45 Applications Manual First Generation Converters and Accessory Modules Eighth Edition +Vout Lo Vs Load Co D2 -Vout + OVP* – C/L OTP* +S – + E/A 2.5V REF.
Total Power Solutions Vicor Corporation produces families of compact, economical, high performance power components and systems that offer the system designer a “total solution” to most power system requirements. This publication provides a review of Vicor’s zero-current-switching technology and helpful applications information as it applies to Vicor’s first generation of DC-DC converters (VI-200, VI-J00) and accessory modules (VI-IAM, VI-RAM, VI-AIM,VI-HAM).
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Table of Contents COMPONENT PRODUCTS SECTION Zero-Current-Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DC-DC Converter Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Module Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Module Packaging Options . . . . . . . . . . . . . .
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1 Zero-Current-Switching Overview The heart of Vicor’s module technology, zero-current-switching, allows Vicor converters to operate at frequencies in excess of 1 MHz, with efficiencies greater than 80% and power densities ten or more times those of conventional converters.
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2 DC-DC Converter Pinouts Pinout Description VI-200, VI-J00 Modules –IN –IN –OUT GATE OUT –S –OUT GATE OUT –S GATE IN +S T T GATE IN +S +IN +OUT +IN +OUT –IN, +IN: DC voltage inputs. See tables below for nominal input voltages and ranges for the VI-200, VI-J00, MI-200 and MI-J00 Family modules (data sheets contain Brownout and Transient ratings).
Applications Manual Pinout Description (cont) T (Trim): Allows fixed or variable adjustment of the module output. Trimming Down: Allows output voltage of the module to be trimmed down, with a decrease in efficiency. Ripple as a percent of output voltage goes up and input range widens since input voltage dropout (loss of regulation) moves down. Trimming Up: Reverses the above effects. –S, +S (–Sense, +Sense): Maintains specified output voltage to the load.
3 Module Do’s and Don’ts Electrical Considerations Gate In and Gate Out Terminals: Logic Disable When the Gate In terminal of a driver module is pulled low with respect to –Vin (CAUTION: with off-line applications –Vin is not earth ground), the module shuts off (see Figure 1, page 9-1). In Logic Disable mode, the Gate In terminal should be driven from either an “open collector” or electromechanical switch that can sink 6 mA when on (Gate In voltage less than 0.65V).
Applications Manual Electrical Considerations (cont) a voltage clipper for DC input transients and provide reverse input protection. It may be necessary to incorporate an LC filter for larger energy transients. This LC filter will integrate the transient energy while the zener clips the peak voltages. The Q of this filter should be kept low to avoid potential resonance problems. Please see Section 14, VI-IAM/MI-IAM Input Attenuator Module, for additional information on transient suppression.
Module Do’s and Don’ts Safety Considerations Shock Hazard Agency compliance requires that the baseplate be grounded or made inaccessible. Fusing Internal fusing is not provided in Vicor DC-DC converters. To meet safety agency conditions, a fuse is required.
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4 Module Packaging Options Up to 50 Watts/Cubic Inch SlimMod™ Vicor’s PC-mountable power components are available in flangeless “SlimMod” package configurations that provide users with the highest power density available in printed circuit mount applications. To order the SlimMod configuration, add the suffix “S” to the standard part number. Example: VI-260-CV-S.
Applications Manual BusMod™ The BusMod is a rugged module housing assembly that combines convenient chassis mounting with a screw/lug wiring interface for all electrical connections. To order the BusMod option, add “B1” to the standard part number. NOTE: The BusMod may be used with any of Vicor’s full-size modules, with the exception of the VI-HAM.
5 Output Voltage Trimming Overview Specifications such as efficiency, ripple and input voltage range are a function of output voltage settings. As the output voltage is trimmed down, efficiency goes down; ripple as a percent of Vout goes up and the input voltage range widens since input voltage dropout (loss of regulation) moves down. As the units are trimmed up, the reverse of the above effects occurs. All converters have a fixed current limit.
Applications Manual Trimming Down –20% A 20% drop of the 2.5V reference at the trim pin is needed to effect a 20% drop in the output voltage. Refer to Figure 2. + OUT Figure 2. Circuit Diagram "Trim Down" + Sense R5 10 kΩ (internal) 2.5V reference (internal) Trim R6 V1 I R6 R8 R7 10 kΩ POT – Sense – OUT Vl = 2.5V – 20% = 2V Therefore: IR5 = (2.5V - 2V) = 50 µA 10 kΩ Since IR5 = IR6 = 50 µA: R6 = 2V = 40 kΩ 50 µA This value will limit the trim down range to –20% of nominal output voltage.
Output Voltage Trimming Trimming Up +10% (cont) Using Kirchoff’s current law: IR8 = IR7 + IR6 = 400 µA Thus, knowing the current and voltage, R8 can be determined: VR8 = (Vout + 10%) – V2 = 13.2V – 3.75V = 9.45V R8 = (9.45V) = 23.63 kΩ 400 µA This resistor configuration allows a 12V output module to be trimmed up to 13.2V and down to 9.6V. Follow this procedure to determine resistor values for other output voltages.
Applications Manual Fixed Trim (cont) Example 3. –25% Fixed Trim Down (24V to 18V) The trim down methodology is identical to that used in Example 2, except that it is utilized to trim the output of a 24V module down 25% to 18V. The voltage on the trim pin must be reduced 25% from its nominal setting of 2.5V. This is accomplished by adding a resistor from the trim pin to negative sense. 2.5V – 25% = 1.875V VR5 = Vbandgap – Vtrim = 2.5V – 1.875V = .
Output Voltage Trimming Dynamic Adjustment Procedure Output voltage can also be dynamically programmed by driving the trim pin from a voltage or current source; programmable power supplies and power amplifier applications can be addressed in this way. For dynamic programming, drive the trim pin from a source referenced to the negative sense lead, and keep the drive voltage in the range of 1.25-2.75V. Applying 1.25 to 2.5V on the trim pin corresponds to 50% to 100% of nominal output voltage.
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6 Using Boosters to Expand Output Power Overview The VI-200 and MI-200 Family of DC-DC converters are available as driver or booster modules. The driver can be used as a standalone module, or in multi-kilowatt arrays by adding parallel boosters. Booster modules do not contain feedback or control circuitry, so it is necessary to connect the booster Gate In pin to the preceding driver or booster Gate Out, to synchronize operation.
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7 Multiple Gate-In Connections Overview A number of Gate In terminals may be connected for remote shutdown and logic disable (Figure 1). Diodes D1 and D2 provide isolation and prevent multiple failures if the Gate In of a module becomes shorted to the +input. The zener diodes Z1 and Z2 and capacitors C1 and C2 attenuate transient voltage spikes caused by differential inductance in the –input leg. Capacitors C1 and C2 will also lengthen turn-on time.
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8 Overcurrent Protection Foldback Current Limiting The MI/VI-200 units with output voltages of 5V or less incorporate foldback current limiting (Figure 1). In this mode, the output voltage remains constant up to the current knee, Icurrent limit (Ic), which is 5-25% greater than full-rated current, Imax. Beyond Ic, the output voltage falls along the vertical line Ic-Ifb until approximately 2V. At ≤2V, the voltage and current fall back along the foldback line Ifb to Ishort circuit (20% to 80% of Imax).
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9 Applications Circuits Figure 1. Logic Disable The Gate In pin of the module may be used to turn the module on or off. When Gate In is pulled low (<.65V @ 6 mA, referenced to –Vin), the module is turned off. When Gate In is floating (open collector), the module is turned on. The open circuit voltage of the Gate In pin is less than 10V. This applies to VI-200, VI-J00 and M modules (see Product Application Legend, page 9-3). Figure 1.
Applications Manual Figure 4. Remote Sensing NOTE: Output voltage between +Out and –Out must be maintained below 110% of nominal. Do not exceed 0.25V drop in negative return as the current limit setpoint is moved out proportionately to the drop >0.25V. The sense must be closed at the module if remote sensing is not desired. Applies to VI-200, VI-J00, C, F, M, and MP modules (see page 9-3 for Product Application Legend).Long sense leads and/or capacitance at the load can result in module instability.
Application Circuits / Power Array Design Considerations Figure 7. Dual Output Voltage Vicor modules have isolated outputs so they can easily be referenced to a common node creating positive and negative rails. Figure 7.
Applications Manual Current Sharing in Power Arrays Whenever power supplies or converters are operated in a parallel configuration—for higher output power, fault tolerance, or both—current sharing is an important consideration. Most current-sharing schemes employed with power converters involve analog approaches.
Application Circuits / Power Array Design Considerations Current Sharing in Power Arrays (cont) In a current-sharing system, the converters or supplies all run at the same temperature. This temperature is lower than that of the hot-running (heavily loaded) modules in a system without current sharing. Furthermore, same-temperature operation means that all of the modules in a current-sharing arrangement age equally. Current sharing, then, is important because it improves system performance.
Applications Manual Current Sharing in Power Arrays (cont) The droop-share method artificially increases the output impedance to force the currents to be equal. It’s accomplished by injecting an error signal into the control loop of the converter, causing the output voltage to vary as a function of load current. As load current increases, output voltage decreases. All of the modules will deliver approximately the same current because they are all being summed into one node.
Application Circuits / Power Array Design Considerations Current Sharing in Power Arrays (cont) Most systems can employ the driver/booster (or master/slave) array for increased power (Fig. 2). The driver is used to set and control output voltage, while booster modules, as slaves to the master, are used to extend output power to meet system requirements. Figure 2. Most converters can use the driver/booster array to increase output power.
Applications Manual Current Sharing in Power Arrays (cont) Analog current-sharing control does support a level of redundancy. But it’s susceptible to single-point failures within the current-sharing bus that at best can defeat current sharing, and at worst can destroy every module in the array. The major reason for this is the single-wire galvanic connection between modules. Current sharing is an essential element in fault-tolerant arrays.
10 EMC Considerations VI-200/MI-200, VI-J00/MI-J00, Mega Modules The DC Source Vicor’s DC-DC converters have several input ranges and are designed to accommodate the dynamic conditions common in computers, industrial control systems, military products, telecommunications products, and a variety of other applications. This section of Vicor’s Applications Manual covers: • Conducted Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications Manual Conducted Noise (cont) 3 Amp Load 15 Amp Load 30 Amp Load Common mode conducted noise current is the unidirectional (in phase) component in both the positive and negative inputs to the module. This current circulates from the converter via the power input leads to the DC source and returns to the converter via the grounded baseplate or output lead connections.
EMC Considerations Conducted Noise (cont) Figure 3. Conducted Input Noise, Typical Fixed Frequency Converter with Filter C3 C4 L1 C2 C1 +IN Common Mode Filter Typical Fixed Frequency Converter 48V Input, 5V Output Conducted Noise vs. Load –O –IN +O C3 C4 Conditions: C1 = 2.
Applications Manual Conducted Noise (cont) 3 Amp/6 Amp Load 6 Amp/15 Amp Load 15 Amp/15 Amp Load 3 Amp/30 Amp Load 15 Amp/30 Amp Load 30 Amp/30 Amp Load Vicor offers three common mode chokes as standard accessories: Part Inductance Max. Resistance Number Each Winding DC Current Each Winding 02134 1000 µH 12 Amperes 6.
EMC Considerations Conducted Noise (cont) 3 Amp Load 15 Amp Load 30 Amp Load All Vicor converters have an internal normal mode LC filter which, in conjunction with a small external capacitor C1 (minimum value in µF = 400/Vin), reduces normal mode conducted noise. The external capacitor should be placed close to the module to reduce loop cross-sectional area. Care should be taken to reduce the loop cross-sectional area of normal mode current flowing between the source and C1.
Applications Manual Noise Considerations (cont) transformer is a half-wave rectified sine wave. Similar in operation to a resonant converter, these products are commonly referred to as quasi-resonant converters. The LC resonant frequency is fixed so the on-time of the switch is about 500 ns. When the switch turns on, energy builds up in the leakage inductance of the transformer (L) and then “transferred” into the capacitor on the secondary side of the module (C, Figure 6).
EMC Considerations Noise Considerations (cont) plane on the PC card under the base of the module. The other effect that occurs as a result of the 50-70 MHz component on the main switch is common-mode noise. This is best explained by the drawings below. Figure 7. The shield layer serves to reduce the capacitance Parasitic Capacitance FET Rectifier Shield Ceramic Shield Ceramic Baseplate The dv/dt of the switch (FET) is a generator.
Applications Manual Noise Considerations (cont) Long ground leads adversely impact the common-mode rejection capability of oscilloscopes because the ground lead has inductance not present on the signal lead. These differing impedances take common-mode signals and convert them to differential signals that show up on the trace.
EMC Considerations Noise Considerations (cont) Differential output noise is the AC component of the output voltage that is not common to both outputs. The noise is comprised of both low frequency, line-related noise (typically 120 Hz) and high frequency switching noise. High Frequency Switching Noise Peak-to-peak output voltage ripple is typically 2% or less (1% for 12V outputs and above). Hence additional output filtering is generally not required. Digital systems rarely need additional filtering.
Applications Manual Noise Considerations (cont) 3 Amp Load 15 Amp Load C2 Figure 11. Output Noise, Additional Output Capacitance C3 +O +IN GATE IN GATE OUT –IN C1 +S TRIM –S –O C1 = 100 µF C2 = 4700 pF C3 = .01 µF C4 = 270 µF (Tant.) C4 Additional Output Capacitor Typical Vicor Module VI-230-CV 48V Input, 5V Output Output Ripple vs.
EMC Considerations Noise Considerations (cont) C2 Figure 12. Output Noise, Additional Output Inductor and Capacitor (LC) C3 L1 +IN GATE IN GATE OUT –IN C1 +O +S TRIM –S –O C2 C4 LC Output Filter Typical Vicor Module VI-230-CV 48V Input, 5V Output Output Ripple vs. Load C3 Vicor Part # C1 = 100 µF C2 = 4700 pF 01000 C3 = .01 µF 04872 C4 = 270 µF (Tant.
Applications Manual VI-RAM Operation (cont) Figure 13. Output Noise, with VI-RAM Ripple Attenuator Module C3 C2 C1 + OUT +S RAM – Sin –S –IN – OUT +Sin +S TRIM –S –O C2 C3 C1 = 100 µF C2 = 4700 pF C3 = .01 µF 3 Amp Load +IN +O +IN GATE IN GATE OUT –IN RAM Output Filter Typical Vicor Module VI-230-CV 48V Input, 5V Output Output Ripple vs.
11 The BatMod™ Overview The BatMod is a programmable current source module that can also be used as a constant voltage converter. It can be controlled externally to meet a wide range of charging parameters: voltage, current, charge rate and charge time. The BatMod is comparable to the VI-200 voltage module with a variable current limit. It has three output terminals that differ from conventional voltage output converters: Current Control, Voltage Adjust and Current Monitor.
Applications Manual Overview (cont) Figure 1. DC Input Single Module +In Gate In DC Input Gate Out BatMod –In Figure 2.
The BatMod™ Designing a Battery Charger (cont) Figure 3. Basic Charging Circuit Using a BatMod Current Source Module To Front End: VI-AIM, VI-HAM, VI-IAM, or Off-Line Front End +IN BatMod VI-2__1-CU-BM GATE IN R1 820Ω VTRIM Error Amp I TRIM R5 10kΩ GATE OUT 10mA +OUT –IN RITRIM ≈ 50kΩ REF 2.5V I MON R3 115kΩ R2 5kΩ 1mA D1 5.1V Zener 12V –OUT To determine the value of R3, follow these steps: Solve for VTRIM: VFLOAT VREF = VTRIM VNOM ( ) ( ) 13.8V 2.5V = 2.
Applications Manual Designing a Battery Charger (cont) The Figure 3 configuration will charge the battery at a maximum of 10A with a 13.8V float voltage. Other charge rates and float voltages may be similarly calculated. If a fixed charge current is desired, the potentiometer can be replaced with two fixed resistors. In applications requiring tight control over the charging current, D1 can be replaced with a precision reference.
12 VI-AIM™/MI-AIM™ Alternating Input Module Overview In combination with VI-200 and VI-J00 Family modules and configured families of DC-DC converters, the Alternating Input Module provides a high density, low profile, universal AC input off-line switching power supply for systems requiring up to 200W of total output power. The VI-AIM accepts 85-264Vac, with a DC output voltage proportional to the peak value of the AC line.
Applications Manual Summary of Compatible Modules (cont) The Gate Out of the VI-AIM must be connected to the Gate Out of only one DC-DC converter. This input signal to the VI-AIM controls a charge pump (D1, D2, C2) that biases the gate of Q1, 10V above its source, which turns on Q1 to shunt out a PTC thermistor that limits inrush. Multiple DC-DC converters operating from an VI-AIM may make it impossible to guarantee a 10% load on the DC-DC converter that provides the Gate Out signal to the VI-AIM.
VI-AIM™ Alternating Input Module Selecting Capacitors for VI-AIM (cont) The basic equations involved in calculating holdup time are: 1 2 x C1 x Vp2 – 1 2 x C1 x Vdo2 = PIM x (T5 – T3) (1) solving for C1: C1 = 2 x P IM x (T5 – T3) Vp2 – Vdo2 (2) Where PIM is power delivered from the VI-AIM: POM PIM = Module Output Power = Module Efficiency Eff %/100 (3) The energy (Joules) delivered from the VI-AIM from the time power is lost (T4), until loss of an output (Figure 2, T5): Energy (Joules) =
Applications Manual Choosing Appropriate Values Sample Calculation: • Converter Output Power (POM) = 100W • Line Frequency = 60 Hz • Line Range = 105Vac to 264Vac • Efficiency = 82% • Desired Holdup Time = 5 ms Minimum therefore: • PIM = 100 = 122 Watts 0.82 • T5 – T3 = 5 ms + 8.3 ms = 13.3ms (minimum holdup time plus half cycle) • Vp = 105 x 2 = 148V • Vdo = 100V and: C1 = 2 x 122 x .0133 1482 - 100 2 C1 = 270 µ F where: Vp = The peak of the rectified AC line or 2 x Vacin.
VI-AIM™ Alternating Input Module Choosing Appropriate Values (cont) The following values are calculated in a similar manner: Table 1. Module(s) Delivered Power 50W 75W 100W 150W 200W 60 Hz 90Vac 105Vac 270 µF 135 µF 400 µF 200 µF 525 µF 270 µF 800 µF 400 µF 1000 µF 540 µF 50 Hz 90Vac 105Vac 300 µF 150 µF 440 µF 230 µF 600 µF 300 µF 890 µF 455 µF 1180 µF 600 µF C1 values as a function of line voltage, frequency and delivered power, for use with 7-Series (90-264Vac) or 5-Series (90-132Vac) modules.
Applications Manual Choosing Appropriate Values (cont) Figure 5. Typical Application for Vicor Converter with VI-AIM 4700 pf F1 Universal AC In .01 µF Ceramic F2 L1 N/C .47 µF +Out L2/N Gate In Gate In Parallel N/C Gate Out -Out +Out +In C* Gate Out -In MI/VI-200/J00 Driver +S Load Trim -S -Out .01 µF Ceramic MI/VI-AIM 4700 pf * Consult factory or see Vicor's Applications Manual, page 12-2, Selecting Capacitors for VI-AIM Modules. Fuse 1: 6.3A/250V (IEC 5X20 mm) Buss GDB-6.
13 VI-HAM Harmonic Attenuator Module (includes VI-HAM, VI-HAMD and VI-BAMD) Overview Conventional capacitive-input front ends draw energy from the AC line in short bursts of current at the peaks of the line voltage waveform. These current bursts are characterized by high peak currents and high harmonic content.
Applications Manual Overview (cont) Housekeeping circuitry provides two signals of use to the system designer (see Figure 2): Module Enable and Power OK. Referencing the timing diagram below, the Module Enable signal, which is connected to the Gate In inputs of the Vicor DC-DC converters powered by the VI-HAM, will come high and enable the DC-DC converters when the VI-HAM output voltage exceeds 240Vdc. The DC-DC converter voltage outputs will be up approximately 10 ms after Module Enable goes high.
VI-HAM Harmonic Attenuator Module Overview (cont) Figure 4. Input Voltage vs. Output Voltage 250Vac 400 Vdc 350 Vdc 300 Vdc 260Vdc 250 Vdc 200 Vdc Output Voltage as a Function of Input Voltage 46V Boost 152Vac 80Vac 85Vac 150 Vdc 100 Vdc Vin x 2 264Vac 50 Vdc Operating Region 75 25 50 125 100 175 150 Vac 275 225 200 250 300 296 Vicor overcomes the “domestic disadvantage” by varying the output voltage of the VI-HAM as a function of incoming AC line voltage.
Applications Manual VI-HAM Configurations (cont) Use the VI-HAM-CM for applications requiring up to 600W from the front end. For applications in excess of 600W, power can be added in 600W increments with booster VI-HAMs. It is not possible to simply parallel two driver VI-HAMs due to conflicting control loops. Gate Out to Gate In connections on respective driver/boosters are used to ensure that the power train of the VI-HAMs current-share.
VI-HAM Harmonic Attenuator Module Figure 8. VI-HAM/VI-HAMD Derating Curve Output Power (Watts) Derating Curves, Pinout — VI-HAM/VI-HAMD 600 400 200 85 110 264 Prod. Grade E C I M Baseplate Temp. -10°C to +85°C –25˚C to +85˚C –40˚C to +85°C –55˚C to +85°C Storage Temp. -20°C to +100°C –40˚C to +100˚C –55˚C to +100˚C –65˚C to +100˚C Model VI-HAM-EM VI-HAM-CM VI-HAM-IM VI-HAM-MM Input Voltage (Vac) Figure 9.
Applications Manual Connecting the VI-HAM, VI-HAMD/VI-BAMD Figure 10. Connection Diagram, VI-HAM 10A 260-400 Vdc Up to 600W MOV P/N 03040 Vicor 26X or J6X Family Converters PC-Tron 3A L1 L1 GND L1 GATE IN GATE OUT L2/N Vicor Line Filter P/N 07818 6.
VI-HAM Harmonic Attenuator Module Functional Description (cont) Gate Output (VI-HAMD, VI-BAMD): The Gate Output pin is an interface pin to BAMDs, depending on configuration. The user should not make any other connection to this pin. No connection for VI-HAM. +Output and –Output and Holdup Capacitor: These outputs should be connected to the respective inputs of Vicor DC-DC converters.
Applications Manual Functional Description (cont) Overtemperature Shutdown The VI-HAM incorporates overtemperature shutdown. It is designed to shut down when the temperature of the baseplate exceeds 90-100°C. This does not mean that it is safe to run the VI-HAM for extended periods above its maximum operating temperature of 85°C. The temperature sensor is monitoring the average internal temperature of the VI-HAM.
VI-HAM Harmonic Attenuator Module Compatible Modules Over the full range of input voltages (85 to 264Vac), the output varies from 260 to 415Vdc. Therefore the DC-DC Converters modules used with the VI-HAM are from the VI-260 and VI-J60 families. VI-200 Family* 2V VI-26Z-CU VI-26Z-CV VI-26Z-CW VI-26Z-CX VI-26Z-CY 12V VI-261-CU VI-261-CV VI-261-CW VI-261-CX VI-261-CY 3.
Applications Manual VI-HAM Do’s and Don’ts The following cautions should be observed before applying power to the VI-HAM. • It is important that the output of the VI-HAM not be loaded until the input voltage has exceeded 85Vac and the output has begun to boost to 260Vdc. This means that if the load on the VI-HAM is a Vicor converter, the Enable Output of theVI- HAM must be connected to the Gate Input of all driver modules.
VI-HAM Harmonic Attenuator Module Mechanical Diagram, Vicor Line Filter P/N 07818 4-40 INSERT .25 DP 4 PL 4.60 ±.02 2.50 1.200 .060 LINE 2.40 ±.02 2.00 LOAD ø.080 PIN 6 PLACES 1.800 VICOR LABEL FACE MAY BE BOWED .04 MAX. .900 .100 .30±.02 .13 ±.02 1.00 MAX .500 .500 2.800 1.45 ±.02 A 3.500 4.000 2 PL 4.410 2.500 2 PL .700 .310 2.260 2.000 2 PL 1.900 2 PL 1.200 2 PL '0' BOTTOM VIEW A ø .102 TPH 6 PL 1.000 2 PL .060 '0' A .100 2 PL '0' A .260 '0' ø .
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14 VI-IAM™ /MI-IAM™ Input Attenuator Module Overview The VI-IAM is a component-level, DC input front end filter that when used in conjunction with Vicor converters provides a highly efficient, high density power system with outputs from 1 to 95Vdc and power expansion from 25 to 800W.
Applications Manual EMC EMC performance is guaranteed when the VI-IAM is used in conjunction with Vicor converters within the permissible power rating and in accordance with the recommended installation procedure (Figure 2, page 14-4). The capacitor shown across the input of the converter, bypass capacitors and series resistors shown on the –In and +In of the DC-DC converters to ground are required to meet EMC specifications. The capacitors should be Y-rated (interference suppression).
VI-IAM / MI-IAM™ Input Attenuator Module Input Transient Protection (cont) Safe Operating Area 24V Inputs Standard R.E. 100V 48V Input Wide Range 100V R.E. 160V I.S.W. Full Load S.D. 100V 36V 32V 1 10ms 100 S.D. 60V Normal Operating Area 21V 0.1 I.S.W. Full Load Normal Operating Area 42V 0.1 18V 1000 1 48V Wide Range Input 10ms 100 VOLTS-PEAK VALUE OF SPIKE VOLTAGE (1% duty cycle max., Zs = .
Applications Manual Expansion Capabilities The input attenuator module incorporates a parallel pin permitting power expansion as long as the total output power from the DC-DC converters does not exceed the power rating of each input attenuator module (EMC specifications are guaranteed for up to two input attenuators in parallel).
VI-IAM / MI-IAM™ Input Attenuator Module Expansion Capabilities (cont) Figure 4.
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15 VI-RAM™ / MI-RAM™ Ripple Attenuator Module Overview The VI-RAM is an accessory product for VI-200, VI-J00 and Mega Modules, ComPAC DC-DC switchers, and FlatPAC AC-DC switching power supplies. It reduces line frequency related ripple and converter switching noise to less than 3 mV p-p (10 mV p-p on VI-J00 modules). Features include: • Reduced Differential Noise (<3 mV p-p at loads up to 20A) The input of the VI-RAM must be between 5 and 50Vdc.
Applications Manual Overview (cont) Figure 2. VI-RAM with Optional Trimming Circuit and Optional Common Mode Choke for Conducted Noise (see Ch. 10 for more details) L1 + In Gate In – Gate Out + S In +S VI-200/MI-200 Trim + Out + S Out VI-RAM N/C – S In –S – In Figure 3. Attenuation vs.
16 VI-ARM™ Autoranging Rectifier Module Overview The VI-ARM (Autoranging Rectifier Module) provides an effective solution for the AC front end of a power supply built with Vicor DC-DC converters. This high performance power system building block satisfies a broad spectrum of requirements and agency standards. The VI-ARM contains all of the power switching and control circuitry necessary for autoranging rectification, inrush current limiting, and overvoltage protection.
Applications Manual Functional Description (cont) 4.1 The converters are enabled 50 milliseconds after the thermistor bypass switch is closed. 5.1 Bus-OK is asserted after an additional 50 millisecond delay to allow the converter outputs to settle within specification. Power-Down Sequence. (See Figure 2.) When input power is turned off or fails, the following sequence occurs as the bus voltage decays: 1.2 Bus-OK is deasserted when the bus voltage falls below 210Vdc. 2.
VI-ARM Autoranging Rectifier Module Off-Line Supply Configuration (cont) proper (autoranging) operation. Gas tubes across the capacitors provide input transient protection. The bleeder resistors (R1, R2, Figure 3) discharge the holdup capacitors when power is switched off. Holdup Box (HUB) 820µF HUB820-S, C3 2200µF HUB2200-S 1200µF HUB1200-S, 2700µF HUB2700-S Figure 3.
Applications Manual Off-Line Power Supply Configuration (cont) Bus-OK (BOK) Pin. (See Figure 5.) The Bus-OK pin is intended to provide early-warning power fail information and is also referenced to the negative output pin. Caution: There is no input to output isolation in the VI-ARM. It is necessary to monitor Bus-OK via an optoisolator if it is to be used on the secondary (output) side of the converters. A line isolation transformation should be used when performing scope measurements.
VI-ARM Autoranging Rectifier Module Selecting Capacitors for the VI-ARM (Visit vicr.com for an online holdup capacitor calculator.) Holdup Capacitors. Holdup capacitor values should be determined according to output bus voltage ripple, power fail holdup time, and ride-through time. (See Figure 7.) Many applications require the power supply to maintain output regulation during a momentary power failure of specified duration, i.e.
Applications Manual Selecting Capacitors for the VI-ARM (cont) It should be noted that the series combination C1, C2, (Figure 3) requires each capacitor to be twice the calculated value, but the required voltage rating is reduced to 200V. Allowable ripple voltage on the bus (or ripple current in the capacitors) may define the capacitance requirement. Consideration should be given to converter ripple rejection and resulting output ripple voltage.
VI-ARM Autoranging Rectifier Module Selecting Capacitors for the Vi-ARM (cont) Calculated values of bus capacitance for various holdup time, ride-through time, and ripple voltage requirements are given as a function of operating power level in Figures 8, 9, and 10, respectively. 100 90 Total capacitance 820µF 80 Hold up Time (ms) Figure 9. Hold up time vs.
Applications Manual Selecting Capacitors for the VI-ARM (cont) Determining Ride-through Time. Figure 9 illustrates hold up time as a function of line voltage and output power, and shows that at a nominal line of 115Vac, ride-through would be 68 ms. Hold up time is a function of line voltage. 80 75 Ripple Rejection (dB) Figure 11. Converter ripple rejection vs. output voltage 70 65 60 55 50 45 40 2 5 15 30 50 Output Voltage Determining Ripple Voltage on the Holdup Capacitors.
17 Optional Filters for Attenuation of Output Ripple Overview The LC filter design below is a comparatively simple solution for reducing ripple on the outputs of Vicor’s 200/J00 Families. These components are small and provide significant peak-to-peak noise attenuation. Since an output filter capacitor is already present in the DC-DC converter, adding an inductor and capacitor to the output creates a pi filter.
Notes 17-2 12 1-800-927-9474
18 The ComPAC™ Family DC-DC Switching Power Supplies Overview The ComPAC is a low profile, highly efficient, high density configurable DC-DC power solution with EMC filtering, transient protection and reverse polarity protection. It has an isolated master disable input for remote shutdown, and provides outputs from 1-95Vdc and power up to 600W.
Applications Manual Features (cont) Weight 1-up: 1.2 lbs (540g); 2-up: 2.4 lbs (1080g); 3-up: 3.6 lbs (1630g) Operating Case Temperature E-Grade = -10˚C to +85˚C C-Grade = -25˚C to +85°C I-Grade = -40˚C to +85°C M-Grade = -55˚C to +85°C Thermal Data Operating Ambient Temperature: Depends on factors such as output power, availability of forced air, and mounting technique. Do not allow the ComPAC to exceed its maximum operating temperature, which is reached when the case is 85˚C.
ComPAC DC-DC Switching Power Supplies Features (cont) EMC Performance, Conducted EMC The ComPAC will conform to the following conducted EMC specifications on the input power leads: Telecom (24V and 48V inputs): Bellcore TR-TSY-000513, Issue 2 July 1987 and Rev. 1, December 1988. British Telecom Document BTR2511, Issue 2. Commercial (300V input): FCC Pt. 15 Subpt. J, Class A/VDE 0871 Class A.
Applications Manual Features (cont) Nominal Input 24 24 (wide) 28 (military) 48 48 (wide) 270 (military) 300 UV Lockout (Vdc, typical) 19 17 17 41 35 121 188 Following startup, the undervoltage lockout will inhibit the converter output(s) should the input drop roughly 8-10V below the UV lockout limits stated above. Recommended Input Line Fusing The ComPAC must be fused externally. The table below lists the fuse ratings for one-, two- and three-up units (max. output 200, 400 and 600W).
ComPAC DC-DC Switching Power Supplies Features (cont) Master Disable The ComPAC incorporates an optically isolated Master Disable input which will shut down the ComPAC output when a current is driven through the disable terminals. Figure 1. ComPAC Module Disable 20 mA Max.
Applications Manual Mechanical Drawings All Models 1 2 3 4 5 INPUTS Ground -Input +Input DisableDisable+ .99 Measure case temperature on this surface. Standard Heatsink .5 (12,57) (25,15) 8.63 ±.025 STANDARD UNITS (219,2±,64) OUTPUTS A +Output B +Sense C Trim D -Sense E -Output .41 (10,4) 1.37 1.12 (28,4) .5 (12,57) (34,80) 9.25 ±.120 Optional H1 Heatsink OPTIONAL HEATSINK (H1) (235,0 ±3,05) 1 Up 6.00 (152,4) .18 (4,6) 0 5 3 .20 (5,1) 2 2.156 (54,76) 1 .20 (5,1) .41 (10,41) .
19 FlatPAC™ Technical Description Overview Vicor’s FlatPAC consists of an off-line single phase AC front end and one, two or three VI-26x/VI-B6x Family DC-DC converter modules (1-up, 2-up, 3-up), combined in an integrated mechanical assembly. This assembly provides a complete, high efficiency, off-line switching power supply delivering power up to 600W.
Applications Manual Circuit Operation (cont) The AC-OK and BUS-OK status lines go to their respective active states almost simultaneously on initial power-up. AC-OK will de-assert prior to BUS-OK on loss of AC input, providing advance warning of impending DC failure should the AC line not return prior to the expiration of the ride thru time (a function of both load and line voltage).
The FlatPAC AC-DC Switching Power Supply MOD-DIS+, MOD-DIS– The module disable function will disable the output(s) of the 2-up- and 3-up FlatPACs. The supply is disabled by applying current to the MOD-DIS+/MOD-DIS– input. The minimum input current for disabling the supplies is 1 mA. The maximum allowable current is 30 mA.
Notes 19-4 12 1-800-927-9474
20 The MegaPAC™ Family AC-DC, DC-DC Switching Power Supplies Overview The MegaPAC family is a line of field configurable switching power supplies that leverage Vicor’s DC-DC converters to provide maximum flexibility. Developing a custom power supply is as easy as selecting a MegaPAC chassis and sliding in the appropriate output assemblies, called ConverterPACs.
Applications Manual PFC MegaPAC Technical Description The PFC MegaPAC chassis consists of an off-line single phase, power factor corrected front end, EMC 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 EMC filter designed to meet conducted noise limit “B” specifications of FCC Part 15 and VDE 0871 and EN55022 level “B”.
MegaPAC™ Family AC-DC, DC-DC Switchers PFC MegaPAC 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 12 AWG. The maximum torque recommended is 10 in-lbs. 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. Figure 1.
Applications Manual PFC Interface Connections (cont) Signal Ground (J10-10) Signal Ground on J10-10 is an isolated secondary ground reference for all J10 interfacing signals, and for ModuPAC output status signals such as Power Good. This is not the same as Earth Ground on input power connector J9. Enable/Disable (J10-8) The Enable/Disable control pins allow ConverterPAC outputs to be sequenced either on or off. J10-1 through J10-8 are the control pins for output positions 1 through 8, respectively.
MegaPAC™ Family AC-DC, DC-DC Switchers PFC Interface Connections (cont) Auxiliary Vcc +5V/0.3A (J10-9) The Vcc on J10-9 is an auxiliary 5V regulated power source. It is +5Vdc +/–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.
Applications Manual Autoranging MegaPAC/Mini MegaPAC Technical Description The MegaPAC and Mini MegaPAC chassis consist of an off-line single phase AC front end, EMC 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 EMC filter designed to meet conducted noise limit “A” specifications of FCC Part 15 and VDE 0871.
MegaPAC™ Family AC-DC, DC-DC Switchers Autoranging MegaPAC/Mini MegaPAC Interface Connections 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 nominal delay associated for an output to come up when measured from release of the Enable/Disable pin is 5-10 ms.
Applications Manual Autoranging MegaPAC/Mini MegaPAC Interface Connections (cont) Figure 10. Enable/Disable 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.
MegaPAC™ Family AC-DC, DC-DC Switchers Autoranging MegaPAC/Mini MegaPAC Interface Connections (cont) Vcc (J3-1) The Vcc on J3-1 is an input that requires +5V either from the Auxiliary Vcc on J10-9, or from another source. Input current to this pin is limited by an internal resistor to 3 mA. If the Auxiliary Vcc on J10-9 is connected to Vcc on J3-1, then Signal Ground J10-10 must also be connected to Signal Ground on J3-4.
Applications Manual Three Phase MegaPAC Technical Description (cont) Upon power-up, all outputs are first disabled to limit the inrush current, and to allow the unregulated 300Vdc to reach correct operating levels for ConverterPAC assemblies. The internal housekeeping supply comes up within 500 ms after input power is applied, at which time the AC Power OK signal asserts to a TTL “1,” indicating that the input power is OK.
MegaPAC™ Family AC-DC, DC-DC Switchers Three Phase MegaPAC Interface Connections (cont) For standard Three Phase MegaPACs, the Enable/Disable controls are configured as active-high with internal pull-up; outputs are enabled when these pins are open-circuited or allowed to exceed 4.5V with respect to Signal Ground. Outputs are disabled when the Enable/Disable control lines are pulled low to less than 0.7V.
Applications Manual Three Phase MegaPAC Interface Connections (cont) Figure 15. Analog Temperature and Overtemperature Warning J10 MC34074 100 + 4.99K 4 Analog Temperature 4.99K 100K 4.99K + Vref +5V 3 Overtemperature Warning 1, 2, 12, 15 Signal Ground LM393 Overtemperature Shutdown If the inlet ambient air temperature exceeds the following factory set levels, then all outputs are disabled. For standard units the shutdown trip point is between 70˚C to 81˚C.
MegaPAC™ Family AC-DC, DC-DC Switchers DC MegaPAC Technical Description The DC MegaPAC chassis consists of an EMC filter, cooling fan, customer interface and associated housekeeping circuits. Input DC voltage (+Vin, –Vin and GND) is applied to the input connectors. The input current is passed through an EMC filter designed to meet British Telecom specifications. At start-up, inrush current is limited by a thermistor.
Applications Manual DC MegaPAC Interface Connections (cont) of 42V), a fast-blow fuse of 50 Amps is recommended. Start-up inrush current is limited by a 10Ω thermistor and in most cases will be less than nominal line current during operation. Start-up inrush current can be calculated by I = MaxVin/10 (where MaxVin is the maximum operating voltage, see Table 1, page 20-16). Example: for a nominal 48V input, the maximum operating voltage is 60V, therefore, I = 60V/10 = 6 Amps. Figure 19.
MegaPAC™ Family AC-DC, DC-DC Switchers DC MegaPAC Interface Connections (cont) Input Power OK (J10-18) This is an active high TTL compatible signal on pin J10-18, and provides a status indication of the DC input power. It is capable of sinking 20 mA maximum. This signal switches to a TTL “1” when Vin voltage is within specification. See Table 1, page 20-16 for specifications.
Applications Manual DC MegaPAC Input Voltage Range and Vin OK Limits Table 1. Code 0 1 W 2 3 N 4 Operating Range Nominal Low High Vdc Line Line 12V 10V 20V 24V 21V 32V 24V Wide 18V 36V 36V 21V 56V 48V 42V 60V 48V Wide 36V 76V 72V 55V 100V Vin OK Trigger Low Line High Line Cut off Cut off 6V to 10V 20V to 23V 16V to 21V 32V to 36V 12V to 18V 36V to 41V 11V to 21V 56V to 63V 34V to 42V 60V to 68V 23V to 36V 76V to 86V 40V to 55V 100V to 112V* *Do not apply greater than 100V to the input of the DC MegaPAC.
MegaPAC™ Family AC-DC, DC-DC Switchers ConverterPAC Functional Descriptions (cont) The JuniorPAC contains output overcurrent protection which recovers automatically when the overcurrent condition is removed. Overvoltage and overtemperature protection are not available. DualPAC This output assembly consists of two VI-J00 DC-DC converters that convert the unregulated high voltage bus to the desired regulated output voltages. The assembly is fused with a single PC-Tron 3A fast-acting fuse.
Applications Manual ConverterPAC Functional Descriptions (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. It is capable of sinking 20 mA maximum when 5V is used as Vcc. 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.
MegaPAC™ Family AC-DC, DC-DC Switchers ConverterPAC Functional Descriptions (cont) Figure 23. Sense Leads (Local Sense) +P +Out (Remote Sense) J2-2 +Sense Load J2-3 -Sense -P -Out Use 20-22 AWG Twisted Pair Wires Trim (J2) The Trim pin on J2-1 may be used to control the output voltage. It is referenced to the –Sense pin on J2-3. For DualPACs, the Trim pins are available on connectors designated as J2A-1 and J2B-1 for outputs A and B, respectively.
Applications Manual MegaPAC Mechanical Considerations (cont) Avoid excessive bending of output power cables after they are connected to the MegaPAC. For high-current outputs, use cable-ties to support heavy cables to minimize mechanical stress on output studs. Be careful to not short-out to neighboring output studs. The MegaPAC is supplied with serrated, flanged hex-nuts on all output studs, therefore, Loc-tite® or lock washers are not required. The maximum torque recommended on flanged nuts is 45 in.
MegaPAC™ Family AC-DC, DC-DC Switchers ConverterPAC Derating Curves Figure 25. Autoranging/Mini/DC/3-Phase MegaPAC Thermal Derating Curve (5V ConverterPACs) ModuPAC, BatPAC 200 Load Power (Watts) 175 150 125 75W Max. @ 65˚C RAMPAC, DualPAC, JPAC 100 75 37.5W Max. @ 65˚C 50 25 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (˚C) Autoranging/Mini/DC/3-Phase MegaPAC Thermal Derating Curve (12-95V ConverterPACs) Figure 26.
Applications Manual ConverterPAC Derating Curves (cont) PFC MegaPAC Thermal Derating Curve (5V ConverterPACs) Figure 27. ModuPAC, BatPAC 200 175 Load Power (Watts) 150 125 RAMPAC, DualPAC, JPAC 100 75W Max. @ 60˚C 75 37.5W Max. @ 60˚C 50 25 0 5 10 15 20 25 30 35 40 45 50 55 60 Ambient Temperature (˚C) PFC MegaPAC Thermal Derating Curve (12-48V ConverterPACs) Figure 28. ModuPAC, BatPAC 200 Load Power (Watts) 175 150 100W Max. @ 60˚C 125 RAMPAC, DualPAC, JPAC 100 50W Max.
21 PFC Mini TM Power Factor Corrected AC-DC Switchers Overview The PFC Mini is an extremely low profile switching power supply that combines the advantages of power factor correction, power density, and user selected isolated outputs. Accepting input voltages of 85Vac to 264Vac, and 100 to 380Vdc, the PFC Mini can provide up to 1500W in a package size of 1.75" x 6" x 12". The PFC Mini can provide up to 6 isolated outputs and is factory configured to meet user requirements.
Applications Manual Interface Connections Chassis Input Power Terminals (J1) Input AC power is applied to terminal block J1 using a pressure screw terminal that accepts a maximum wire size of 10 AWG. The maximum torque recommended is 10 in-lbs. J1-1 (GND) is Earth Ground for safety; J1-2 (L2) and J1-3 (L1) are the other Hot connections. A fault clearing device, such as a fuse or circuit breaker, with a maximum 15A rating at the power supply input is required for safety agency compliance.
PFC Mini Power Factor Corrected AC-DC Switchers Interface Connections (cont) General Shutdown /GSD (J3-7) The GSD control pin on J3-7 allows simultaneous shutdown of all outputs. This pin must be pulled down to less than 0.7V, and will source 3 mA maximum to shut down all outputs. The GSD pin should be open circuited or allowed to exceed 4.5V when not in use, or when the outputs are to be enabled. Do not apply more than 5V to this input at any time. Normal open circuit voltage is 1.
Applications Manual Interface Connections (cont) Installing Remote Sense requires the Local Sense jumpers to be removed. On single output cards, the Local Sense jumpers are located behind the Sense connector at J1. To remove the jumpers, pull them off the four pins at J1. On dual output cards, the Local Sense jumpers are on either side of the output connector at J1 and J3. The jumpers at J1 are for output #1, and the jumpers at J3 are for output #2.
PFC Mini Power Factor Corrected AC-DC Switchers PFC Mini Do’s and Don’ts • If Sense jumpers are removed, do not leave Sense lines open. Use twisted pair 20-22 AWG wire when installing Remote Sense. • 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.
Applications Manual Notes 21-6 12 1-800-927-9474
22 Front End Application Notes Single Phase Front Ends Vicor’s single phase non-isolated AC front ends are available in both PCB and chassis mount versions, and deliver reliable DC bus voltage to VI-x6x converter modules or Mega Modules at power levels up to 250, 500 and 750W. These front ends are strappable to provide operation from either 115Vac or 230Vac single phase lines, and provide conducted EMC filtering to VDE/FCC Level B.
Applications Manual 250W, 500W, and 750W Front Ends (cont) Thermal Considerations Free Convection Derating • 250W: Derate output power linearly at 7.2W/˚C over 50˚C. • 500W: Derate output power linearly at 14.3W/˚C over 50˚C. • 750W: Derate output power linearly at 18.8W/˚C over 45˚C. Forced Convection The curves below represent worst case data for chassis mounted (enclosed) front ends; i.e., low line, full load.
Front End Application Notes Three-Phase Front Ends Vicor’s three-phase front ends are available as chassis mount products that deliver reliable DC bus voltage to x6x family (nominal 300Vdc input) converters up to 1.5 kW, 3 kW and 5 kW.
Applications Manual Three-Phase Front Ends (cont) Fusing Information 1.5 kW Front End 7A/250V normal blow in all three phases of the AC line (Bussman ABC-7 or Littlefuse 314-007). 3 kW Front End 12A/250V normal blow in all three phases of the AC line (Bussman ABC-12 or Littlefuse 314-012). 5 kW Front End 20A/250V normal blow in all three phases of the AC line (Bussman ABC-20).
23 Thermal Considerations Overview Simplified thermal management is one of the benefits of using Vicor converters. High operating efficiency minimizes heat loss, and the low profile package features an easily accessible, electrically isolated thermal interface surface. Proper thermal management pays dividends in terms of improved converter and system MTBFs, smaller size and lower product life-cycle costs. The following pages provide guidelines for achieving effective thermal management of Vicor converters.
Applications Manual Removing Heat From Vicor Converters (cont) All three of these heat transfer mechanisms are active to some degree in every application. Convection will be the dominant heat transfer mechanism in most applications. Nondominant effects will provide an added contribution to cooling; in some cases, however, they may result in undesirable and unanticipated thermal interactions between components and subassemblies.
Thermal Considerations Conduction (cont) Figure 2. Surface Irregularities Produce Temperature Drop in the Interface Θbs Mating Member at Temperature = Ts (+) + Heat Flow Pdiss Power Dissipated by Converter (Watts) Baseplate Θbs = Interface Thermal Resistance (°C / Watt) Ts Tb (–) Tb = Baseplate Temperature = Ts + Pdiss x Θbs – Temperature of Mating Surface (°C) Temperature rise across a surface interface can be significant if not controlled.
Applications Manual Convection Convective heat transfer into air is a common method for cooling Vicor converters. “Free” or “natural” convection refers to heat transfer from a dissipative surface into a cooler surrounding mass of otherwise still air; forced convection refers to heat transfer into a moving air stream. The convection cooling model is shown in Figure 4, page 23-3.
Thermal Considerations Free Convection (cont) 4. Select several heatsinks that appear physically acceptable for the application. Using data provided, obtain values for their free convection thermal resistance, preferably at worst-case ambient temperature, Ta. If values obtained are less than the value calculated in Step 3, go on to Step 5. If the values are greater, then either a physically larger heatsink will be required or a different cooling method will need to be used (i.e., forced air, etc.). 5.
Applications Manual Free Convection (cont) Figure 5. Heatsink Torquing Sequence VI-200/VI-J00 4 2 5 1 4 3 1 6 3 2 Multiple Modules Using Common Fasteners The following mounting scheme should be used to attach modules to a heatsink for two or more modules. A large, heavy washer should be used on the common fasteners to distribute the mounting force equally between modules. The torquing sequence shown in Figure 6 can easily be expanded from two to any number of modules. An array of three is shown.
Thermal Considerations Forced Convection (cont) Forced air implies the use of fans. Many applications require that fans be used to achieve some desired combination of overall system reliability and packaging density. In other applications, however, fans are considered taboo. “Dirty” environments will require filters that must be changed regularly to maintain cooling efficiency, and neglecting to change a filter or the failure of the fan could cause the system to shut down or malfunction.
Applications Manual Forced Convection (cont) The cross-sectional area between the fins is the area through which the total airflow must pass (Figure 8). Correct interpretation of heatsink data requires that only the airflow through this area be considered. Simply pointing a fan at a heatsink will clearly not result in all of the flow going through the cooling cross-section of the sink; some channeling of air is usually required to get the full benefit of fan output.
Thermal Considerations DC-DC Converters and Off-Line Power Supplies (cont) Consideration should be given to module baseplate temperature during operation. The most common cause of power supply failure is thermal stress beyond maximum rating. Refer to the product data sheet for the maximum baseplate temperature specification.
Applications Manual Typical Examples — Thermal Equations Tmax = maximum baseplate temperature (From product specifications.) Ta = ambient temperature η = efficiency = Pout Pin (Assume efficiencies of 81% for 5V outputs and 85% for 12V out and above.
Thermal Considerations Typical Examples — Thermal Equations (cont) EXAMPLE 1. Determine the maximum output power for a 100W, VI-200 converter, no heat sink, delivering 5V in 400 LFM at a maximum ambient temperature of 45°C. - Ta T Maximum Output Power = max 1-1 θ sa η ( ) Tmax = 85°C Ta = 45°C θsa = 1.8°C/W η = 81% = (.81) Maximum Output Power = 85 - 45 1.8 ( 1 -1 0.81 ) = 95W max. EXAMPLE 2.
Typical Examples — Thermal Equations (cont) EXAMPLE 3. Determine the maximum ambient temperature of a 3-up FlatPAC delivering 12V at 600W in 500 LFM with no additional conduction cooling to the chassis. ( Maximum Ambient Temperature = Tmax - θ sa x P out 1 - 1 η ) Tmax = 85°C θsa = 0.3°C/W Pout = 600W η = 85% = (.85) Maximum Ambient Temp. = 85 - 0.3 x 600 ( 1 -1 0.85 ) = 53°C EXAMPLE 4.
24 Thermal Curves Thermal Curves (Use as a design guide only. Verify final design by actual temperature measurement.) 200 VI-200 Family Baseplate-to-Air (No Heatsink) 5V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) VI-200 Family 2111 Heatsink, 5V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) VI-200 Family 2111 Heatsink, 12-48V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 200 VI-200 Family 2112 Heatsink 5V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 55 60 65 70 75 80 85 Ambient Temperature (Deg. C) 200 VI-200 Family 2112 Heatsink 12-48V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) VI-200 Family 2113 Heatsink, 5V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 200 VI-200 Family 2113 Heatsink, 12-48V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) VI-200 Family 6927 Heatsink 5V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 55 60 65 70 75 80 85 Ambient Temperature (Deg. C) VI-200 Family 6927 Heatsink 12-48V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) VI-J00 Family Baseplate-to-Air (No Heatsink) 5V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) VI-J00 Family Baseplate-to-Air (No Heatsink) 12-48V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 95 100 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) VI-J00 Family 4306 Heatsink, 5V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) VI-J00 Family 4306 Heatsink, 12-48V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) VI-J00 Family 4307 Heatsink, 5V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) 100 VI-J00 Family 4307 Heatsink, 12-48V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (Deg.
Thermal Curves 100 VI-J00 Family 5738 Heatsink 5V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) VI-J00 Family 5738 Heatsink 12-48V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) 200 FinMod VI-200 Family F1/F3 Configuration 5V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) FinMod VI-200 Family F1/F3 Configuration 12-48V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 200 FinMod VI-200 Family F2/F4 Configuration 5V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 200 FinMod VI-200 Family F2/F4 Configuration 12-48V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) 100 FinMod VI-J00 Family F1/F3 Configuration 5V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) FinMod VI-J00 Family F1/F3 Configuration 12-48V Output 100 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 100 FinMod VI-J00 Family F2/F4 Configuration 5V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) 100 FinMod VI-J00 Family F2/F4 Configuration 12-48V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) SlimMod VI-200 Family 5V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 200 SlimMod VI-200 Family 12-48V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 100 SlimMod VI-J00 Family 5V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 70 75 80 85 90 95 100 Ambient Temperature (Deg. C) 100 SlimMod VI-J00 Family 12-48V Output 90 Output Power (Watts) 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) 200 1-Up ComPAC, 5V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 200 1-Up ComPAC, 12-48V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 2-Up ComPAC, 5V Output 400 350 Output Power (Watts) 300 250 200 150 100 50 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 2-Up ComPAC, 12-48V Output 400 350 Output Power (Watts) 300 250 200 150 100 50 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) 3-Up ComPAC, 5V Output 600 525 Output Power (Watts) 450 375 300 225 150 75 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 3-Up ComPAC, 12-48V Output 600 525 Output Power (Watts) 450 375 300 225 150 75 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 1-Up FlatPAC, 5V Output 200 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (Deg. C) 200 1-Up FlatPAC, 12-48V Output 175 Output Power (Watts) 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (Deg.
Applications Manual Thermal Curves (cont) 400 2-Up FlatPAC, 5V Output 350 Output Power (Watts) 300 250 200 150 100 50 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 400 2-Up FlatPAC, 12-48V Output 350 Output Power (Watts) 300 250 200 150 100 50 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Thermal Curves Thermal Curves (cont) 600 3-Up FlatPAC, 5V Output 525 Output Power (Watts) 450 375 300 225 150 75 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 60 65 70 75 80 85 Ambient Temperature (Deg. C) 600 3-Up FlatPAC, 12-48V Output 525 Output Power (Watts) 450 375 300 225 150 75 0 0 5 10 15 20 25 30 35 40 45 50 55 Ambient Temperature (Deg.
Notes 24-22 12 1-800-927-9474
25 Agency Approvals Overview Below are the agency approvals received on Vicor products as of 1/98. Please consult the factory for the approvals on our more recent product introductions. DC-DC Products Approvals VI-200 Family UL: 544, 1012, 1950, 2601-1 CSA: 0, 0.4, 0.
Applications Manual DC-DC Products (Cont) ComPAC UL: 1012, 1950, 1604 CSA: 0, 0.4, 0.7, 220, 234, 950; 1402C TÜV: EN 60950 VDE: VDE 0805, IEC 60950, EN 60950 BABT: EN 41003, EN 60950 CE: Low Voltage Directive (73/23/EEC, 93/68/EEC) ConverterPACs UL: 1012, 1950 CSA: 0, 0.4, 234, 950; 1402C TÜV: EN 60950 DC MegaPAC UL: 1950 CSA: 0, 0.4, 0.
Agency Approvals AC-DC Products VI-ARM UL: 544, 1950 CSA: 0, 0.4, 234, 950 TÜV: EN 60950 VDE: VDE 0805, IEC 60950, EN 60950 BABT: EN 41003, EN 60950 CE: Low Voltage Directive (73/23/EEC, 93/68/EEC) VI-HAM UL: 544, 1950 CSA: 0, 0.4, 234, 950; 1402C TÜV: EN 60950 BABT: EN 41003, EN 60950 CE: Low Voltage Directive (73/23/EEC, 93/68/EEC) Mini MegaPAC UL: 1950 CSA: 0, 0.4, 950 TÜV: EN 60950 CE: Low Voltage Directive (73/23/EEC, 93/68/EEC) Autoranging MegaPAC UL: 1950 CSA: 0, 0.
Agency Classifications United States UL (Underwriters Laboratories, Inc.
26 Product Weights Overview The following is a list of typical weights for Vicor products. DC-DC Products VI-200/MI-200 Family (Including SlimMod) 6.0 oz. 170 grams VI-J00/MI-J00 Family 3.0 oz. 85 grams BatMod 6.0 oz.
Applications Manual AC/DC Products MI-/VI-AIM AC Input Module 3.0 oz. 85 grams VI-ARM Autoranging Rectifier Module 2.1 oz. 60 grams VI-HAM Harmonic Attenuator Module 6.0 oz. 170 grams FlatPAC LU Family (1-up) PU, MU Family (2-up) NU, QU, RU Family (3-up) 1.4 lbs. 2.75 lbs. 4.0 lbs. Off-Line Front Ends (Includes Industrial Grade) VI-FPE6-CUX (250W PC Mount) 6.5 oz. VI-FKE6-CUX (250W Chassis Mount) 12.0 oz. VI-FPE6-CQX (500W PC Mount 13.8 oz. VI-FKE6-CQX (500W Chassis Mount) 1.3 lbs.
27 Glossary of Technical Terms Glossary AC-OK SIGNAL. The signal used to indicate the loss of AC input voltage from the 115/230V line. ALTITUDE TESTING. Generally performed to determine the proper functionality of equipment in airplanes and other flying objects. MIL-STD-810. AMBIENT TEMPERATURE. The temperature of the environment, usually the still air in the immediate proximity of the power supply. APPARENT POWER.
Applications Manual Glossary (cont) BURN-IN. Operating a newly manufactured power supply, usually at rated load, for a period of time in order to force component infant mortality failures or other latent defects. CAPACITIVE COUPLING. Coupling of a signal between two circuits, due to discrete or parasitic capacitance between the circuits. CENTER TAP.
Glossary Glossary (cont) CSA. Canadian Standards Association. Defines the standards and safety requirements for power components. CURRENT LIMITING. An overload protection circuit that limits the maximum output current of a power supply in order to protect the load and/or the power supply. CURRENT MODE. A control method for switch-mode converters where the converter adjusts its regulating pulsewidth in response to measured output current and output voltage, using a dual loop control circuit.
Applications Manual Glossary (cont) ELECTRONIC LOAD. An electronic device designed to provide a load to the outputs of a power supply, usually capable of dynamic loading, and frequently programmable or computer controlled. EMC. Electromagnetic Compatibility, relating to compliance with electromagnetic emissions and susceptibility standards. EMI. Electromagnetic Interference, which is the generation of unwanted noise during the operation of a power supply or other electrical or electronic equipment. ESR.
Glossary Glossary (cont) GROUND LOOP. An unintentionally induced feedback loop caused by two or more circuits sharing a common electrical ground. HAM (VI-HAM Harmonic Attenuator Module). The VI-HAM is a component level front end that accommodates universal input voltage (85-264), provides line rectification, filtering, transient protection, unity power factor, inrush limiting and a DC output compatible with the 300V input families of DC-DC converters. HAVERSINE.
Applications Manual Glossary (cont) INPUT LINE FILTER. An internally or externally mounted lowpass or band-reject filter at the power supply input that reduces the noise fed into the power supply. INRUSH CURRENT. The peak current flowing into a power supply the instant AC power is applied. This peak may be much higher than the steady state input current due to the charging of the input filter capacitors. INRUSH CURRENT LIMITING.
Glossary Glossary (cont) MEGA MODULES. A chassis mount packaging option that incorporates one, two or three VI/MI-200 Family converters for single, dual or triple outputs having a combined power of up to 600W. M-GRADE. An industry standard where the operating temperature of a device does not drop below –55 degrees Celsius. MIL-SPECS. Military standards that a device must meet to be used in military environments. MINIMOD.
Applications Manual Glossary (cont) OUTPUT GOOD. A power supply status signal that indicates the output voltage is within a certain tolerance. An output that is either too high or too low will deactivate the Output Good signal. OUTPUT IMPEDANCE. The ratio of change in output voltage to change in load current. OUTPUT NOISE. The AC component that may be present on the DC output of a power supply.
Glossary Glossary (cont) POST REGULATOR. A secondary regulating circuit on an auxiliary output of a power supply that provides regulation on that output. POWER FAIL. A power supply interface signal that gives a warning that the input voltage will no longer sustain full power regulated output. POWER FACTOR. The ratio of true power to apparent power in an AC circuit. In power conversion technology, power factor is used in conjunction with describing AC input current to the power supply. PRELOAD.
Applications Manual Glossary (cont) REMOTE INHIBIT. A power supply interface signal, usually TTL compatible, that commands the power supply to shut down one or all outputs. REMOTE ON/OFF. Enables power supply to be remotely turned on or off. Turn-on is typically performed by open circuit or TTL logic “1”, and turn-off by switch closure or TTL logic “0”. REMOTE SENSE.
Glossary Glossary (cont) SOFT LINE. A condition where there is substantial impedance present in the AC mains feeding input power to a power supply. The input voltage to the power supply drops significantly with increasing load. SPLIT BOBBIN WINDING. A transformer winding technique where the primary and secondary are wound side-by-side on a bobbin with an insulation barrier between them. STANDBY CURRENT.
Applications Manual Glossary (cont) UNIVERSAL INPUT. An AC input capable of operating from major AC lines worldwide, without straps or switches. VOLTAGE BALANCE. The difference in magnitudes, in percent, of two output voltages that have equal nominal voltage magnitudes but opposite polarities. VOLTAGE MODE. A method of closed loop control of a switching converter to correct for changes in the output voltage. WARM-UP DRIFT.
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