Vicor PFC Mini-EL User Manual
PFC Mini-EL™
Power Factor Corrected AC-DC Switcher
PFC Mini-EL Design Guide
Design Guide
and
“Quick Install” Instructions
www.vicorpower.com
Rev. 12/2003 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474
TABLE OF CONTENTS
Overview of Product...........................................................................................................................3
Part Numbering...................................................................................................................................3
Mechanical Considerations.................................................................................................................4
PFC Mini-EL Do’s and Don’ts............................................................................................................4
Technical Description..........................................................................................................................5
PFC Mini-EL Configuration Layout...................................................................................................6
Quick Install Instructions....................................................................................................................8
Mechanical Drawings..........................................................................................................................10
Output Connectors...............................................................................................................................11
Interface Connections..........................................................................................................................12
Using Batmod......................................................................................................................................16
7 Output PFC Mini-EL.......................................................................................................................16
Output Power Derating.......................................................................................................................17
Specifications......................................................................................................................................18
Current Share Board............................................................................................................................20
Pg 2 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Rev. 12/2003
PFC Mini-EL Design Guide
PFC Mini-EL™
Power Factor Corrected AC-DC Switcher
Overview
The PFC Mini-EL is an extremely low profile switching power supply that combines the advantages of power factor correction and high power density. It can provide up to 6 isolated outputs (3 slots) and each slot accommodates
the following Vicor DC-DC Converters.
1st Generation: 1 Full Size (VI-200) or 2 Junior modules (VI-J00)
2nd Generation: 1 Maxi, 2 Minis (Micros cannot be used)
The use of these converters give the PFC Mini-EL the inherent power flexibility typical of all Vicor products.
Accepting input voltages of 85 Vac to 264 Vac, and 100 to 380 Vdc, the PFC Mini-EL can provide up to 1,500
Watts in a package size of 1.72" H (43,6mm) x 6" W (152,4mm) x 13.2" L (335,3mm). The PFC Mini-EL is factory configured to meet user requirements.
A special 7 output PFC Mini is available in four models. See page 16 for more details.
Standard Features
• Power Factor Correction: 0.99 at 115 Vac; 0.95 at 230 Vac
• Universal Input: 85-264 Vac, 47-500 Hz, or 100-380 Vdc
• Power Output: 1,500W at 230 Vac; 800W at 115 Vac
• Up to 6 isolated outputs (3 slots)
• Fan cooled
• Full power to 45°C; half power at 65°C
• Conducted EMI: 1st Generation (VI-200, VI-J00) 2nd Generation (Maxi, Mini)
FCC Class B FCC Class A
EN 55022 Class B EN 55022 Class A
(certain configurations meet EN55022 Class B.)
• Low ripple: 50mVp-p max. 15V & less; 150mVp-p max. >15V to 24V; 1%Vout p-p max above 24V
• Harmonic Distortion complies with EN61000-3-2
• AC Power OK status signal
• Autosense (for more information, see page 8 and page 12)
• 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 1,200W load (nominal line)
• Size: 1.72" H (43,6mm) x 6" W (152,4mm) x 13.2" L (335,3mm)
• Safety Agency Approvals: CE Marking, CTÜVUS
Optional Features
• Extended temperature range output converters
• Current Share Board - See page 20
• BatMOD current sources available (see page 16 for more information)
• Connector kits available (#19-130047 and # 19-130050)
Part Numbering
PFC Mini-EL PMx1-x2 x3-xxx -EL x
1
Number of outputs
e.g. PM4-22-501-EL x
2
Number of 1st Gen VI-200 & VI-J00 modules
x
3
Number of 2nd Gen Maxi and Mini modules
xxx Sequential number assigned by Westcor
EL Extended length
Rev. 12/2003 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 3
PFC Mini-EL Design Guide
Mechanical Considerations
The PFC Mini-EL can be mounted on either of two surfaces using standard 8-32 (4 mm) size screws. Maximum
allowable torque is 4.4 in. lbs., and the maximum penetration is 0.16 in. (4mm).
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 Mini-EL, 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 20 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. In such applications, a shock
absorbing mount design is required.
PFC Mini-EL Do’s and Don’ts
• Use twisted pair 20-22 AWG wire when installing Remote Sense.
• To prevent damage to supply, verify polarity of remote sense connection before turning supply on.
• Always turn the power supply off, before disconnecting input or output wires.
• When using the remote sense feature, the +Out and -Out load wires should never be disconnected while the
supply is operating. Failing to do so could damage the power supply.
• Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the output power
terminals.
• 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. Contact Westcor’s Repair Service.
• Insert proper fault protection at power supply input terminals (i.e., a fuse).
• Use proper size wires to avoid overheating and excessive voltage drop.
Pg 4 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Rev. 12/2003
PFC Mini-EL Design Guide
Technical Description
The PFC Mini-EL consists of an off-line single phase, power-factor-corrected front end, EMI filter, cooling fan,
customer interface, associated housekeeping circuits, low noise filters and a selection of Vicor’s DC-DC converters.
Input AC mains voltage is applied to a terminal block. The input current is passed through an EMI filter designed
to meet conducted noise limit “B” specifications in FCC Part 15 and EN55022, Class B (with 1st Gen modules. If
2nd Gen modules are used, it meets FCC Class A and EN 55022 Class A. Certain configurations meet Class B).
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
EN61000-3-2). 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.
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 Mini-EL outputs are disabled to limit the inrush current and to allow the DC bus
potential to settle out to the correct operating level. A low-power flyback converter operating with PWM currentmode control converts the high voltage DC bus into regulated low voltage to power the internal housekeeping circuits and DC cooling fans.
The internal housekeeping Vcc comes up within 2 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
enables the power outputs. An auxiliary Vcc output of 5 Vdc sourcing up to 0.3A is provided for peripheral use.
An output Enable/Disable function is provided by using an optocoupler to control Vicor’s DC-DC converters. If
the Enable/Disable control pin is pulled low, the optocoupler turns on and disables the output. The nominal delay
associated for an output to come up when measured from release of the Enable/Disable pin is 5-10 ms. The
General Shutdown function controls all outputs simultaneously and works in a similar manner.
Rev. 12/2003 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 5
PFC Mini-EL Design Guide
Figure 1. PFC Mini-EL Architecture
High Voltage
Input
Line Filter
Current
Sample
Rectifier
Waveform
Sample
Soft Start
Circuit
PFC Control
Boost Converter
Bus
Low Noise
Output Card #1
Low Noise
Output Card #2
Low Noise
Output Card #3
Power
Output
Power
Output
Power
Output
Customer
Interface
E/D Control
Fan
Enable/Disable Co
Isolated
Housekeeping
Power
ntrol
PFC Mini-EL Configuration Layout
Shown above are two sample PFC Mini-EL configuration layouts. The PFC Mini-EL has three
slots and each slot accomodates either full or half brick modules. Quarter bricks cannot be used.
Pg 6 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Rev. 12/2003
PFC Mini-EL Design Guide
AC input
Fan
S2-M1S1-M1
Fan
S3-M1
AC input
Fan
S2-M1S1-M1
Fan
S
2
M
3
-
3
S
-
1
M
Slot 1
Slot 2 Slot 3
Slot 1
Slot 2 Slot 3
PFC Mini-EL Configuration Layout
E/D = Enable/Disable
Rev. 12/2003 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg. 7
PFC Mini-EL Design Guide
Configuration Example:
Output #2
VI-J63-CW
E/D#3
V375A5C400AL1
V375A5C400AL1
E/D#2
E/D#1
Output #1
VI-J60-CY
E/D#3
ModulesWATTSAMPSVOLTSSLOT#
ModulesWATTSAMPSVOLTSSLOT#
V375A5C400AL1800805.01
V375A5C400AL1800805.01
V375A5C400AL12
V375A5C400AL12
VI-J60 CY50105.03 (M1)
VI- CY50105.03 (M1)
VI-J63CW1004.224.03 (M2)
VI- CW1004.224.03 (M2)
SLOT#3SLOT#2SLOT#1
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