FlatPAC-EN/EN MI Design Guide FlatPAC-EN™ and FlatPAC-EN MI EN Compliant Autoranging Switchers Design Guide and “Quick Install” Instructions www.vicorpower.
FlatPAC-EN/EN MI Design Guide TABLE OF CONTENT Overview of Product...........................................................................................................................3 Part Numbering...................................................................................................................................3 Mechanical Considerations.................................................................................................................4 FlatPAC-EN/EN MI Do’s and Don’ts.
FlatPAC-EN/EN MI Design Guide FlatPAC-EN™ and FlatPAC-EN MI EN Compliant Autoranging Switcher Overview The FlatPAC-EN/EN MI is an ultra low profile switching power supply that provides up to 500 Watts from up to 4 isolated outputs. It operates on either 115 or 230 Vac nominal (47-63 Hz), or 250-380 Vdc. It can be populated with either VI-200/VI-J00 or Maxi/Mini/Micro Vicor converters. The use of these converters gives the FlatPACEN/EN MI the inherent power flexibility typical of all Vicor products.
FlatPAC-EN/EN MI Design Guide Mechanical Considerations The FlatPAC-EN/EN MI is mounted on the bottom surface using standard 8-32 or 4 mm screws (cannot be mounted from the front.) A1 C1 A3 B1 Identical mounting holes (C1 & C2) to Vicor's 2 UP FlatPAC B2 A4 A2 C2 Maximum allowable torque is 5 in. lbs.,. The maximum penetration for mounting holes A1, A2, A3 and A4 is 0.125 in. (3mm) and for mounting holes B1, B2, C1 and C2 is 0.250 in. (6mm). The minimum recommended mounting holes are as follows: 1.
FlatPAC-EN/EN MI Design Guide Technical Description The FlatPAC-EN/EN MI consists of an off-line single phase autoranging front end, EMI filter, customer interface, power supply control circuit, associated housekeeping circuits, a MiniHAM module and a selection of Vicor’s VI200/VI-J00 and/or Maxi/Mini/Micro DC-DC converters. The MiniHAM was specifically designed for EN compliance using passive filtering.
Pg 6 Vicor 800-735-6200 Westcor Division 408-522-5280 VI-200 Maxi M2 CBJ1 Interface Conn. Applications Engineering 800-927-9474 VI-J00 or Mini M2 VI-J00 or Mini M3 CBJ1 Interface Conn. (Two 18 pin Molex Connectors) (assumes only half bricks are used) Single, Dual orTriple Outputs VI-J00 or Mini M1 MiniHAM MBJ1 Input Conn. Micro M2 Micro M3 VI-J00 or Mini M4 CBJ1 Interface Conn.
FlatPAC-EN/EN MI Design Guide FlatPAC-EN/EN MI “Quick Install” Instructions (For mechanical drawings, see page 10) Mounting the FlatPAC-EN/EN MI • Mount the FlatPAC-EN on the bottom (cannot be mounted from the front). • For standard mounting (forced air cooling), use A1, A2, A3, A4 mounting holes. For standard mounting (conduction cooling), use A1, A2, A3, A4, B and B2 mounting holes.
FlatPAC-EN/EN MI Design Guide Installing power connectors on outputs with 18 pin Molex connectors (only half and/or quarter bricks used): • The output M1 slot only accepts a Micro module. J2-7, J2-8, J2-13 and J2-16 are positive, while pins J2-9, J2-15, J2-17 and J2-18 are the returns. • The output M2 slot only accepts a Micro module. J2-1, J2-4, J2-10, J211 are positive, while pins J2-2, J2-3, J2-5 and J2-12 are the returns. • The output M3 slot only accepts a Micro module.
FlatPAC-EN/EN MI Design Guide Trim Connections for 18 pin Molex output connectors (when half and/or quarter bricks used): • For outputs M1 and M2, J2-6 and J2-14 provide Trim access respectively. • For outputs M3 and M4, J3-6 and J3-14 provide Trim access respectively. • Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals. • Attach 18-24 AWG stranded wire using Molex tool #11-01-0197. Interface Connections • CBJ1-1 is Signal Ground and CBJ1-3 is AC OK.
Pg 10 2 3 Vicor 800-735-6200 Westcor Division 408-522-5280 SIGNAL GROUND N/C AC POWER OK TRANSMIT 4 RECEIVE ENABLE/DISABLE ENABLE/DISABLE ENABLE/DISABLE ENABLE/DISABLE GENERAL SHUTDOWN N/C +5V@300mA CBJ1-1 SGND CBJ1-2 N/C CBJ1-3 ACOK CBJ1-4 TX CBJ1- 5 RX CBJ1-6 E/D-4 CBJ1-7 E/D-3 CBJ1- 8 E/D-2 CBJ1-9 E/D-1 CBJ1-10 GSD CBJ1-11 N/C CBJ1-12 +5VS 3 MATING CONNECTOR: 2 HOUSING: MOLEX (50-57-9412) SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0097) CRIMP TOOL: MOLEX (11-01-0209) CBJ1 E/D INTERFACE CONNECTOR 5.
FlatPAC-EN/EN MI Design Guide Output Connectors for FlatPAC-EN/EN MI Refer to page 6 to review configuration layout of FlatPAC-EN A. STUD OUTPUT CONNECTOR - when configured with full brick and/or half brick -V OUT 10-32 OUTPUT STUDS SxJ2 REMOTE SENSE/TRIM PIN CONNECTOR +V OUT 3 2 1 - SENSE + SENSE TRIM MATING CONNECTOR: HOUSING: MOLEX (50-57-9403) TERMINAL FEM CRIMP 24-30 AWG: MOLEX (16-02-0103) USE CRIMP TOOL: MOLEX (11-01-0208) B.
FlatPAC-EN/EN MI Design Guide FlatPAC-EN - Connector Kit listing Connector Kit 19-130044 - Available for purchase from Westcor Pg 12 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 03-000050 rev A
FlatPAC-EN/EN MI Design Guide Interface Connections Chassis Input Power Terminals (MBJ1) Input AC power is applied through connector MBJ1 using Molex mating connector 39-01-4051. Use 16 AWG wire with Molex Socket Pin 39-00-0090 and Crimp Tool 11-01-0199. A fault clearing device, such as a fuse or circuit breaker, with a maximum 9A rating at the power supply input is required for safety agency compliance. It should be sized to handle the start-up inrush current of 8.
FlatPAC-EN/EN MI Design Guide Signal Ground on CBJ1-1 is an isolated secondary ground reference for all CBJ1 interfacing signals. This is not the same as Earth Ground on input power connector MBJ1. AC OK (CBJ1-3) AC OK is an active high TTL compatible signal and provides a status indication of the AC input power. It is on pin CBJ1-3 and is capable of sinking 16 mA maximum. This signal switches to a TTL "1" when the high voltage bus exceeds low-line condition during turn-on.
FlatPAC-EN/EN MI Design Guide This command turns all modules off. If either a Power Up or Power Down sequence is active at the time, it will be terminated immediately. A response of "OK" is returned. TON1, TON2, TON3, TON4 - Turn On commands for modules 1, 2, 3, or 4. These commands turn on the module identified by the trailing digit. If an automatic sequence is in effect at the time this command is received, a reply of "Inv Command" is returned; otherwise "OK" is returned.
FlatPAC-EN/EN MI Design Guide Enable/Disable Mode (CBJ1-8 and CBJ1-9) The Enable/Disable control pins allow outputs to be sequenced either on or off. CBJ1-4 through CBJ1-9 are the control pins for outputs 1 through 4. The Enable/Disable pins should be pulled low to less than 0.7V with respect to Signal Ground to disable the outputs. They will source 9mA maximum. These pins should be open circuited or allowed to exceed 4.5V when enabled. Do not apply more than 5V to these inputs.
FlatPAC-EN/EN MI Design Guide +Out +Sense Load Use 24-30 AWG Twisted Pair Wires -Sense -Out Figure 7: Remote Sense Note: Remote sense is not available for output configurations using the Micro modules. External Trim (Not applicable when using BatMod current source) The Trim pin can be used for external control of the output voltage. Trim connections on single and dual output connector for output M1 is J1-1 while for output M2 is J2-2.
FlatPAC-EN/EN MI Design Guide Consult Applications Engineering when trimming outputs below 5V.
FlatPAC-EN/EN MI Design Guide 2 VI-J00 modules only. OUTPUT (CONT’D.) Maxi/Mini/Micro Modules Parameter Setpoint Accuracy* Load Regulation MIN. MAX. UNITS ±0.5 ±1 % of VNOM ±0.01 Temperature Regulation Long Term Drift Output Ripple and noise: 0.002 Maxi Mini Micro Voltage Trim Range Maxi/Mini/Micro Slots Total Remote Sense Compensation OVP Set Point Current Limit Overtemperature Limiting TYP. 0.005 %/°C See module design guide for e exact specifications. -20 to 100°C 0.
FlatPAC-EN/EN MI Design Guide Output Power Derating Pg 20 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 03-000050 rev A
FlatPAC-EN/EN MI Design Guide Output Power Derating -continued All module configurations: The FlatPAC-EN/EN MI or an individual output may be limited by module power limitations. 1. One cannot exceed the output power rating of the FlatPAC-EN regardless of the module capability. 2. Also see Output Power vs. Input Voltage charts on page 21. 3. Please note that FlatPAC-EN configurations that uses Molex outputs connectors are limited to 9A/pin (27A per output).
FlatPAC-EN/EN MI Design Guide Thermal Curves for FlatPAC-EN/EN MI Pg 22 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 03-000050 rev A
FlatPAC-EN/EN MI Design Guide Thermal Curves for FlatPAC-EN/EN MI - continued 03-000050 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg.
FlatPAC-EN/EN MI Design Guide Thermal Curves for FlatPAC-EN/EN MI - continued Pg 24 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 03-000050 rev A
FlatPAC-EN/EN MI Design Guide Thermal Curves for FlatPAC-EN/EN MI - continued 03-000050 rev A Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 Pg.
FlatPAC-EN/EN MI Design Guide Current Share Boards - Optional Feature "Current sharing" also known as Load Sharing, is the ability to divide the output current evenly across all active power supplies. This greatly reduces stresses on each power supply and allows them to run cooler, resulting in higher reliability. Standard "current sharing" techniques typically utilize shunt resistors or Hall Effect devices to measure the current from each power supply.
FlatPAC-EN/EN MI Design Guide Current Share Boards - Optional Feature (contd) 0.13" (3.3mm) Dia Non Plated thru hole 4 places 1.74" (44.2mm) 2 1 4 3 6 5 Molex CT43045F surface mountable connector. .390" height above board. 1.500" (38.1mm) J1 Pinout Pin 1 2 3 4 5 6 Description P ow e r T1 -V1 T2 -V2 No Connection 0.12" (3.0mm) 0.12" (3.0mm) 0.900" (22.9mm) 1.14" (29.0mm) Figure 2. Mechanical Drawing 24.0" +/- 1.
FlatPAC-EN/EN MI Design Guide Notes Pg 28 Vicor 800-735-6200 Westcor Division 408-522-5280 Applications Engineering 800-927-9474 03-000050 rev A
FlatPAC-EN/EN MI Design Guide VICOR GLOBAL OFFICES USA EUROPE Vicor Corporation, Corporate Headquarters 25 Frontage Road Andover, MA 01810 Tel: 800-735-6200, Tel: 978-470-2900 Fax: 978-475-6715 Vicor France Tel: 33-1-3452-1830 Free Phone France Only: 0800 419 419 Fax: 33-1-3452-2830 Email: vicorfr@vicr.com Vicor Germany Tel: +49-89-962439-0 Free Phone Germany Only: 0800 018 29 18 Fax: +49-89-962439-39 Email: vicorde@vicr.com Vicor Corporation 377 E.
