USER GUIDE | UG:119 PFC MegaPAC-ELTM PFC MegaPAC-HPELTM Power Factor Corrected AC-DC Switchers January 2009 Contents Page Overview of Product 1 Mechanical Considerations 3 MegaPAC Do’s and Don’ts 3 Technical Description 4 Configuring and Reconfiguring MegaPACs 5 ConverterPAC Description 6 Overview ConverterPAC 10 Output and Connector Pin Identification Quick Install Instructions 11 Mechanical Drawings 14 Interface Connections 15 Specifications 22 Power Derating 24 Connector Kit Li
voltages (total output voltage should not exceed 400 V). The driver is to the left of the boosters when looking at the output end of the supply. A user-friendly interface provides control and output sequencing capability (see Page 16 for more information about this capability), in addition to useful status indicators. Please consult our Applications Engineering Department if you have other special requirements. Standard Features n Power Factor Correction; 0.99 at 115 Vac, 0.
Mechanical Considerations The PFC MegaPAC-EL and PFC MegaPAC-HPEL can be mounted on any of four surfaces using standard 8-32 or 4 mm 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. (3.8 mm). When selecting a mounting location and orientation, the unit should be positioned so air flow is not restricted.
n For power expansion, use booster ConverterPACs. Viewing the unit from the output terminal side, always insert boosters to the right side of the driver. n Do not use boosters as independent outputs. Disconnecting bus bars will damage booster ConverterPACs. n For booster arrays, do not remove busbars. n Always ensure that output hex-nuts are properly torqued before applying power to supply. n Run the output (+/–) power cables next to each other to minimize inductance.
comes up within two seconds after the application of input power. Once the high voltage bus is within its limits, the AC OK signal asserts to a TTL “1” indicating the input power is OK, and enables the power outputs. An auxiliary Vcc output of 5 Vdc sourcing up to 0.3 A is provided for peripheral use. An output Enable/Disable function is provided by using an optocoupler to control the Gate In pins of the ConverterPAC assemblies.
Installing ConverterPACs as Drivers ConverterPACs can be installed in empty slots by simply sliding in the new ConverterPAC and securing the screw at the base. Power and interface connections can be made after the ConverterPAC has been installed. Installing Booster ConverterPACs to Increase Output Power ConverterPACs can be paralleled for more power. Additional power to an output is obtained by connecting one or more boosters in parallel with a single driver. The driver can be placed in any open slot.
module increases, the preload removes itself from the circuit. QPACs, using the VI-200 module, have an optional DC OK TTL signal. All QPACs have overcurrent protection with automatic recovery when the overcurrent condition is removed. Overvoltage Protection (OVP) and Overtemperature Limiting (OTL) are available. Please note that for the QPAC (L) the output voltage from either output terminal to chassis should not exceed 400 Vdc, or peak.
List of ConverterPACs used in the PFC MegaPAC-EL and PFC MegaPAC-HPEL Low Noise and their features ConverterPAC OVP OCP OTL RS/AS* LS/AS* PG TrimPot QPAC (L) Std Std Std AS* AS* Opt Opt DualQPAC (LD) N/A Std N/A AS* AS* Opt N/A JuniorQPAC(LJ) N/A Std N/A AS* AS* Opt Opt FinQPAC(PZL)+ Std Std Std AS* AS* Opt Opt OVP Overvoltage Protection (latching) RS Remote Sense OCP Overcurrent Protection (auto-recovery) LS Local Sense OTL Overtemperature Limiting AS Au
ConverterPAC XxDV/xEAxF ex. L15V/10A X = ConverterPAC type (For RoHS, add G to current prefix) xD = voltage out xE = current out (rounded to 1 decimal point) xF = Can be multiple options* (see Page 9) Part Numbering (Cont.) * ConverterPAC options B Booster module M Military Grade module D DC OK or Power Good1 R RAM external3 F Full 50-110% output adjustment2 S Trimpot removed for external F1 50-107.
QPAC VI-200 MODULE ConverterPAC Output and Connector Pin Identification QPAC JuniorQPAC J2 REMOTE SENSE TRIM/SC & POWER GOOD + V0UT MATING HDWR: HOUSING- MOLEX P/N: 39-01-0073 TERMINALS- MOLEX P/N: 39-00-0031 CRIMP TOOL MOLEX P/N: 57005-5000 OUTPUT ADJUST - VOUT DUAL QPAC 7 6 5 4 3 2 1 J2-PIN1 DualQPAC J1-B-PIN1(M1) J2-PIN1 7 6 5 TRIM TOP TRIM BOT N/C J1-B +SENSE -SENSE TRIM Vcc IN POWER GOOD POWER GOOD INVERTED SIGNAL GROUND (OUTPUT CONNECTORS) 1 AND 4 +V OUT 4 5 1 2 2 AND 5 -V OUT 6 3 3
PFC MegaPAC-EL and -HPEL “Quick Install” Instructions (For Mechanical Drawing, see Page 14) Mounting the PFC MegaPAC-EL and PFC MegaPAC-HPEL n Mount the power supply on any of its four sides. n Use #8-32 or 4 mm mounting screws. Do not exceed a maximum penetration of 0.15" (3,8 mm). The maximum allowable torque is 20 lb-in. n Maintain 2" (5,1 cm) clearance at either end for airflow.
Sense Connector J2 (and P2 for the FinQPAC): J2-PIN1 n Sense connections do not have to be made if either the Local Sense option was 7 6 5 TRIM TOP 4 3 2 1 Vcc IN POWER GOOD TRIM BOT N/C POWER GOOD INVERTED SIGNAL GROUND J2/P2 Sense Connectors ordered (older units) or if Autosense is present (see previous note on Autosense.) n Attach opposite ends of Sense lines to point where regulation is desired. n Verify that Sense lines are not cross-connected before applying input power.
7 6 5 4 3 2 1 +SENSE DC OK (Power Good) Connection J2 (and P2 for FinQPAC) -SENSE n DC OK is only available as an option and is not present unless requested. TRIM Vcc IN POWER GOOD POWER GOOD INVERTED SIGNAL GROUND DC OK/Power Good Connection on the J2 /P2 Connector 5 6 2 3 4 7 8 9 10 11 12 n Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided. n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.
UG:119 47 TO 500 Hz LABEL NO: 94-00046 REV B vicorpower.com 47 TO 500 Hz L2 Applications Engineering: 800 927.9474 ORIGINAL FLANGED NUT RE-DESIGNED OUTPUT PANEL AND STUDS LABEL NO: 94-00046 REV B .25 [6.35] BRASS INSERT 2.75 [69.85] (T0P AND BOTH SIDES) CUSTOMER MOUNTING HOLES (16X) M4 OR #8-32 THREAD MAXIMUM SCREW PENETRATION .150 [4.00 MM] FROM OUTSIDE SURFACE. 10.01 [254.25] (ORIGINAL LENGTH) 15.50 [393.63] 10.01 [254.25] (RE-DESIGNED LENGTH) 15.62 [396.81] 10.01 [254.25] 1.40 [35.
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 14 AWG. The insulation should be stripped 0 .35 inches and the maximum torque applied to the screws should not exceed 4.4 lb-in. The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N 32-00-58-0, purchased from other sources) can be used to prevent fraying.
Signal Ground (J10-10) Signal Ground (see Figure 4 and Connector Pin Identification below) 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.
Enable/Disable control of Maxi Module Arrays When using the Enable/Disable function on an output that consists of two or more Maxi modules, it is necessary to connect the E/D pins of the corresponding module locations together such that both modules are commanded to turn ON or OFF simultaneously. Example: Slots 2, 4 and 6 have been configured as a single output parallel array (see Fig. 6) In order to disable the 48V output, E/D 2, E/D 4 and E/D 6 should be shorted together as shown in Fig. 6.
Figure 7. J10 AC OK Power Fail +5V 10K 2.49K 11 AC Power OK PN2222 10 Signal Ground Auxiliary Vcc +5V/0.3A (J10-9) The Vcc on J10-9 is an auxiliary 5 V regulated power source (see Figure 8 and Connector Pin Identification on Page 16). It is +5 Vdc +/–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.
Power Good Inverted (J2-2/P2-2) This is the inverse of the Power Good signal and is referenced to Signal Ground on J2-1/P2-1. Signal Ground (J1-1/P2-1) Signal Ground on J2-1/P2-1 is an isolated secondary ground reference for J2/P2 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.
External Trim (J2-5/P2-5) Output voltage can be trimmed using an optional factory-installed Trim potentiometer or with the Trim pin (see Figure 11). The Trim potentiometer is located on the ConverterPAC. If the Trim potentiometer has not been ordered, the Trim pin must be used. When using the Trim pin, the Trim limits are determined by the DC-DC converter used on the ConverterPAC.
Example: ±10% Trim adjust on a 12 V nominal output. Figure 11 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 = 2.5 V (see Table 1) IR5 = (2.75 V - Vref)/RTH = (2.75 V - 2.5 V)/10 kW = 25 mA Setting the bottom limit: VR6 = 2.5 V - 10% = 2.25 V And since IR5 = IR6 = 25 mA, R6 = VR6/IR6= 2.25 V/25 mA = 90 kW V2 = V1 + VR6 = 2.75 V + 2.
Specifications Input Characterisitcs Input Voltage 85-264 Vac, 47-500 Hz 100-380 Vdc Power Factor 0.99 @ 115 Vac ; 0.95 @ 230 Vac Inrush Current 25 A pk @ 115 Vac and 230 Vac Ride Through Time > 20 ms at nominal line, full load Power Fail > 3 ms warning Conducted EMI EN55022 Class A; FCC Class A (Certain configurations meet B. Contact factory.
Specifications (Cont.) Environmental Characteristics Storage Temperature -40°C to 85°C Derate 2.6% total output power for each 1,000 ft to a maximum operating Altitude altitude of 15,000 ft. Non-operating storage maximum altitude is 40 K.
Output Power Derating Output Power vs Input Voltage (Vac) (47 - 500 Hz) 2,400 W @ 200 Vac Output Power (Watts) 2400 2200 Derate at 12W/volt Power Exceeded 2000 1800 1600 1400 Safe Operating Area 1200 1000 85 95 105 125 145 165 185 200 215 235 255 265 Input Voltage (Vac or Vdc) (For VDC, 100 V min applies) PFC MegaPAC-EL/HPEL Connector Kit (19-130040) Listing Item Qty 1 1 12 2 ** 3 8 Description Vendor #1 Part # HOUSING 12 POS.
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.
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 12. Each leg of the "Y" must have a minimum of a few millivolts of drop in order for proper operation.
Current Share Boards - Optional Feature (Cont.) 0.13" (3.3mm) Dia Non Plated thru hole 4 places 1.74" (44.2mm) 1 3 6 5 Molex CT43045F surface mountable connector. .390" height above board. 1.500" (38.1mm) J1 Pinout Pin Description 2 T1 3 -V1 4 T2 5 -V2 6 No Connection 1 2 4 Power 0.12" (3.0mm) 0.12" (3.0mm) 0.900" (22.9mm) 1.14" (29.0mm) Figure 13. Mechanical Drawing 24.0" +/- 1.
Output Sequencing Using the MegaPAC's standard Input Interface Connector (J10) along with the ConverterPAC's optional DC OK Option, it is possible to implement unique output voltage power up and power down sequences. Below is an example showing how this may be done. Requirement: 5 V must start before the 3.3 V output. If the 5 V output is lost, the 3.3 V output must turn off.
Figure 16. J3 DC OK Connector DC OK (Power Good) J3 4 3 2 1 Pin J3-4 J3-3 J3-2 J3-1 Vcc Power Good Power Good Inverted Signal Ground 3 4 Figure 17. Output Sequencing Wire Interconnect 1 2 5 6 7 8 6 12 5 11 4 10 3 9 2 8 1 7 L L 1 2 3.3V Output 5V with "D" option (DC OK) UG:119 vicorpower.com Applications Engineering: 800 927.
Output Sequencing (Cont.) Channel #1: 5 V Output Channel #2: 3.3 V Output Channel #3: 5 V DC OK signal Figure 18. Startup Waveforms 5V Output 3.3V Output 5V DC OK Figure 19. Shutdown Waveforms 5V Output 3.3V Output 5V DC OK UG:119 vicorpower.com Applications Engineering: 800 927.
NOTES: UG:119 vicorpower.com Applications Engineering: 800 927.
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