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UG:110 vicorpower.com Applications Engineering: 800 927.9474 Page 1

Mini MegaPAC

AC-DC Switcher

USER GUIDE | UG:110

November 2013

Overview

The Mini MegaPAC AC-DC switcher allows users to instantly conﬁgure high eciency,

o-line power supplies that operate on either 115 or 230 Vac (47-500 Hz),

or 260-380 Vdc. Although small in size, (3.4"H x 6.0"W x 9.5”L), (85,8 x 153,4 x 241,3 mm),

the Mini MegaPAC provides up to 1,000 W of output power. The chassis has ﬁve slots

and can provide up to ten isolated outputs.

A complete power supply is conﬁgured at the factory by selecting and inserting up

to ﬁve same length slide-in output assemblies called ConverterPACs. ConverterPACs

incorporate one or two VI-200/VI-J00 and/or Maxi Vicor DC-DC converters and are

available in a wide array of output voltages and power levels. The net result is a power

supply that oers the advantages of a custom supply, but is assembled from standard

and modular building blocks. For detailed information about the ConverterPACs, refer

to the ConverterPAC data sheets. The ConverterPACs used in the Mini MegaPAC use VE-

2xx and VE-Jxx modules. In addition, there is a four output model called a FlexPAC that

uses discrete circuits to support low power needs.

Manufactured at Westcor, a division of Vicor, the entire family of MegaPAC power

supplies is completely user-conﬁgurable. If output requirements change, i.e., more

power or a dierent output voltage is needed, upgrading is easy: simply unlock a single

screw and replace the slide-in ConverterPAC assembly with one of the same length

and 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. Using the VSPOC conﬁgurator tool available on

vicorpower.com, anybody can now conﬁgure a Mini MegaPAC (and other Westcor

power supplies) online.

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 8

ConverterPAC Output 9

and Connector Pin

Identiﬁcation

Quick Install 10

Instructions

Mechanical Drawings 13

Interface Connections 14

Speciﬁcations 20

Output Studs 21

Connector Kit Contents 21

Current Share Boards 22

Low Leakage Version 25

Summary of content (27 pages)

PAGE 1
USER GUIDE | UG:110 Mini MegaPACTM AC-DC Switcher November 2013 Contents Page Overview of Product 1 Mechanical Considerations 2 MegaPAC Do’s and Don’ts 3 Technical Description 3 Configuring and Reconfiguring MegaPACs 5 ConverterPAC Description 6 Part Numbering 8 ConverterPAC Output and Connector Pin Identification 9 Overview Quick Install Instructions 10 Mechanical Drawings 13 Interface Connections 14 Specifications 20 Output Studs 21 Connector Kit Contents 21 Current Share Bo
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Standard Features n Input voltage: 90-132 or 180-264 Vac, 47-500 Hz, or 260-380 Vdc n Output power: 1,000 W @ 115 Vac or 230 Vac n Outputs: 5 slots (up to 10 outputs) n Full power output to 45°C; half power to 65°C n Fan cooled n Conducted EMI meets EN55022 Class A and B n AC Power OK status signal n RoHS compliant available n Output Sequencing and General Shutdown (Consult Applications Engineering for automatic sequencing circuitry) n Autosense (Refer to Page 10 and Page 14 for more information on Autos
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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. Use twisted pair 22-24 AWG wire. If ConverterPAC has Autosense, no local sense connection is required. See Page 10 and Page 14 for more information on Autosense. n If needed, use Connector Kit # 19-130040 for the Mini MegaPAC. n Always fill all output slots of the MegaPAC.
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rectifier/voltage doubler configuration. This operates as a full wave bridge rectifier on 230 Vac, or can be manually strapped for operation as a 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. Voltage conversion in the output assemblies is achieved by Vicor's family of Zero-Current-Switching (ZCS) DC-DC converters.
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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. (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). They are driver ConverterPACs and can be inserted into any available slot.
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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 AC input MegaPAC chassis. They can be added, moved, or changed as necessary. The following ConverterPACs are used in the Mini MegaPAC.
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ConverterPAC Functional Description (Cont.) FlexPAC The FlexPAC output assembly consists of from two to four 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.
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Part Numbering Mini MegaPAC MMxA-1xBxxxx eg. MM4-143605 MM = Mini MegaPAC Prefix xA = number of outputs 1 = Mini MegaPAC Chassis xB = number of modules + FlexPACs xxxx = assigned by Westcor ConverterPAC XxDV/xEAxF eg. M15V/10A eg. M15V/10ADFI eg. D15V/6.7A-12V/8.
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ConverterPAC Output and Connector Pin Identification for the Mini MegaPAC MODUPAC ModuPAC JuniorPAC RAMPAC J2 (REMOTE SENSE) + V0UT 1 2 3 J2-PIN1 MATING HDWR: TRIM PIN ACCESS HOUSING- MOLEX P/N: 50-57-9403 + SENSE TERMINALS- MOLEX P/N: 16-02-0103 CRIMP TOOL MOLEX P/N: 11-01-0118 - SENSE 0UTPUT ADJUST - VOUT J3 DC OK (POWER GOOD) 4 3 2 1 J3-PIN1 DUALPAC DualPAC J1-B-PIN1 J2-B-PIN1 OUTPUT ADJUST J1-A-PIN1 MATING HDWR: Vcc IN POWER GOOD POWER GOOD INVERTED SIGNAL GROUND J1 (OUTPUT CONNECTORS)
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Mini MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see Page 13) Mounting the Mini MegaPAC n The Mini MegaPAC can be mounted on any of four sides. n Use #8-32 or 4 mm mounting screws. Maximum penetration should not exceed 0.15” (3,8 mm). n Maintain 2” (5,1 cm) clearance at either end for airflow. n Maximum allowable torque is 20 lb-in. Input Connections S1 S2 L1/N L2 230 VAC AS IS -OR115 VAC WITH S1-S2 JUMPER DO NOT RUN W/O EARTH GROUND HERE.
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Mini MegaPAC “Quick Install” Instructions (Cont.) Sense Connector J2 1 2 3 Pin J2-1 Trim Pin Access J2-2 +Sense J2-3 -Sense Sense Connector Sense Connector J2: n Sense connections do not have to be made if the Local Sense option has been ordered. n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided. n J2-2 is the +Sense and J2-3 is the -Sense. n Attach terminals to 22-24 AWG twisted pair wire using Molex tool #11-01-0118.
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3 4 5 6 9 10 11 12 4 5 6 1 2 3 7 8 9 10 11 12 J10 INTERFACE OUT Mini PIN MegaPAC “Quick Install” Instructions (Cont.) E/D-1 J10-1 J10-2 E/D-2 J10-3 Interface E/D-3 Connections J10 E/D-4 J10-4 n Use Molex mating receptacle #39-01-2120 with #39-00-0039 terminals provided. J10-5 E/D-5 J10-6 n J10-1 NC to 8 are Enable/Disable for slots 1-8. J10-7 NC J10-8 n J10-9 NC is Vcc, J10-10 is Signal Ground, J10-11 is AC Power OK J10-9 VccJ10-12 +5V, 0.3Ais General Shutdown.
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HDWR: 3 9 2 8 1 7 5 6 10 11 12 4 vicorpower.com L2 230 VAC AS IS -OR115 VAC WITH S1-S2 JUMPER L1/N (SCALE: NONE) S2 INPUT LEGEND DO NOT RUN W/O EARTH GROUND HERE. 3 2 1 6 5 4 -RS - + +RS - + 1 & 4 +V OUT 2 & 5 -V OUT 3 +REMOTE SENSE 6 -REMOTE SENSE PIN DUAL MODUPAC OUTPUT CONNECTIONS J10-1 J10-2 J10-3 J10-4 J10-5 J10-6 J10-7 J10-8 J10-9 J10-1O J10-11 J10-12 2 1 6 5 4 -RS - + +RS - + 3 J9-1 J9-5 E/D-1 E/D-2 E/D-3 E/D-4 E/D-5 NC NC NC Vcc +5V, 0.
PAGE 14
Interface Connections Chassis Input Power Terminals (J9) Input AC power is applied to terminal block J9 using a pressure screw terminal that accepts a maximum wire size of 10 AWG. The maximum torque recommended is 10 lb-in. 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. Mini MegaPACs are normally shipped for operation from a 230 Vac source.
PAGE 15
Interface Connections (Cont.) Signal Ground (J10-10) Signal Ground (see Figure 4 and Connector Pin Identification on Page 9) is an isolated ground reference for all J10 interfacing signals, and can be used for ConverterPAC output status signals such as Power Good. This is not the same as Earth Ground on input power connector J9. Figure 4.
PAGE 16
Interface Connections (Cont.) AC OK / Power Fail (J10-11) This is an active high TTL compatible signal and provides a status indication of the AC input power (see Figure 6 and Connector Pin Identification on Page 12). It is capable of sinking 20 mA maximum. This signal switches to a TTL “1” when the high voltage bus exceeds low-line condition during turn-on, and switches to a TTL “0” 3 ms (minimum) before loss of output regulation due to the loss of input AC power.
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Interface Connections (Cont.) Power Good (J3-2) The optional Power Good signal on J3-3 is referenced to Signal Ground on J3-1, and indicates the status of the output voltage. This signal is asserted a TTL “1” when the output voltage is above 95% of nominal. It is a TTL “0” when the output voltage is below 85% of nominal. If the Trim option is also used, the Power Good trip points DO NOT track with the trimmed voltage.
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Interface Connections (Cont.) Figure 9. Sense Leads (Local Sense) +P +Out (Remote Sense) J2-2 +Sense Load Use 22-24 AWG Twisted Pair Wires J2-3 -Sense -P -Out External Trim (J2-1) Output voltage can be trimmed using an optional factory-installed Trim potentiometer or with the Trim pin (see Figure 10). The Trim potentiometer is located on the ConverterPAC. If the Trim potentiometer has not been ordered, the Trim pin must be used.
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Interface Connections (Cont.) Figure 10. External Trim +P +Out Use 22-24 AWG Twisted Pair Wires (Remote Sense) R1 J2-2 +Sense To Error Amplifier + RTH R5 V1 V Ref - R8 R2 J2-1 R3 R6 + V2 R7 Load - J2-3 -Sense R4 -P -Out Use 22-24 AWG Twisted Pair Wires Example: ±10% Trim adjust on a 12 V nominal output. Figure 10 shows a typical variable Trim circuit. Using a 10 k trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: V1= Vref + 10% = 2.75 V Given: Vref = 2.
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Specifications Input Characterisitcs Input Voltage 90-132 Vac, 180-264 Vac; 47-500 Hz; 260-380 Vdc Power Factor (passive) 0.
PAGE 21
New Output Studs New, more robust output studs (with a 3:1 safety margin @ 45 in. lbs.) were installed in ConverterPACs, the slide-in assemblies used in the MegaPAC Family. These new outputs studs are 1/8" longer to allow for multiple lugs. They are fully compatible with the original flanged nut ConverterPACs for use in parallel arrays.
PAGE 22
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.
PAGE 23
Current Share Boards - Optional Feature (Cont.) Requirements: 1. For proper operation, the power supplies being paralleled should be enabled at the same time. 2. -Out conductors must be of equal length and wire gauge. Separate -Out conductors must be used from each supply to the load, or the use of a "Y" connection to a common point must be used as shown in Figure 11. Each leg of the "Y" must have a minimum of a few millivolts of drop in order for proper operation.
PAGE 24
Current Share Boards - Optional Feature (Cont.) 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 12. Mechanical Drawing 24.0" +/- 1.
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Low Leakage Version If Low Leakage is required, the MegaPAC family of power supplies has a model variant (must be requested). This model enables the user to meet various additional specifications. Presently, the PFC MegaPAC, Mini MegaPAC and Autoranging MegaPAC are available in Low Leakage versions. Other models can be made available.
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NOTES: UG:110 vicorpower.com Applications Engineering: 800 927.
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For Vicor Global Office Locations, please go to: http://www.vicorpower.com/contact-us or call 800-735-6200. For more information about this or other Vicor products, or for assistance with component-based power system design, contact the Vicor office nearest you. Vicor's comprehensive line of power solutions includes modular, high-density DC-DC converters and accessory components, configurable power supplies, and custom power systems.