VICOR 4kW MegaPAC User Manual Download

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For more information about this or other Vicor products, or for assistance with component-based power

system design, contact the Vicor office nearest you. The Vicor comprehensive line of power solutions

includes modular, high-density DC-DC converters and accessory components, configurable power

supplies and custom power systems. Vicor designs and builds configurable power supplies incorporating

its high-density DC-DC converters and accessory components.

This product line includes:
LoPAC™ Family:

PFC MicroS

PFC Micro

PFC Mini

MegaPAC™ Family:

PFC MegaPAC™

4kW MegaPAC

PFC MegaPAC (High Power)

PFC MegaPAC (Low Noise/High Power)

PFC MegaPAC-EL™ (Low Noise)

Mini MegaPAC™

ConverterPACs™

Others:

FlatPAC-EN™

Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini and PFC MegaPAC.

Summary of Contents for 4kW MegaPAC

Page 1: ...If output requirements change i e more power or a different output voltage is needed upgrading is easy simply unlock a single screw and replace the slide in ConverterPAC with one of the same length and has the desired voltage power rating For additional flexibility same length ConverterPACs can be connected in parallel to increase output power booster ConverterPACs or in series for higher voltages...

Page 2: ...egaPAC and 4kW MegaPAC can be mounted on any of four surfaces using standard 8 32 or 4mm screws The chassis comes with four mounting points on each surface maximum allowable torque is 20lb in The maximum penetration is 0 15in 3 8mm When selecting a mounting location and orientation the unit should be positioned so air flow is not restricted Maintain a two inch minimum clearance at both ends of the...

Page 3: ...he output terminal side always insert boosters to the right side of the driver n n Do not use boosters as independent outputs Disconnecting bus bars will damage booster ConverterPACs n n Always ensure that output hex nuts are properly torqued before applying power to supply n n For booster arrays do not remove bus bars n n Run the output power cables next to each other to minimize inductance n n W...

Page 4: ... power is recycled This occurs when the peak input current reaches 30A An analog temperature monitor is provided as well as overtemperature shut down An active high TTL compatible Enable control is included for each ConverterPAC assembly as well as an active low General Shut Down control the polarities active high or active low are factory set The 3 Phase MegaPAC and 4kW MegaPAC can be safely para...

Page 5: ...ly 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 Torque the retaining screw to 0 23N m 2lb in do not overtighten Power and interface connections can be made after the ConverterPAC has been installed Installing Booster ConverterPACs to Increase Output Power ConverterPACs can be parallele...

Page 6: ...nsists of a VI J00 Vicor DC DC converter with a Ripple Attenuator Module RAM and is designed for applications requiring low output ripple noise BatPAC The BatPAC output assembly consists of a VI 200 BatMod current source that converts the unregulated high voltage bus to the desired regulated output voltage The BatPAC is a 200W programmable current source that can be configured as a battery charger...

Page 7: ...rPAC and RamPAC List of ConverterPACs used in the 3 Phase 4kW MegaPACs and their features ConverterPAC OVP OCP OTL RS AS a LS AS a PG TrimPot ModuPAC Std Std Std AS a AS a Opt Opt JuniorPAC N A Std N A AS a AS a Opt Opt DualPAC N A Std N A AS a AS a N A Opt RamPAC N A Std N A AS a AS a Opt Opt BatPAC N A Std N A N A N A N A Std UniPAC b Std Std N A AS a AS a Opt Opt a See Pages 13 and 17 for more ...

Page 8: ... SENSE 6 R SENSE 1 2 J1 TERMINALS MOLEX P N 39 00 0039 HOUSING MOLEX P N 39 01 2060 CRIMP TOOL MOLEX P N 63819 0901 MATING HDWR 6 5 4 2 AND 5 VOUT DUALPAC VOLTAGE LIMIT ADJUST J2 BATPAC REMOTE INTERFACE CURRENT MONITOR CURRENT LIMIT ADJUST VOUT VOLTAGE LIMIT ADJUST 1 VOUT 3 2 4 J2 PIN1 CURRENT LIMIT ADJUST CRIMP TOOL MOLEX P N 63828 1900 TERMINALS MOLEX P N 80 70 1040 HOUSING MOLEX P N 50 37 5043 ...

Page 9: ...SE TRIM CRIMP TOOL MOLEX P N 63828 1900 UNIPAC J2 PIN1 J3 PIN1 0UTPUT ADJUST VOUT VOUT REMOTE SENSE J2 2 1 3 SENSE SENSE MATING HDWR TRIM PIN ACCESS 3 POWER GOOD 2 1 SIGNAL GROUND POWER GOOD INVERTED MATING HDWR 4 J3 DC OK POWER GOOD VCC IN HOUSING MOLEX P N 50 57 9403 TERMINALS MOLEX P N 16 02 0103 CRIMP TOOL MOLEX P N 63811 8700 HOUSING MOLEX P N 50 37 5043 TERMINALS MOLEX P N 08 70 1040 CRIMP T...

Page 10: ...x2 number of modules xxxx assigned by Vicor x3 Optional Code 2 VI J00 or VI 200 module in slot 1 3 Maxi in Slot 1 x4 Optional Code 2 VI J00 or VI 200 module in slot 10 3 Maxi in Slot 10 x5 Optional Code x6 Optional Code ConverterPAC XxDV xEAxF e g M15V 10A e g M15V 10ADF e g D15V 6 7A 12V 8 3AT X ConverterPAC type If RoHS precede with a G M ModuPAC D DualPAC R RamPAC J JuniorPAC B BatPAC XU UniPAC...

Page 11: ...put adjustment F9 100 110 output adjustment V1 VXI low noise 150mV 15V VOUT 24V outputs g I H I H Grade module V2 VXI low noise 50mV VOUT 15VDC K Custom SRF module used V3 1 ripple for outputs 24V c D option Optional for all ConverterPACs EXCEPT the DualPAC BatPAC d F option Optional for all ConverterPACs EXCEPT the BatPAC and DualQPAC e R option When using an external RAM components such as autos...

Page 12: ... for safety reasons Output Connections Power Connections Installing ring lugs and or bus bars on output studs n n The upper stud is Positive and the lower stud is the Return n n Remove outer nut Do not remove or loosen inner nut n n Place ring lug over output stud n n Replace and tighten outer nut to a maximum torque of 45lb in Do not over tighten nuts n n Verify all output nuts are properly insta...

Page 13: ... tool 63811 8700 n n Attach opposite ends of Sense lines to point where regulation is desired n n Verify that Sense lines are not cross connected before applying input power n n For the UniPAC P2 7 is the SENSE and P2 6 is the SENSE n n Use Molex mating receptacle 50 37 5073 with 08 70 1040 terminals provided n n Attach terminals to 22 28AWG stranded wire using Molex tool 63828 1900 Sense Connecto...

Page 14: ...ating receptacle 50 37 5073 with 08 70 1040 terminals provided n n Attach terminals to 22 28AWG stranded wire using Molex tool 63828 1900 Interface Connections J10 n n J10 7 to 11 and J10 20 to 24 are Enable Disable for slots 1 10 n n J10 16 17 are VCC J10 12 and 15 are Signal Ground J10 18 is AC Power OK and J10 5 is General Shut Down Gate 1 Input isolated 25 J10 INTERFACE CONNECTOR IDENTIFICATIO...

Page 15: ...65 1mm 6 75 57 2mm 171 5mm 4 90 124 5 MM P8 TYP P8 P1 P1 BUS BARS FOR PARALLEL OUTPUTS BUS BAR FOR SERIES OUTPUTS DUAL CONVERTERPAC NO POWER GOOD OPTION AVAILABLE AIR BLOCK EXAMPLE J2 PIN1 J3 PIN1 R4 TRIMPOT PRESENT WHEN ADJUSTABLE OUTPUT OPTION IS SPECIFIED R12 R4 C L L C J2A PIN1 SAME AS J2 SAME AS J2 J2B PIN1 1 J1A PIN1 DUALPAC J1B PIN1 DUALPAC TYP TYP TYP NO 54489 4 HOUSING FOR 3 PHASE INPUT W...

Page 16: ...ATES WITH HSG AMP NO 747547 2 PLUS SLIDE 2 OUTER NUT ONLY FOR FLAT RIBBON CABLE AMP NO 746862 2 PLUG LATCH OR SIMILAR MATING HSG IS AMP NO 54483 4 AND CONTACTS ARE AMP 53892 5 CRIMP OR AMP NO 54329 1 SOLDER DO NOT LOOSEN OR TIGHTEN INNER NUTS J3 PIN1 POWER 3 AIR FLOW STANDARD 9 SP 7285 6 56 166 6mm 18 5mm 1 40 25 6 35mm L3 1 15 29 2mm 54 13 7mm L2 L1 2 068 1 852 240 6 1mm 12X 1 8 X 1 2 SLOTS 1 852...

Page 17: ...utput current including short circuit levels Avoid large current loops in output cables run power and return cables next to one another to minimize inductive effects All outputs are isolated and can provide positive or negative outputs Output SENSE Connections J2 for Single Output or J1A J1B for Dual Outputs Newer power supplies may have some outputs configured with the Autosense feature that auto...

Page 18: ...es allow ConverterPAC outputs to be sequenced either on or off For DualPACs both outputs are sequenced In parallel arrays only the driver ConverterPAC needs to be sequenced The GSD control line on J10 5 allows simultaneous shut down of all ConverterPAC outputs An internal factory configured jumper selects polarity either active high or active low Another jumper selects a pull up or pull down sourc...

Page 19: ...simplest method of remotely enabling and disabling the output is to use the General Shut Down GSD function Figure 6 Enable Disable control of Maxi arrays L1 L2 L3 14 1 2 15 16 3 4 17 18 5 6 19 20 7 8 21 22 9 10 23 24 11 12 25 13 1 2 3 4 5 6 7 8 10 9 Figure 7 AC OK Power Fail 10kΩ 1 2 12 15 Signal Ground 19 AC Power Fail 5V J10 2 49kΩ 2N2222 2 49kΩ 2N2222 2N2222 14 Phase Fail 18 AC Power OK 4 99kΩ ...

Page 20: ...nd can be used to provide input to the Gate In or PC pin of the ConverterPAC in slot 1 of a different 3 Phase MegaPAC or 4kW MegaPAC The ConverterPAC in slot 1 of the second chassis must be a booster and additional boosters can be connected in parallel to it The ConverterPAC in slot 10 of the first 3 Phase MegaPAC or the 4kW MegaPAC must be either a driver or a booster in a parallel array Converte...

Page 21: ...e connected to the J3 1 Signal Ground pin of the ConverterPAC Figure 8 Auxiliary VCC 78M05 Auxiliary VCC 16 17 0 1µF Signal Ground J10 1 2 12 15 5V 300mA Figure 9 Power Good and VCC Signal Ground 2 VCC IN 4 J3 10kΩ 2 49kΩ 2N2222 2 49kΩ 1 Power Good 3 Power Good Inverted ConverterPAC Power Good J3 3 The optional Power Good signal on J3 3 is referenced to Signal Ground on J3 1 and indicates the stat...

Page 22: ...e Power OUT terminal Do not reverse or leave the sense pins open Sense pins can be terminated locally at the output of the power supply in which case the power supply will provide regulation at the output terminals The voltage appearing at the load may drop slightly due to voltage drop in the power cables If it is necessary to compensate for voltage drop along the output power cables this terminat...

Page 23: ...gaPAC The Trim pin on J2 can be used to control the output voltage It is referenced to the SENSE pin on J2 and can be controlled by either a resistor network or an external voltage source To increase an output voltage above its nominal it is necessary to increase the voltage at the Trim pin above the internal reference voltage VREF The reverse is true to decrease an output voltage Note Converters ...

Page 24: ...R6 2 5V 10 2 25V And since IR5 IR6 25mA R6 VR6 IR6 2 25V 25mA 90kΩ V2 V1 VR6 2 75V 2 25V 5V IR7 V2 R7 5V 10kΩ 500mA IR8 IR7 IR6 525mA VR8 VNOM 10 V2 13 2V 5V 8 2V Given VNOM 12V R8 VR8 IR8 8 2V 525mA 15 62kΩ Using the previous resistor combination a 12V output can be trimmed externally up to 13 2V and down to 10 8V For further information on external trimming refer to Chapter 5 of the Applications...

Page 25: ...ltages 2 for special adjustable voltages and 48VDC outputs Ripple and Noise Std outputs 2 or 100mVP P max whichever is greater 10 min load VXI options 50mVP P 15VDC 150mVP P max for 15V 24V 1 ripple for 24V RamPAC 10mVP P max or 0 15 whichever is greater UniPAC see Vicor module specifications Output Trim Range 10 110 of nominal voltage Maxi modules 50 110 of nominal voltage VI 200 VI J00 modules 9...

Page 26: ...ween the Negative Output power rails This accuracy translates to a 1 current sharing if there is a total of 100mV conductional voltage drop in the negative return path Constructed as a current source to drive the Trim pin of a Vicor module the design uses an accurate comparator circuit to monitor the power returns In addition the circuit is unidirectional and can only trim an output voltage up The...

Page 27: ...lts of drop in order for proper operation 50 100mV of drop will provide from 5 to 1 accuracy 3 V1 and V2 for all box to box circuits must be connected directly at the negative output power studs or terminals to achieve accurate current sharing 4 D can be added if redundancy is needed If redundancy is not required D can be replaced with direct wire connections 5 When using D the Power input should ...

Page 28: ...V1 T2 V2 Red 22AWG Yellow 22AWG Brown 22AWG White 22AWG Black 22AWG 1 2 3 4 5 6 1 74 44 2mm 0 12 3 0mm 1 500 38 1mm 0 12 3 0mm 0 900 22 9mm 1 14 29 0mm 0 13in 3 3mm Dia Non Plated thru hole four places Molex CT43045F surface mountable connector 0 390in height above board Pin Description 1 P o w e r 2 T1 3 V 1 4 T2 5 V 2 6 No Connection J1 Pinout P1 24 0 1 0 Power T1 V1 T2 V2 Red 22AWG Yellow 22AWG...

Page 29: ...n the EMI filter of the MegaPAC as well as the Y capacitors on the input of the ConverterPACs This reduces the leakage current from the AC input to AC ground chassis to below 500mA At the same time since the Y capacitors are a vital component of the EMI filter without them the EMI will go up When this happens the unit will no longer meet the Vicor published specifications for conducted EMI In orde...

Page 30: ...d custom power systems Vicor designs and builds configurable power supplies incorporating its high density DC DC converters and accessory components This product line includes LoPAC Family n n PFC MicroS n n PFC Micro n n PFC Mini MegaPAC Family n n PFC MegaPAC n n 4kW MegaPAC n n PFC MegaPAC High Power n n PFC MegaPAC Low Noise High Power n n PFC MegaPAC EL Low Noise n n Mini MegaPAC n n Converte...

Page 31: ...r the Vicor product is suitable and fit for your applications and products and to implement adequate design testing and operating safeguards for your planned application s and use s VICOR PRODUCTS ARE NOT DESIGNED AUTHORIZED OR WARRANTED FOR USE IN LIFE SUPPORT LIFE CRITICAL OR SAFETY CRITICAL SYSTEMS OR EQUIPMENT VICOR PRODUCTS ARE NOT CERTIFIED TO MEET ISO 13485 FOR USE IN MEDICAL EQUIPMENT NOR ...

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