VICOR UG:106 User Manual

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USER GUIDE | UG:106

Autoranging MegaPACTM AC-DC Switcher

June 2013

Contents Page

Overview 1 of Product

Mechanical 2 Considerations

MegaPAC 3 Do’s and Don’ts

Technical Description 3

Conﬁguring and 5 Reconﬁguring MegaPACs

ConverterPAC 6 Description

Part Numbering 7

ConverterPAC Output 9 and Connector Pin Identiﬁcation

Quick Install 10 Instructions

Mechanical Drawings 13

Interface Connections 14

Speciﬁcations 20

Current Share Boards 21

Low Leakage Version 23

Overview

The Autoranging MegaPAC AC-DC switcher allows users to instantly conﬁgure high eciency, o-line power supplies that operate on either 115 or 230 Vac (47-500 Hz), or 260-380 Vdc. The Autoranging MegaPAC provides up to 1,600 W of output power with a power density of 6.6 W per cubic inch. The chassis has 8 slots and can provide up to 16 isolated outputs. Its dimensions are 3.4"H x 6.0"W x 11.9"L (86,4 x 152,4 x 302,3).

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 two VI-200/VI-J00 and/or Maxi Vicor DC to DC converters and are available in a wide array 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. For detailed information about ConverterPACs, refer to the ConverterPAC information sheets. Currently, the ConverterPACs used in the Autoranging MegaPAC only use VI-200/VI-J00 Vicor DC to DC converters. Refer to page 6 for a brief overview of the ConverterPACs used.

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 a same length ConverterPAC and one that 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, in addition to useful status indicators. Please consult our Applications Engineering Department if you have other special requirements.

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Standard Features

n Input Voltage: 90-132 or 180-264 Vac, 47-500 Hz, or 260-380 Vdc

n Output Power: 1,600 W at 230 Vac or 300 Vdc, 1,200 W at 115 Vac

n Outputs: 8 slots (up to 16 outputs)

n Fan Cooled

n Full power output to 45°C; half power to 65°C

n So start for limiting inrush current

n Conducted EMI meets EN55022 level A speciﬁcations

n AC Power OK status signal

n Output Sequencing and General Shutdown

(Consult Applications Engineering for automatic sequencing circuitry.)

n Autosense (Refer to page 11 and 14 for more information on Autosense.)

n Output overcurrent protection standard for all outputs

n Output overvoltage protection on all ConverterPAC outputs with VI-200 module

n Output overtemperature limiting on all ConverterPAC outputs with VI-200 module

n Ride-Through (Holdup) time: >20 ms at full load with nominal input line voltage

n Size: 3.4"H x 6.0"W x 11.9"L, (86,4 x 152,4 x 302,3)

n Safety Agency Approvals: cURus, cTUVus, CE Mark

Optional Features

n DC OK status signal

n Output voltage adjustment range with built-in potentiometer

n Reversed fan airﬂow direction

n Low Leakage Version available - see page 23

n Current Share Boards - see page 21 and page 22

Mechanical Considerations

The Autoranging 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 20 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 inch (5,1cm) minimum clearance at both ends of the Autoranging MegaPAC and route all cables so airﬂow is not obstructed. The standard unit draws air in at the fan 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 30 CFM of air.

Avoid excessive bending of output power cables aer they are connected to the Autoranging MegaPAC. For high-current outputs, use cable ties to support heavy cables, minimizing mechanical stress on output studs. Be careful not to short-out to neighboring output studs. The Autoranging MegaPAC is 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.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 2

MegaPAC Do’s and Don’ts

n For units without Autosense, do not leave ConverterPAC Sense lines open. Always

terminate them to their respective output locally or at the load. If ConverterPAC

has Autosense, no local sense connection is required. See page 11 and page 14 for more information on Autosense.

n If needed, use Connector Kit # 19-130040 for the Autoranging MegaPAC.

n Always ﬁll all output slots of the MegaPAC. If a slot is not ﬁlled with a

ConverterPAC, it should be ﬁlled with an airblock. Airblocks are plastic assemblies whose main function is to ﬁll up an empty slot. Any airﬂow escape from an empty slot signiﬁcantly degrades thermal performance, and can result in overheating and damage to the power supply.

n Do not unplug ConverterPACs while input power is applied.

They are not designed for hot-plug applications.

n Do not restrict airﬂow to the unit. The cooling fan draws air into the unit and forces it

out at the output power terminals.

n For power expansion use booster ConverterPACs. Viewing the unit from the output

terminal side, always insert boosters to the right side of the driver.

n Do not use boosters as independent outputs.

Disconnecting bus bars will damage booster ConverterPACs.

n For booster arrays, do not remove busbars.

n Always ensure that output hex-nuts are properly torqued before applying

power to supply.

n Run the output (+/–) power cables next to each other to minimize inductance.

n Wait 5 minutes aer shutting o power before inserting or removing ConverterPACs.

n Do not attempt to repair or modify the power supply in any manner other than

the exchange of ConverterPACs as described in this Design Guide. There are no user serviceable components.

n Insert proper fault protection at power supply input terminals (i.e., a fuse).

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

n Never loosen the inner nut on a ConverterPAC.

n Verify output nuts are tight before powering up.

Technical Description

The Autoranging MegaPAC chassis consists of an o-line single phase AC front end, EMI ﬁlter, cooling fan, customer interface and associated housekeeping circuits. Input AC mains voltage (L1, L2/N and GND) is applied to a terminal block. The input current is passed through an EMI ﬁlter designed to meet conducted noise limit "A" speciﬁcations of EN55022, Level A. At start-up, inrush current is limited by an NTC thermistor prior to being passed to the power rectiﬁers. The thermistor is shunted out shortly aer initial power-up using a DC bus voltage Sense circuit and a relay. The sense circuit also controls the input autoranging selection relay. The power rectiﬁers and ﬁlter capacitors are arranged in a conventional full wave bridge rectiﬁer/voltage doubler conﬁguration. This operates as a full wave bridge rectiﬁer on 230 Vac, and voltage doubler on 115 Vac, delivering unregulated 300 Vdc to a high voltage backplane. The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired low voltage, regulated outputs.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 3

Voltage conversion in the output assemblies 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 eciencies.

At initial power-up, the Autoranging MegaPAC outputs are disabled to limit the inrush current, reduce peak currents in the autoranging relay contacts, and allow the DC bus potential to settle out to the correct operating level. A low-power 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. When operating on 115 Vac, the internal housekeeping Vcc comes up within 1s aer the application of input power. On 230 Vac, it comes up within 500 ms. The input range selection circuit may take up to 200 ms to select the range if 115 Vac is applied. When 230 Vac is applied, the circuit immediately selects for operation on 230 Vac. Once the input range selection has taken place, the AC Power OK signal asserts to a TTL "1" indicating that the input power is OK, and allows the power outputs to come up typically within 15-30 ms later. 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 typical 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.

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. A minimum of 3 ms warning time is given. Following the loss of input power, the outputs are disabled aer the bus voltage drops below its operating limit.

Figure 1.

Autoranging MegaPAC

Architecture

High Voltage Unregulated

300 VDC Bus

Power Input

EN 55022 Level A

DC Fan

Customer Interface

Housekeeping

Circuits

(Optoisolators)

AC/DC Power Rectification,

Inrush Current Limiting,

Input Voltage Strapping

Inrush Current & Autoranging Control

Logic Power

Supply

DC Bus Sense

Control

DC/DC Output Assembly #1

DC/DC Output

Assembly #2

DC/DC Output

Assembly #3

DC/DC Output

Assembly #4

DC/DC Output Assembly #8

Power Output

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 4

Conﬁguring and Reconﬁguring MegaPACs

Most ConverterPACs of the same length can be easily added, replaced, or moved by sliding the assemblies in or out of a MegaPAC chassis. They are driver ConverterPACs and can be inserted into any available slot. (Currently, the exceptions are the FinPACs which can only be used in the PFC MegaPAC-High Power and the UniPACs which can only be used in the 4 kW MegaPAC.) For outputs greater than 200 Watts, a driver ConverterPAC 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 can 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.

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 available on the website at www.vicorpower.com.

Figure 2.

Paralleling ConverterPACs

Bus Bars for Paralleling

Loosen screw to

remove ConverterPAC

Driver

Boosters

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Remote Sense

Output Adjust

- Vout

+ Vout

DC OK (Power Good)

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

VI-200

ModuPAC

JuniorPAC

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. They can be added, moved, or changed as necessary. The following ConverterPACs can be used in the Autoranging MegaPAC.

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.

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.

VI-J00 VI-J00

VI-J00 RAM

VI-200/BatMOD

DualPAC

RAMPAC

BatPAC

DualPAC

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

voltage bus to the desired regulated output voltages as noted above.

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 (or 0.15% whichever is greater) over a 20 MHz bandwidth from 10% to 100% of rated load of the converter.

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 12V, 24V and 48V battery systems.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 6

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

FlexPAC

ConverterPAC Functional Description (Cont.)

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.

List of ConverterPACs used in the Autoranging MegaPAC 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

FlexPAC Std Std Std LS LS N/A Std

* See page 11 and 14 for more information on Autosense.

OVP Overvoltage Protection (latching) OCP Overcurrent Protection (auto-recovery)

OTL Overtemperature Limiting (latching) RS Remote Sense

PG Power Good (DC OK TTL Signal) LS Local Sense

AS Autosense

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

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 7

Part Numbering

PFC MegaPAC MPxA-9xBxxxx

eg. MP5-981439

MP = MP

xA = number of outputs

9 = autoranging Chassis preﬁx

xB = number of modules

xxxx = assigned by Westcor

ConverterPAC XxDV/xEAx

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

X = ConverterPAC type (For RoHS, add G to current preﬁx) M = ModuPAC D = DualPAC R = RamPAC J = JuniorPAC B = BatPAC xD = Voltage out

= Current out (rounded to 1 decimal point)

xF = Can be multiple options* (see below)

* ConverterPAC options

Booster module (SI for FasTrak)

D DC OK or Power Good

F Full 50-110% output adjustment

50-107.5% output adjustment

50-105% output adjustment

50-102.5% output adjustment

50-100% output adjustment

60-110% output adjustment

70-110% output adjustment

80-110% output adjustment

90-110% output adjustment

100-110% output adjustment

I-Grade module

Custom SRF module used

M Grade module

Preload

R RAM external

Trimpot removed for external BatPAC adjustment

T 90-110% output adjustment

90-100% output adjustment

98-105% output adjustment

100-110% output adjustment

90-100% output adjustment

98-105% output adjustment

100-110% output adjustment

"VXI" low noise (150 mV)15 V < V

"VXI" low noise (50 mV) V

1% ripple for outputs >24 V

< 24 V output

OUT

< 15 Vdc

OUT

[1]

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

[2]

F option: Optional for all ConverterPACs EXCEPT the BatPAC and DualQPAC

[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 and DualQPAC

[5]

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

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 8

ConverterPAC Output and Connector Pin Identiﬁcation for the A/R MegaPAC

20-130182-TAB

ModuPAC JuniorPAC

RAMPAC

DualPAC

MODUPAC/JR.PAC/RAMPAC

(REMOTE SENSE)

+ V0UT

J2-PIN1

R4-(OUTPUT ADJUST)

- VOUT

J3-PIN1

TRIM PIN ACCESS

+ SENSE

- SENSE

J3 DC OK (POWER GOOD)

Vcc IN

POWER GOOD

POWER GOOD INVERTED

SIGNAL GROUND

DUALPAC

J1-B-PIN1

J2-B-PIN1

OUTPUT ADJUST

J1-A-PIN1

J2-A-PIN1

OUTPUT ADJUST

MATING HDWR:

HOUSING- MOLEX P/N: 50-57-9403

TERMINALS- MOLEX P/N: 16-02-0103 CRIMP TOOL MOLEX P/N: 11-01-0118

MATING HDWR:

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

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

(OUTPUT CONNECTORS)

1 AND 4 +V OUT

2 AND 5 -V OUT

3 +R/SENSE 6 -R/SENSE

(REMOTE SENSE)

TRIM PIN ACCESS

+ SENSE

- SENSE

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

DUALPAC - COMPONENT SIDE VIEW

J1-B (M1)

BatPAC

FlexPAC

BATPAC

Output A 48V/2.1A

+ V0UT

CURRENT LIMIT ADJUST

VOLTAGE LIMIT ADJUST

- VOUT

J2-PIN1

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

Output B 12V/8.3A

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

J2 (BATPAC REMOTE INTERFACE)

CURRENT LIMIT ADJUST

VOLTAGE LIMIT ADJUST

CURRENT MONITOR

- VOUT

J1-A (M2)

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 39-01-2120

TERMINALS MOLEX P/N 39-00-0039

CRIMP TOOL MOLEX P/N 11-01-0197

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 9

A/R MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 13)

Mounting the Autoranging MegaPAC

n The Autoranging MegaPAC can be mounted on any of four sides.

n Use #8-32 or 4mm mounting screws.

Maximum penetration should not exceed 0.15" (3,8mm).

n Maintain 2" (5,1cm) clearance at either end for airﬂow.

n Maximum allowable torque is 20 lb-in.

L1/N

NOTE

THIS POWER SUPPLY CAN BE CONNECTED TO ANY SINGLE PHASE AC SOURCE OPERATING

AUTO-

FROM 47 TO 500 Hz

MAX TORQUE ON SET SCREWS - 10 IN LBS

AC INPUTS

100-120 VAC 200-240 VAC

RANGING

DO NOT

RUN W/O

EARTH GROUND HERE.

Input Panel Connectors

MODUPAC

+ V0UT

J2-PIN1

0UTPUT ADJUST

- VOUT

J3-PIN1

Single Output ModuPAC

J1A

++-

-RS

+RS

321

1 & 4 +V OUT

2 & 5 -V OUT

3 +REMOTE SENSE

6 -REMOTE SENSE

J1B

-RS

+RS

321

DualPAC Output Connector

Input Connections

Input Power J9

n Input AC power is applied to terminal block J9 using a pressure screw terminal.

n Maximum torque is 10 lb-in.

n A fuse or circuit breaker in the input line is required for safety reasons.

n Use a maximum wire size of 10 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 Remove outer nut. Do not remove or loosen inner 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.

+46-

Installing power connectors on DualPACs (J1A and J1B):

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

terminals provided.

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.

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Sense Connector

J2-1 Trim Pin Access

J2-2 +Sense

J2-3 -Sense

Sense Connector

A/R MegaPAC “Quick Install” Instructions (Cont.)

Sense Connections

Note: Newer power supplies have a new feature called Autosense. If Remote Sense connections are not made or needed, no Local Sense selection is necessary - simply hook up the output 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 14 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.

Sense Connector J2:

n Sense connections do not have to be made if the Local Sense option has been ordered.

(An “L” in the ConverterPAC part number means the Local Sense option has been installed; e.g. M5V/40AL.)

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.

J1A

++-

-RS

+RS

321

1 & 4 +V OUT

2 & 5 -V OUT

3 +REMOTE SENSE

6 -REMOTE SENSE

J1B

-RS

+RS

321

+46-

DualPAC Output Connector

Sense Connector

J2-1 Trim Pin Access

J2-2 +Sense

J2-3 -Sense

Sense Connector

Sense Connections on DualPACs:

n Sense connections do not have to be made if the Local Sense option has been ordered.

(An “L” in the ConverterPAC part number means the Local Sense option has been installed; e.g. D5V/20AL-12V/4.2AL.)

n Sense connections are available on the J2 connector or the J1A and J1B connectors.

Either can be used.

n If using J2 connector, see instructions on page 9.

n For 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 - Note - does not apply to FlexPAC

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 FlexPAC trim see FlexPAC Data Sheet

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 11

A/R MegaPAC “Quick Install” Instructions (Cont.)

DC OK (Power Good)

Pin J3-4 Vcc

4 3

J3-3 Power Good

J3-2 Power Good Inverte

J3-1 Signal Gro

und

DC OK (Power Good) Connection J3

n DC OK is available as an option and is only present when requested.

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.

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.

J10

1110

J10 INTERFACE

J10-1 J10-2 J10-3 J10-4 J10-5 J10-6 J10-7 J10-8

J10-9 J10-10 J10-11 J10-12

E/D-1 E/D-2 E/D-3 E/D-4 E/D-5 E/D-6 E/D-7 E/D-8

Vcc +5V, 0.3A

SIGNAL GROUND

AC POWER OK

GEN SHUTDOWN

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 12

PFC MegaPAC Mechanical Drawing

(18.5 MM)

7 SP. @ .7285

J2A-PIN1

(SAME AS J2)

5.10 (129.5 MM)

J1A-PIN1

(DUAL MOD)

-P8 TYP.

J2B-PIN1

(SAME AS J2)

J3-PIN1

.46 (11.7 MM)

-P1

TYP.

J2-PIN1

+P8

TYP.

1/4 - 20 ZINC PLATED STEEL,

SERRATED FLANGED NUTS

45 IN-LBS ±5

11.20 (284.5 MM)

M4/#8-32 THDS 16 PLACES

MAX SCREW PENETRATION - .15

BUS BARS - FOR

PARALLEL OUTPUTS

R4 "TRIMPOT" PRESENT

R12

J1B-PIN1

DUAL MODUPAC

(NO "POWER GOOD"

OPTION AVAILABLE)

WHEN ADJUSTABLE OUTPUT

OPTION IS SPECIFIED.

WESTCOR

MegaPAC

COR

AUTO-RANGING

AIR BLOCK

(DUAL MOD)

(EXAMPLE)

BUS BAR - FOR

SERIES OUTPUTS

.64

(16.2 MM)

LABEL LOCATED

1.40

(35.6 MM)

+P1

TYP.

LABEL LOCATED

APPROXIMATELY

AS SHOWN (TYP)

(MODUPAC MODEL NO.)

APPROXIMATELY

AS SHOWN

6.750 1.85

2.74

(171.4 MM) (47 MM)

(69.6 MM)

MODUPAC REMOVAL

#4-40 CAPTIVE SCREWS

TO SECURE/REMOVE

MODUPACS, 8 PLACES

11.525

11.840

(292.7 MM)

(300.7 MM)

.040 X .13 SLOT

CLAMPING SCREWS FOR INPUT LEADS,

MAXIMUM TORQUE 10 IN-LBS

2.00

(51.0 MM)

2.920

(74.2 MM)

.220

(5.6 MM)

.60 (15.2 MM)

5.10

(129.5 MM)

.47 (12.0MM)

FAN

(DIRECTION OF AIR

J9-1 EARTH GROUND

J9-2 AC HOT

J9-3 AC NEUTRAL

INPUT CONNECTIONS

FLOW OPTIONAL)

J9-3

J9-1

.20 SQ. (5.2 MM) OPENINGS (J9-1 THRU

J9-3) FOR #10 AWG INPUT WIRES

J10

3.38 (85.8 MM)

6.04 (153.4 MM)

3.52

(89.4 MM)

.60

(15.2 MM)

1.06

(26.9 MM)

.50 (12.7 MM)

INPUT LEGEND

L1/N

NOTE

THIS POWER

EARTH

DO NOT

RUN W/O

AC INPUTS

100-120 VAC

200-240 VAC

SUPPLY CAN

BE CONNEC-

TED TO ANY

SINGLE PHASE

AC SOURCE

GROUND

HERE.

RANGING

AUTO-

(SCALE: NONE)

MAX TORQUE ON SET SCREWS - 10 IN LBS

OPERATING

FROM 47 TO 500 Hz

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 13

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 10 AWG. The maximum torque recommended is 10 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) is the Hot connection; J9-3 (L1/N) is the other Hot or input Neutral connection.

A fault clearing device, such as a fuse or circuit breaker at the power supply input is required per safety agency conditions of acceptability. It should be sized to handle the start-up inrush current.

INPUT CONNECTIONS

J9-1 EARTH GROUND J9-2 AC HOT J9-3 AC NEUTRAL

J10 (PIN 1)

L1/N

NOTE

THIS POWER SUPPLY CAN

AC INPUTS

BE CONNEC-

100-120 VAC

TED TO ANY SINGLE PHASE

200-240 VAC

AC SOURCE OPERATING

AUTO-

FROM 47 TO 500 Hz

RANGING

MAX TORQUE ON SET SCREWS - 10 IN LBS

DO NOT

RUN W/O

EARTH GROUND HERE.

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 J1B. 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 (See page 9 for additional information on Autosense)

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.

For units without 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 Autoranging MegaPAC is 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 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:106 vicorpower.com Applications Engineering: 800 927.9474 Page 14

Figure 4.

Interface Connector (J10)

Interface Connections (Cont.)

Signal Ground (J10-10)

Signal Ground (see Figure 4 and Connector Pin Identiﬁcation on Page 12) is an isolated ground used as a 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

J10-1

E/D-2

J10-2

J10-3 J10-4 J10-5 J10-6

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

J10

1110

J10-7 J10-8

J10-9 J10-10 J10-11 J10-12

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 12). For DualPACs and FlexPACs, all outputs are sequenced. In parallel arrays, 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 6V 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.

E/D-7 E/D-8

Vcc +5V, 0.3A

SIGNAL GROUND AC POWER OK GEN SHUTDOWN

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

Enable/Disable Control

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

1 0

General Shutdown

Signal Ground

J10

Autoranging MegaPAC

Vcc

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 15

Figure 6.

AC OK / Power Fail

Interface Connections (Cont.)

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 6 and Connector Pin Identiﬁcation on Page 12). It is capable of sourcing 0.5 mA at >3.2 V and sink 16 mA 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

Figure 7.

Auxiliary Vcc

10K

2.49K

PN2222

AC Power OK

Signal Ground

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

The Vcc on J10-9 is an auxiliary 5V regulated power source (see Figure 7 and Connector Pin Identiﬁcation on Page 12). 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.

J10

+5V/300 mA

Auxiliary Vcc

78M05

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 16

0.1 µF

Signal Ground

Figure 8.

Power Good and Vcc

Interface Connections (Cont.)

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 (see Figure 8). 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.

Power Good Inverted (J3-2)

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

ConverterPA C

2N2222

2.49K

10K

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 +5V 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.Earth Ground on input power connector J9.

Vcc In

Power Good

Power Good Inverted

Signal Ground

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 17

Figure 9.

Sense Leads

Interface Connections (Cont.)

+Sense/ –Sense -J2-2 and J2-3 (See page 10 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 wil 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.

+P +Out

J2-2 +Sense

(Local Sense)

(Remote Sense)

Use 22-24 AWG

Load

Twisted Pair Wires

J2-3 -Sense

-P -Out

External Trim (J2-1)

Output voltage can be trimmed using an optional factory-installed Trim potentiometer or with the Trim pin. 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 as measured from the output studs or output connector of the power supply.

Note: The combined effects 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 pretrimmed 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 19. Please consult the factory for assistance.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 18

Figure 10.

External Trim

Interface Connections (Cont.)

To Error Amplifier

RTH

2.5V Bandigap

+P +Out

J2-2 +Sense

J2-1

J2-3 -Sense

-P -Out

Use 22-24 AWG Twisted Pair Wires

(Remote Sense)

Load

Table 1.

Module Internal Reference

Voltages and Thevenin

Resistances.

Output Module V

ref

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

Example:

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

Figure 10 shows a typical variable Trim circuit. Using a 10 k 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

= 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 Manual or consult the factory for assistance.

CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS THAT ARE 5 V OR LESS.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 19

Speciﬁcations

Input Characterisitcs

Input Voltage 115-230 Vac, 1 Phase, 90-132 Vac, 180-264 Vac, (47-500 Hz) 260-352 Vdc

Power Factor (passive) 0.65

Inrush Current

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

Power Fail >3 ms warning

Conducted EMI (47-63 Hz) EN55022 Level A

Surge Immunity

(Common

Mode and Normal Mode)

Dielectric Withstand

Ouput Characterisitcs

Line/Load Regulation*

Setpoint Accuracy

Ripple and Noise

Output Trim Range

Overcurrent Trip Point

Overvoltage Protection ModuPACs: 115- 135%; FlexPACs 125% set voltage

Efﬁciency Up to 82% typical

Output Power

Environmental Characteristics

Storage Temperature -40°C to +85°C

Operating Temperature** -20°C to +45°C full power, -20°C to +65°C half power

Humidity 0-95% non-condensing

Altitude

Safety Approvals

Product Weights

Warranty

30A rms @ 115 Vac

60A rms @ 230 Vac

EN 61000-4-5 Class 3

(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

0.2% max. from 10% to 100% load

0.5% max. from 0% to 10% load

1% for standard voltages

2% for special, adjustable voltages or 48 Vdc

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

VXI options: 50 mV p-p for output voltages <15 Vdc; 150 mV p-p for

output voltages > 15 V and up to and including 24 V; 1% maximum for output

voltages > 24 V. (VXI requires 15% minimum load)

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

FlexPAC: Mets VXI requirement over total output range

50% -110% of nominal voltage VI-200/VI-J00 modules

90% -110% of nominal voltage VI-200/VI-J00 modules 10-15 V

2 V - 25V FlexPACs

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

Dependent on voltage set for FlexPAC - contact factory

1,600 W at at 230 Vac;

1,200 W at at 115 Vac

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

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

9.0 lbs. (4,08 kg) fully conﬁgured

0.7 lbs. (0,32 kg) ConverterPAC

2 years limited warranty.

See vicorpower.com for complete warranty statement.

* See Vicor module speciﬁcations. A preload may be necessary for modules trimmed down below 90% of normal output voltage. ** The maximum operating temperature is 45°C. If one is using a VI-200 with output voltage less than

12 V and more than 150 Watts, the operating temperature decreases to 40°C.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 20

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.

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 1. Each leg of the "Y" must have a minimum of a few millivolts of drop in order for proper operation. 50mV to 100mV 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 1.

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

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 21

Current Share Boards - Optional Feature (Cont.)

(page 2)

J1 Pinout

Pin Description

1 Power 2T1 3 -V1 4T2 5 -V2 6 No Connection

1.74"

(44.2mm)

24.0" +/- 1.0"

1.500"

(38.1mm)

0.12"

(3.0mm)

0.12"

(3.0mm)

0.900"

(22.9mm)

1.14"

(29.0mm)

Figure 11. Mechanical Drawing

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

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

Red, 22 AWG

Yellow, 22 AWG

Brown, 22 AWG

White, 22 AWG

Black, 22 AWG

Power

-V1

-V2

Figure 12. Cable Drawing

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).

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.

6. CSB02 MUST be used for current sharing Maxi converters .

Please note: The CSB is NOT intended for Hotswap Applications

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 22

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 mA or less. An additional external EMI ﬁlter is typically 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 mA. 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 will 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 is 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 FlexPAC

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

JuniorPAC (J) UniPAC (XU)

DualPAC (D) QPAC (XQ)

RamPAC (R)

BatPAC (B)

QPAC (L)

DualQPAC (LD)

Junior QPAC (LJ)

For RoHS compliant versions a preceeding G is added to the part number.

Please note: The MegaPACs (including the Low Leakage versions) are not UL 2601/60601

compliant or EN60601 compliant.

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 23

NOTES:

UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 24

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 07-040831-01A vicorpower.com Applications Engineering: 800 927.9474 Page 25

VICOR UG:106 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual