Vicor PFC MicroS Power Factor Corrected AC-DC Switcher User Manual
03-00049 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474
PFC MicroS Design Guide
PFC MicroS™
Power Factor Corrected AC-DC Switcher
Design Guide
and
“Quick Install” Instructions
www.vicorpower.com
Pg. 2 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 03-000049 rev A
PFC MicroS Design Guide
TABLE OF CONTENT
Overview of Product...........................................................................................................................3
Part Numbering...................................................................................................................................4
Mechanical Considerations.................................................................................................................4
PFC MicroS Do’s and Don’ts.............................................................................................................4
Technical Description.........................................................................................................................5
Quick Install Instructions....................................................................................................................6
Mechanical Drawings.........................................................................................................................8
Output Connectors...............................................................................................................................9
Connector Kit......................................................................................................................................9
Interface Connections.........................................................................................................................10
Specifications......................................................................................................................................15
Output Power Derating.......................................................................................................................17
Current Share Board...........................................................................................................................19
03-000049 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 3
PFC MicroS™
Power Factor Corrected AC-DC Switcher
Overview
The PFC MicroS is an ultra low profile switching power supply that combines the advantages of power factor correction (PFC) with high power density. This guide covers both the standard and rugged COTS (MI) versions of the
supply. The PFC MicroS provides up to 3 isolated outputs (from 1 slot) and accommodates the following Vicor
DC - DC Converters:
VI-200/VI-J00: 1 full brick or 2 half brick
Maxi/Mini/Micro: 1 full brick, 2 half bricks or 3 quarter bricks
The use of these converters give the PFC MicroS 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 MicroS can provide up to 600 Watts
in a package size of 1.86" H (47.mm) x 5.06" W (128,5mm) x 7.95" L (201,9mm). The PFC MicroS is factory configured to meet output requirements of the user. Using the VSPOC configurator tool available on vicorpower.com,
anybody can now configure a PFC MicroS (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: 600W at 230 Vac (200 Vac minimum input) ; 500W at 115 Vac (100 Vac minimum input)
• Up to 3 isolated outputs (1 slot)
• 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;
• 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 (not applicable when using VI-J00 DC-DC Converters)
• Output overtemperature limiting
(not applicable when using VI-J00 DC-DC Converters )
• Ride-through (holdup) time: >20 ms at 500W load (nominal line)
• Size: 1.86" H (47,3mm) x 5.06" W (128,5mm) x 7.95" L (201,9mm)
• Safety Agency Approvals: CE Marking, TUV CUE. (certain configurations 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 18 and 19
• Connector kits (#19-130044)
• MI Chassis specific options:
• Mil-STD 810 for Shock and Vibration
• Mil-STD 704 and 1399 for Overvoltage and Transients
• -40oC operation
• Conformal coating - contact factory
PFC MicroS Design Guide
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PFC MicroS Design Guide
Part Numbering
PFC MicroS PSx1-x2 x3(x4)-xxxx-x
5
x
1
Number of outputs
e.g. PS2-20-6544-G x
2
Number of VI-200 & VI-J00 modules
x
3
Number of Maxi/Mini/Micro modules
xxxx Sequential number assigned by Westcor
x
5
Optional Factory assigned
note: x5= MI for rugged chassis, = MC for rugged chassis w/conformal coating
Mechanical Considerations
The PFC MicroS 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 (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 MicroS, and route all cables so airflow is not
obstructed. The power supply draws air in at the fan side/AC input side and exhausts air out the load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fans move approximately 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 MicroS Do’s 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 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. Use twisted pairs if possible
• 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.
03-000049 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 5
Technical Description
The PFC MicroS consists of an off-line single phase, power-factor-corrected front end, EMI filter, cooling fan,
customer interface, power supply control circuitry, associated housekeeping circuits, and a selection of Vicor’s
VI-200/VI-J00 and/or Maxi/Mini/Micro DC-DC converters.
Input AC mains voltage is applied to input connector MBJI. 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 MicroS 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 MicroS Design Guide
Figure 1. PFC MicroS Architecture
Line Filter
Bridge
Rectifier
Soft Start
Circuit
Boost Converter
PFC Control
Power Supply
Control
Output Card #1
Fan
Isolated
Housekeeping
Power Supply
Custom
er
Interface
Power
Output
Input
Enable/Disa
ble -Power Good Read
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PFC MicroS Design Guide
PFC MicroS “Quick Install” Instructions (For mechanical drawings, see page 8)
Mounting the PFC MicroS
* The PFC MicroS can be mounted on either of three sides.
* Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed
0.25 in. (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 MBJI
* Input AC power is applied to connector MBJI.
* Maximum torque is 5 in.lb.
* A fuse or circuit breaker in the input line is necessary for safety requirements (10A).
* Molex mating receptable 39-01-4051, terminals 39-00-0089, crimp tool 11-01-0199.
Output Connections
Power Connections
Installing bus bars on output studs (when full size and half size modules 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 16 pin Molex connectors (when quarter size
modules used):
* S1J1-7 and S1J1-15 are Positive for output #1, while pins S1J1-8 and S1J1- 16
are the Return. S1J1-4 and S1J1-12 are Positive for output #2, while pins
S1J1-5 and S1J1- 13 are the Return. S1J1-1 and S1J1-9 are Positive for output # 3, while pins S1J1-2, and S1J1-10 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.
See page 10 for diagrams of output connections.
Sense Connections
Sense Connections on output connection(s) with studs:
* The PFC MicroS is shipped with Auto Sense installed (For more information
on Autosense, refer to page 12)
* For Remote Sense, connect Remote Sense wires to the Trim Connector (S1J2
connector for single outputs, and S1J1/J3 connector for dual outputs).
* Pin 2 is the +Sense and Pin 3 is the -Sense.
* Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
* Attach terminals to 24-30 AWG stranded twisted pair wire using Molex tool #
11-01-0208.
* Attach opposite end of sense lines to point where regulation is desired.
* Verify that sense lines are not cross-connected.
Note: Remote Sense is not available for triple output configurations.
Trim Connections
Trim Connections on output connection(s) with studs:
* Pin 1 on the Trim connector provides Trim access. (S1J2 connector for
single outputs, and S1J1/J3 connector for dual outputs).
* Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
* Attach 24-30 AWG stranded wire using Molex tool #11-01-0208.
MBJ1-5 PIN
Not Connected
GND
L2/N
L1
Not Connected
DUAL MINI
MODULES
MAXI
MODULE
M1
S1J1
M1
M2
M2
M1
M1
S1J2
-
+
10-32 STUDS
+
-
-
+
S1J3
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
S1J1
1
2
3
Sense Connections
Trim Pin
+ Remote Sense
- Remote Sense
Pin
1
2
3
Trim Connections
Trim Pin
+ Remote Sense
- Remote Sense
Pin
S1J1 (16 Pin)
- + T - +
- + T - + T - +
N/C - +
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PFC MicroS Design Guide
Trim Connections for output connections with 16 pin Molex connectors:
* S1J1-14 provides Trim access for output #1, and S1J1-6 provides Trim access
for output #2, and S1J1-3 provides Trim access for output #3.
* Use Molex mating receptacle #39-01-2160 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.
* CBJ3-7-9 are Enable/Disable (For the PFC MicroS, CBJ3 4-6 are not
used/connected), 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.
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 N/C*
CBJ3-5 N/C*
CBJ3-6 N/C*
CBJ3-7 ED3
CBJ3-8 ED2
CBJ3-9 ED1
CBJ3-10 GSD
CBJ3-11 PGDV
CBJ3-12 +5 VS
*For the PFC MicroS, ED4-6
are NOT used/connected.
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
S1J1
S1J1 (16 Pin)
- + T - +
- + T - + T - +
N/C - +
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