VICOR UG:106 User Manual
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
eciency, 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 oers 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 dierent 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.
UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 1
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 aer 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 aer 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 aer
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 eciencies.
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
aer 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 aer the loss of input power. Detecting the loss of input power
takes a finite time period, aer which the AC Power OK signal goes from a TTL “1” to “0.”
This signal is available for use within 1.2 seconds aer 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 aer 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
Power Output
Power Output
Power Output
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 aer 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. Aer
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
12
Driver
Boosters
UG:106 vicorpower.com Applications Engineering: 800 927.9474 Page 5
4
3
5
6
8
7
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 dierent 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
M2
VI-J00 RAM
M1
VI-200/BatMOD
DualPAC
RAMPAC
BatPAC
M1
DualPAC
This output assembly consists of two VI-J00 DC to DC converters that convert the high
M2
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
F
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
x
= Current out (rounded to 1 decimal point)
E
xF = Can be multiple options* (see below)
* ConverterPAC options
Booster module (SI for FasTrak)
B
D DC OK or Power Good
F Full 50-110% output adjustment
50-107.5% output adjustment
F1
50-105% output adjustment
F2
50-102.5% output adjustment
F3
50-100% output adjustment
F4
60-110% output adjustment
F5
70-110% output adjustment
F6
80-110% output adjustment
F7
90-110% output adjustment
F8
100-110% output adjustment
F9
I-Grade module
I
Custom SRF module used
K
1
2
M Grade module
M
Preload
P
R RAM external
Trimpot removed for external BatPAC adjustment
S
T 90-110% output adjustment
90-100% output adjustment
T1
98-105% output adjustment
T2
100-110% output adjustment
T3
90-100% output adjustment
T4
98-105% output adjustment
T5
100-110% output adjustment
T6
"VXI" low noise (150 mV)15 V < V
V1
"VXI" low noise (50 mV) V
V2
1% ripple for outputs >24 V
V3
3
4
< 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
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