VICOR FlatPAC-EN Design Manual Download Page 1

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FlatPAC-EN™ and FlatPAC-EN MI
EN Compliant Autoranging Switchers

FlatPAC-EN/EN MI Design Guide

Design Guide

and

“Quick Install” Instructions

www.vicorpower.com

Rev. 2/2012

Vicor 800-735-6200

Westcor Division 408-522-5280 Applications Engineering 800-927-9474

Summary of Contents for FlatPAC-EN

Page 1: ...MI EN Compliant Autoranging Switchers FlatPAC EN EN MI Design Guide Design Guide and Quick Install Instructions www vicorpower com Rev 2 2012 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 ...

Page 2: ... Install Instructions 7 Mechanical Drawings 10 Output connector information 11 Connector Kit listing 12 Interface Connections 13 RS 232 Microcontroller 14 Specifications 18 Output vs AC DC Voltage Graphs 20 Thermal Curves 22 Current Share Boards 26 Pg 2 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 2 2012 FlatPAC EN EN MI Design Guide ...

Page 3: ...mpliant to EN61000 4 4 Electrical Fast Transient Burst and EN61000 4 5 Surge Immunity MI version meets Mil STD 810 for Shock and Vibration with extended temp range MI version also available with 40C temp rating Efficiency typical 70 Autosense3 RS 232 microcontroller interface Output overcurrent protection on all outputs Size 1 4 H 35 6mm x 5 0 W 127 0mm x 9 2 L 233 7mm Safety Agency Approvals cURu...

Page 4: ...n lbs For applications that require vibration levels above MIL STD 810E minimum integrity test a shock absorbing mount design is required FlatPAC EN EN MI Do s and Don ts Do not exceed an operating case temperature of 90oC To prevent an overtemperature condition an external fan may be required Run the output power cables next to each other to minimize inductance Always turn the power supply off be...

Page 5: ... charged up the bus capacitors within the specified range 205Vdc 390Vdc Approximately 1 second after the application of the input voltage the bus volt age is within operating limits and the AC OK signal asserts to a TTL 1 indicating the input power is OK After AC OK is asserted high the user can now control the power outputs Output voltage conversion is achieved by Vicor s 300Vin family of Zero Cu...

Page 6: ... Mini Single or Dual Outputs Stud Connectors Single Dual orTriple Outputs Two 18 pin Molex Connectors Single Dual Triple or Quadruple Outputs Two 18 pin Molex Connectors For a single output configuration either M1or M2 is used assumes either a full brick and or half brick is used assumes only half bricks are used Note The type of output connector a FlatPAC EN has depends on which modules are used ...

Page 7: ... from the output end Remove the nut and place ring lug over output stud Replace and tighten the nut to a torque of 10 inch pounds Do Not Over Tighten Nuts Installing power connectors on outputs with 18 pin Molex connectors only half bricks used The output M1 slot accepts either a Mini or a Junior module J2 7 J2 8 J2 16 are positive while pins J2 9 J2 17 and J2 18 are the returns J2 1 J2 2 J2 3 J2 ...

Page 8: ...d J3 for outputs 2 and 3 For Output M1 J2 13 is the Sense and J2 15 is the Sense For Output M2 J3 13 is the Sense and J3 15 is the Sense For Output M3 J3 4 is the Sense and J3 5 is the Sense Use Molex mating receptacle 39 01 2180 with 39 00 0039 terminals Attach 18 24 AWG stranded twisted pair wire using Molex tool 11 01 0197 Sense Connections on 18 pin output connectors only half and or quarter b...

Page 9: ...CBJ1 1 is Signal Ground and CBJ1 3 is AC OK CBJ1 4 is the Transmit and CBJ1 5 is the Receive functions for the RS 232 command protocol CBJ1 4 thru 9 are Enable Disable CBJ1 10 is General Shutdown and CBJ3 12 is 5VS For the FlatPAC EN CBJ1 2 and CBJ1 11 are not connected Use Molex mating receptacle 50 57 9412 with 16 02 0097 cinch pins Attach 24 30 AWG stranded wire using Molex tool 11 01 0209 Thes...

Page 10: ...CBJ1 3 ACOK AC POWER OK CBJ1 4 TX TRANSMIT CBJ1 5 RX RECEIVE CBJ1 6 E D 4 ENABLE DISABLE CBJ1 7 E D 3 ENABLE DISABLE CBJ1 8 E D 2 ENABLE DISABLE CBJ1 9 E D 1 ENABLE DISABLE CBJ1 10 GSD GENERAL SHUTDOWN CBJ1 11 N C N C CBJ1 12 5VS 5V 300mA 3 2 1 REFERENCE DESIGNATION NOTES UNLESS OTHERWISE SPECIFIED MB MOTHER BOARD CB CONTROL BOARD CONNECTOR PART NUMBERS SPECIFIED ARE MOLEX OR EQUIVALENT A COMPLETE...

Page 11: ...UT M1 17 V OUT M1 18 V OUT M1 PIN DESCRIPTION 1 N C 2 N C 3 N C 4 N C 5 N C 6 TRIM M1 7 V OUT M1 8 V OUT M1 9 V OUT M1 Outputs M1 10 V OUT M3 11 V OUT M3 12 V OUT M3 13 SENSE M2 14 TRIM M3 15 SENSE M2 16 V OUT M2 17 V OUT M2 18 V OUT M2 PIN DESCRIPTION 1 V OUT M3 2 V OUT M3 3 V OUT M3 4 SENSE M3 5 SENSE M3 6 TRIM M2 7 V OUT M2 8 V OUT M2 9 V OUT M2 Outputs M2 and M3 OUTPUT M2 M3 OUTPUT M1 J2 3 1 V...

Page 12: ...onnector 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 Rev 2 2012 FlatPAC EN EN MI Design Guide ...

Page 13: ...pplications that use long cable lengths and excessive load capacitance User Interface Connections Signal Ground CBJ1 1 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 MATING CONNECTOR HOUSING MOLEX 39 01 4051 SOCKET CRIMP 16 AWG MOLEX 39 00 0090 CRIMP TOOL MOLEX 11 01 0199 MBJ1 A C...

Page 14: ...initiate conversations Communications are half duplex in that only the FlatPAC EN EN MI receiver or transmitter may be active at one time The unit will reply to all commands or requests with a defined response followed by a carriage return and line feed character pair CR LF The user must wait for the reply from the FlatPAC EN before issuing the next command or request The data bytes will have a fo...

Page 15: ...to 255 and is in 10 millisecond increments The effective range of delay then becomes 10 to 2550 milliseconds or 0 01 to 2 55 sec onds Out of range arguments are replied to with an Inv Range message otherwise OK is returned The delay times are effective and run concurrent from either receipt of the Power Down command or from an error condition with the unit If these commands are entered without an ...

Page 16: ...te Sense connections are made But in the event that the Remote Sense is not connect ed or needed no Local Sense selection is necessary simply hook up the outputs and the FlatPAC EN will auto matically operate in Local Sense mode To check if an output has the Autosense feature measure the impedance from the Out to Sense and Out to Sense pins If the impedance is 5 ohms then the output has Autosense ...

Page 17: ...3 88kΩ Maxi Mini Micro Predefined 1 23V 1kΩ Maxi Mini Micro Userdefined 1 23V Consult Factory Table 1 Module Internal Reference Voltages and Thevenin Resistances Example 10 trim adjust on a 12V nominal output Figure 8 shows a typical variable trim circuit Using a 10k trimpot R7 the resistor values for R6 and R8 can be calculated as follows V1 Vref 10 2 75V Given Vref 2 5V see Table 1 IR5 2 75V Vre...

Page 18: ...may require external filter contact factory Power Factor 70 Transient Burst Immunity EN61000 4 4 Surge Immunity EN61000 4 5 Voltage Dips EN61000 4 11 Dielectric Withstand Primary to Chassis GND 1 500 VRMS Primary to Secondary 3 000 VRMS Secondary to Chassis GND 500 VRMS See Vicor module specifications A preload may be necessary for modules trimmed down below 90 of normal output voltage OUTPUT VI 2...

Page 19: ...point accuracy is 2 of Vnom Note See individual module datasheets for specific module specifications ENVIRONMENTAL Storage Temperature 40 C to 100 C Operating Temperature Ambient air see derating curves 20 C to 70 C MI 40 C to 70 C Case Temperature 20 C to 90 C MI 40 C to 90 C 75 for full size VI 200 module Specific temperature data on all module configurations can be obtained by contacting Applic...

Page 20: ...Output Power Derating Pg 20 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 2 2012 FlatPAC EN EN MI Design Guide ...

Page 21: ...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 This is a Molex connector limitation NOT a module power limitation Westcor s online configuration tool VSPOC will not provide a FlatPAC EN EN MI solution for requirements that exceed the 27A limitation Rev 3 2009 Vicor 800 735 6200 Westcor Division 408 522 ...

Page 22: ...Thermal Curves for FlatPAC EN EN MI Pg 22 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 2 2012 FlatPAC EN EN MI Design Guide ...

Page 23: ...Thermal Curves for FlatPAC EN EN MI continued Rev 2 2012 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 23 FlatPAC EN EN MI Design Guide ...

Page 24: ...Thermal Curves for FlatPAC EN EN MI continued Pg 24 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 2 2012 FlatPAC EN EN MI Design Guide ...

Page 25: ...Thermal Curves for FlatPAC EN EN MI continued Rev 2 2012 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 25 FlatPAC EN EN MI Design Guide ...

Page 26: ...pply that is supporting less current is adjusted up This action balances the cur rents to the load by matching the output voltages of the supplies In the case of one supply failing the circuit will attempt to trim the failed supply only This will leave the remaining functional supply alone to provide power to the load at its nominal voltage Thus the circuit also offers simple redundancy In additio...

Page 27: ... APPLICATIONS Contact your Regional Applications Engineer at 1 800 927 9474 for additional information Rev 2 2012 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Pg 27 FlatPAC EN EN MI Design Guide Figure 3 Cable Drawing P1 24 0 1 0 Power T1 V1 T2 V2 Red 22 AWG Yellow 22 AWG Brown 22 AWG White 22 AWG Black 22 AWG 1 2 3 4 5 6 1 74 44 2mm 0 12 3 0mm 1 500 38 1m...

Page 28: ...Notes Pg 28 Vicor 800 735 6200 Westcor Division 408 522 5280 Applications Engineering 800 927 9474 Rev 2 2012 FlatPAC EN EN MI Design Guide ...

Page 29: ...ned to be used in applications such as life sup port systems wherein a failure or malfunction could result in injury or death All sales are subject to Vicor s Terms and Conditions of Sale which are available upon request Specifications are subject to change without notice The latest data is available on the Vicor website at vicorpower com ___________________________________________________________...

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