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PFC Micro Power Factor Corrected AC-DC Switcher
User Manual
23 pgs612.73 Kb0

Vicor PFC Micro Power Factor Corrected AC-DC Switcher User Manual

03-000048 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474
PFC Micro Design Guide
PFC Micro™ Power Factor Corrected AC-DC Switcher
Design Guide
and
“Quick Install” Instructions
www.vicorpower.com
PFC Micro Design Guide
TABLE OF CONTENT
Overview of Product...........................................................................................................................3
Part Numbering...................................................................................................................................3
Mechanical Considerations.................................................................................................................4
PFC Micro Do’s and Don't.................................................................................................................4
Technical Description.........................................................................................................................5
Quick Install Instructions....................................................................................................................6
Mechanical Drawings.........................................................................................................................8
Output Connections.............................................................................................................................9
Interface Connections..........................................................................................................................10
Specifications......................................................................................................................................16
Output Power Derating.......................................................................................................................18
Current Share Board...........................................................................................................................20
03-000048 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 3
PFC Micro™ Power Factor Corrected AC-DC Switcher
Overview
The PFC Micro is an 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 6 isolated outputs (from 2 slots) and each slot accommodates the following Vicor DC ­DC Converters:
VI-200/VI-J00: 2 VI-200 or 4 VI-J00 Maxi/Mini/Micro Series: 2 Maxis, 4 Minis or 6 Micros.
The use of these converters gives the PFC Micro the inherent power flexibility typical of all Vicor products. Accepting input voltages of 85 Vac to 264 Vac, and 100 to 300 Vdc, the PFC Micro can provide up to 800 Watts in a package size of 1.86" H (47.3mm) x 5.06" W (128,5mm) x 10.40" L (264,1mm). The PFC Micro is factory con­figured to meet user output requirements. Using the PowerBench configurator tool available on vicorpower.com, anybody can now configure a PFC Micro (and other Westcor power supplies) online.
Standard Features
• Power Factor Correction: Typically 0.98 (>75% Load)
• Universal Input: 85-264 Vac, 47-500 Hz, or 120-300 Vdc
• Power Output: 800W at 230 Vac (200 Vac minimum input) ; 500W at 115 Vac (100 Vac minimum input)
• Up to 6 isolated outputs (2 slots)
• Fan cooled
• Full power to 45°C; half power at 65°C
• Soft start for limiting inrush current
• Conducted EMI: FCC Class A; EN 55022 Class A (consult factory)
• Harmonic Distortion to EN61000-3-2
• AC Power OK status signal
• RoHS compliant available
• Output Sequencing and General Shutdown
• Autosense (Refer to page 6 and 11 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 (holdup) time: >20 ms at 500W load
• Size: 1.86" H (47,3mm) x 5.06" W (128,5mm) x 10.4" L (264,1mm)
• Safety Agency Approvals: CE Marking, TUV CUE (certain models may not have all listed approvals)
• Uses 300 Vdc input VI-200/VI-J00 modules and/or 375 Vdc input Maxi/Mini/Micro modules
• Power good status signal when Maxi, Mini, or Micro modules used
Optional Features
• I/T/H Grade output converters
• Current Share Board for unit to unit power sharing- See page 19 and page 20
• Connector kits (# 19-130044)
• MI Chassis Specific
• Mil-STD 810 for Shock and Vibration
• Mil-STD 704 and 1399 for Overvoltage and transients
• -40C operation
• Conformal coating - contact factory
PFC Micro Design Guide
PFC Micro Design Guide
Part Numbering
PFC Micro PCx1-x2 x3 (x4)-xxxx-x
5
x
1
Number of outputs
e.g. PC6-06-5012-G x
2
Number of VI-200/VI-J00 modules
x
3
Number of Maxi, Mini and Micro modules
x
4
Optional Factory assigned
xxxx Sequential number assigned by Westcor x5 Optional Factory assigned
note: x5 = MI for rugged chassis, =MC for rugged chassis w/conformal coating
Mechanical Considerations
The PFC Micro can be mounted on one of three surfaces using standard 8-32 or 4 mm screws. Maximum allowable torque is 5 in. lbs., and the maximum penetration of 0.25 in (6mm) on the sides and 0.125 in. (3mm) on the bot­tom.
When selecting a mounting location and orientation, the unit should be positioned so air flow is not restricted. Maintain a 2" (5,1cm) minimum clearance at both ends of the PFC Micro, and route all cables so airflow is not obstructed. The power supply draws air in at the fan side/AC input side and exhausts air out the load side. If air­flow ducting is used, avoid sharp turns that could create back pressure. The fan moves approximately 10 CFM 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 10 in. 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 Do’s and Don't
• 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 2” 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.
03-000048 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 5
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’s VI­200/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 Vicor’s family of Zero-Current-Switching (ZCS) DC-DC converters. These are forward converters in which the main switching element switches at zero current. This patented topology has a number of unique attributes: low switching losses; high frequency operation, resulting in reduced size for magnetics and capacitors; excellent line and load regulation; wide adjustment range for output; low EMI/RFI emis­sion and high 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 1 s 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 250 ms later.
An output Enable/Disable function is provided to control Vicor’s 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 9-12 ms. The General Shutdown function controls all outputs simultaneously and works in a similar manner.
PFC Micro Design Guide
Figure 1. PFC Micro Architecture
Line Filter
Bridge Rectifier
Soft Start
Circuit
Boost Converter
PFC Control
Power Supply Control
Output Card #1
Output Card #2
Fan
Isolated Housekeeping
Power Supply
Custom
er
Interface
Power
Output
Power
Output
Input
Enable/Disa
ble -Power Good Read
PFC Micro Design Guide
PFC Micro “Quick Install” Instructions (For mechanical drawings, see page 8)
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. (6mm) on the side and 0.125 in. (3mm) on the bottom.
* Maintain 2" (5,1cm) clearance at both ends of power supply for airflow.
Input Connections
Input Power MBJ1
* Input AC power is applied to connector MBJ1. * Maximum torque is 5 in.lbs * 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 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 mod-
ules 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 18-24 AWG 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 18-24 AWG stranded wire using Molex tool #11-01-0197.
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 12)
* 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.
MBJ1-5 PIN
Not Connected
GND
L2/N
L1
Not Connected
1 2 3
Sense Connections
Trim Pin
+ Remote Sense
- Remote Sense
Pin
S1/S2 J2
- + + T - + - - +
- - + - T + - + +
S1/S2 J1 (18 Pin)
10-32 STUDS
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
S1/S2J1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
MAXI MODULE
(2 ISOLATED OUTPUTS)
-
S1
+
-
S2
+
S1/S2J1 (16 Pin)
- + T - +
- + T - + T - +
N/C - +
03-000048 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 7
PFC Micro Design Guide
* Attach terminals to 24-30 AWG 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 11) * 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 18-24 AWG stranded twisted pair wire using Molex tool #11-01-0197
Note: Remote Sense is NOT available for triple output slots.
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 18-24 AWG 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 18-24 AWG 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 18-24 AWG 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 Shutdown, CBJ3-11 is
Power Good Data Valid (PGDV) and CBJ3-12 is +5VS. * Use Molex mating receptacle #50-57-9412 with #16-02-0097 cinch pins. * Attach terminals to 24-30 AWG stranded wire.
1 2 3
Trim Connectio
ns
Trim Pin Access + Sense
- Sense
P
in
S1/S2 J2
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
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
S1/S2 J1
- + + T - + - - +
- - + - T + - + +
S1/S2 J1 (18 Pin)
- + + T - + - - +
- - + - T + - + +
S1/S2 J1 (18 Pin)
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
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 - +
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