DC MegaPAC™ DC-DC Switcher Operator’s Manual and “Quick Install” Instructions www.mpwrs.com Rev. 3/04 Vicor 800-735-6200 Mission Power Solutions (760) 631-6846 (phone) or (760) 631-6972 (fax) sales@mpwrs.
DC MegaPAC Operator’s Manual DC MegaPAC™ DC-DC Switcher DC MegaPAC “Quick Install” Instructions Mounting the DC MegaPAC * The DC MegaPAC can be mounted on any of four sides. * Use #8-32 or M4 mounting screws. Maximum penetration should not exceed 0.15" (3,8mm). * Maintain 2" (5,1cm) clearance at either end for airflow. Output Connections Power Connections Installing ring lugs and/or bus bars on output studs: * The upper stud is Positive and the lower stud is the Return. * Remove outer nut.
DC MegaPAC Operator’s Manual Trim Pin Connection J2 * 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.) * Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided. * J2-1 provides Trim access. DC OK (Power Good) Connection J3 * DC OK is only available as an option and is not always present.
DC MegaPAC Operator’s Manual DC MegaPAC™ DC-DC Switcher Overview The DC MegaPAC DC-DC switcher allows users to instantly configure high efficiency power supplies. Although small in size (3.4"H x 6.0"W x 11.7"L), (85,8mm x 153,4mm x 296,7mm), the DC MegaPAC provides up to 1600W of output power with up to 16 isolated outputs. A complete power supply is configured by selecting and inserting up to eight slide-in output assemblies called “ConverterPACs.
DC MegaPAC Operator’s Manual Technical Description The DC MegaPAC chassis consists of an EMI 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 EMI filter designed to meet conducted British Telecom specifications. At start-up, inrush current is limited by a thermistor.
DC MegaPAC Operator’s Manual ConverterPAC Functional Description ConverterPACs are the family of slide-in output assemblies used in MegaPAC power supplies. ConverterPACs are interchangeable within a MegaPAC so they can be added, moved, or changed as necessary. They are also interchangeable between different AC input MegaPAC chassis. A ConverterPAC removed from a Mini MegaPAC could be used in a 3 Phase MegaPAC, for example.
DC MegaPAC Operator’s Manual 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.
DC MegaPAC Operator’s Manual Interface Connections Chassis Input Power Terminals (J9) Input DC power is applied to solderless lugs J9, using a wire size of 2 AWG. J9-1 is the +DC Voltage IN connection, and J9-3 is the -DC Voltage IN connection. The Earth Ground is accessed via J9-2, a size 10-32 self-locking PEM nut. Maximum torque recommended is 25 lb-in. A fault clearing device, such as a fuse or circuit breaker at the power supply input is strongly recommended.
DC MegaPAC Operator’s Manual J10 INTERFACE CONNECTOR IDENTIFICATION 1 Signal Ground 14 No Connection 2 Signal Ground 15 Signal Ground 3 Overtemp.
DC MegaPAC Operator’s Manual Input Power Fail (J10-19) The Input Power Fail signal on pin J10-19 is the inverse of the Input Power OK signal on J10-18, and goes to a TTL "0" when the input DC power is OK. It is capable of sinking 20 mA maximum. Overtemperature Warning (J10-3) J10-3 is a signal that asserts a TTL level "1" if the air temperature exceeds the following factory set levels. The warning trip point is 65°C to 76°C, typically, and recovery point is 60°C to 71°C, typically.
DC MegaPAC Operator’s Manual Figure 11. Power Good and Vcc 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.
DC MegaPAC Operator’s Manual Note: Converters are sometimes pretrimmed at the factory if a nonstandard output voltage is requested. Standard voltages include 2V, 3.3V, 5V, 12V, 15V, 24V, 28V, and 48V. If using a nonstandard voltage, or if a ConverterPAC is ordered with a Trim option, the resistor calculations will differ from those below. Please consult the factory for assistance.
DC MegaPAC Operator’s Manual Mechanical Considerations The DC MegaPAC can be mounted on any of four surfaces using standard 8-32/M4 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.
DC MegaPAC Operator’s Manual ConverterPAC Output and Connector Location and Connector Pin Identification Sense Connector ModuPAC JuniorPAC RAMPAC 1 2 3 Molex #50-57-9403 housing, using #16-02-0103 terminals and 22-24 AWG stranded wire. Use Molex tool #11-01-0208. Pin 1 Trim Pin Access 2 +Sense 3 -Sense J2 Molex #39-01-043 housing using #39-00-0031 terminals and 22-28 AWG stranded wire. Use Molex tool #57005-5000.
DC MegaPAC Operator’s Manual Specifications Input Characteristics Input Voltage 12 Vdc (10-20), 24 Vdc (18-36), 36 Vdc (21-56), 48 Vdc (36-76), 72 Vdc (55-100) Power Factor 1.0 Line Regulation 0.2% max. from 10% to full load Inrush Current 5A peak @ 48 Vdc input Conducted EMI BTR 2511 Issue 4 Transient Surge EN/IEC 1000-4-2 Level 4 Output Characteristics Load Regulation 0.2% max. from 10% to 100% load 0.5% max.
DC MegaPAC Operator’s Manual DC MegaPAC Part Numbering DC MegaPAC MDx A - x C x B xxx e g . MD2- N 8103 xA xB xxx xC Number of outputs Number of modules Assigned by Mission Power Solutions DC input voltage range 0 12 Vdc input (10-20V range) 1 24 Vdc input (21-32V range) W 24 Vdc input (18-36V range) 2 36 Vdc input (21-56V range) 3 48 Vdc input (42-60V range) N 48 Vdc input (36-76V range) 4 72 Vdc input (55-100V range) ConverterPAC xCXx D V/x E Ax F e g. 3M15V/10A NM 1 5V/10ADF I L D15V/6.7A-12V/8.
DC MegaPAC Operator’s Manual Notes Rev. 3/04 Vicor 800-735-6200 Mission Power Solutions (760) 631-6846 (phone) or (760) 631-6972 (fax) Pg.
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