power Good Read and
CBJ3-3 is AC-OK.
CBJ3-4-9 are Enable/Disable,
CBJ3-10 is General Shut Down,
CBJ3-11 is Power Good Data Valid (PGDV) and
CBJ3-12 is +5 VS.
Use Molex mating receptacle #50-57-9412 with #16-02-0097 cinch pins.
Attach terminals to 24 – 30AWG stranded wire.
UG:121 Page 6
PFC Micro™ Mechanical Drawings
10-32 STUDS
-
S1
18 PIN CONNECTOR
S1
SEE PAGE 9 FOR DETAILED OUTPUT
CONNECTION INFORMATION .
1
1
-
+
S2
1
S2
1
+
MAXI
MODULES)
PICTURED (TWO
DUAL OUTPUT UNIT
MODULES)
(FOUR MINI
QUAD OUTPUT
UNIT PICTURED
S1/S2 J2 REMOTE SENSE/TRIM PIN
ACCESS CONNECTOR
1
PFC MICRO
31.041.22190.507.50032.691.29
16 PIN CONNECTOR
3
6.35±0.51.25±.024.09.16 260.0210.24
47.291.86
4
4
MOUNTING HOLES; 2 PLACES
USE 8-32 X 0.25 or M4 X 6MM MAX LENGTH
FROM OUTSIDE OF UNIT
32.691.29 190.507.500
S1
1
128.525.06
AIR
FLOW
88.903.500
S2
1
MICRO
MODULES)
SIX OUTPUT UNIT
PICTURED (THREE
3
264.1110.40 18.03.71
270.46±0.5110.65±.02
2
NOTE: FOR INCREASED OUTPUT POWER, CURRENT SHARE BOARDS ARE
AVAILABLE.
WITH VI-200/VI-J00 MODULES CSB-01
WITH MAXI/MINI/MICRO MODULES CSB-02
(SEE PAGE 19 AND 20 FOR MORE INFORMATION ON CURRENT SHARE
4
MOUNTING HOLES; 4 PLACES
USE 8-32 X 0.12 or M4 X 3MM MAX LENGTH
FROM OUTSIDE OF UNIT
MOUNTING HOLES; 2 PLACES
31.041.22
USE 8-32 X 0.25 or M4 X 6MM MAX LENGTH
FROM OUTSIDE OF UNIT
BOARDS.
All Westcor power supplies can now be configured online
using VSPOC, the online configurator tool available on vicorpower.com
32.691.29 190.507.500
PIN-1
CBJ3 (12 PIN)
PIN REF DESCRIPTION
CBJ3 INTERFACE CONNECTOR
CBJ3-1 SGND SIGNAL GROUND
CBJ3-2 PGR POWER GOOD/READ
CBJ3-3 ACOK AC POWER OK
CBJ3-4 ED6 ENABLE/DISABLE S2M3
CBJ3-5 ED5 ENABLE/DISABLE S2M2
CBJ3-6 ED4 ENABLE/DISABLE S2M1
CBJ3-7 ED3 ENABLE/DISABLE S1M3
1
CBJ3-8 ED2 ENABLE/DISABLE S1M2
UG:121 Page 7
CBJ3-9 ED1 ENABLE/DISABLE S1M1
CBJ3-10 GSD GENERAL SHUTDOWN
CBJ3-11 PGDV POWER GOOD/DATA VALID
CBJ3-12 Vcc +5V@40mA
MATING CONNECTOR:
HOUSING: MOLEX (50-57-9412)
SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0097)
2
CRIMP TOOL: MOLEX (11-01-0209)
MBJ1 A/C INPUT
MATING CONNECTOR:
HOUSING: MOLEX (39-01-4051)
TERMINAL: MOLEX (39-00-0090)
CRIMP TOOL: MOLEX (11-01-0199)
L2/N
L1
GND
MBJ1 (5 PIN)
N/C
N/C
REFERENCE DESIGNATIONS
MB MOTHER BOARD
CB CONTROL BOARD
1
NOTES: UNLESS OTHERWISE SPECIFIED
WITH OPTIONAL BUS BAR
A COMPLETE SET OF MATING CONNECTORS
IS AVAILABLE FOR PURCHASE BY SPECIFYING
S(x) SLOT NUMBER
WESTCOR CONNECTOR KIT P/N: 19-130044.
M(x) MODULE NUMBER
2
3
DIMENSIONS SHOWN ARE FROM BOTTOM SURFACE
MOUNTING PEMNUTS EXTEND .010 PAST BOTTOM
SURFACE.
4
Output Connections for the PFC Micro™
A. OUTPUT STUDS - SINGLE OUTPUT (when populated with full size module)
–VOUT
10-32 OUTPUT STUDS
MATING CONNECTOR:
HOUSING: MOLEX (50-57-9403)
TERMINAL FEM CRIMP 24-30 AWG: MOLEX (16-02-0103)
USE CRIMP TOOL: MOLEX (11-01-0208)
+VOUT
SxJ2 REMOTE SENSE/TRIM
PIN CONNECTOR
–SENSE
3
2
+SENSE
1
TRIM
B. 18 PIN MOLEX CONNECTOR - SINGLE OR DUAL OUTPUTS (when populated with half size modules)
9
18
8
17
7
16
15
6
5
14
13
4
12
3
2
11
10
1
SxJ1 (18 PIN OUTPUT, REMOTE SENSE
AND TRIM PIN CONNECTOR)
PIN DESCRIPTION PIN DESCRIPTION
1 +VOUT M2
2 –VOUT M2
3 –VOUT M2
4 +SENSE M2
5 –SENSE M2
6 TRIM M1
7 +VOUT M1
8 +VOUT M1
9 –VOUT M1
10 +VOUT M2
11 +VOUT M2
12 –VOUT M2
13 +SENSE M1
14 TRIM M2
15 –SENSE M1
16 +VOUT M1
17 –VOUT M1
18 –VOUT M1
MATING CONNECTOR:
18 PIN HOUSING: MOLEX (39-01-2180)
TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039)
USE CRIMP TOOL: MOLEX (11-01-0197)
Note: The current molex connectors are limited
to 9A/pin (27A per output). A PFC Micro with
DIFFERENT molex connectors that are capable
of 40A is available. Contact factory!
C. 16 PIN MOLEX CONNECTOR - SINGLE, DUAL, TRIPLE OUTPUTS (when populated with quarter size modules)
8
16
15
7
6
14
5
13
4
12
3
11
2
10
1
9
*SxJ1 (16 PIN OUTPUT, REMOTE SENSE
AND TRIM PIN CONNECTOR)
PIN DESCRIPTION PIN DESCRIPTION
1 +VOUT M3
2 –VOUT M3
3 TRIM M3
4 +VOUT M2
5 –VOUT M2
6 TRIM M2
7 +VOUT M1
8 –VOUT M1
9 +VOUT M3
10 –VOUT M3
11 N/C
12 +VOUT M2
13 –VOUT M2
14 TRIM M1
15 +VOUT M1
16 –VOUT M1
MATING CONNECTOR:
16 PIN HOUSING: MOLEX (39-01-2160)
TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039)
USE CRIMP TOOL: MOLEX (11-01-0197)
UG:121 Page 8
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