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UG:106 

vicorpower.com  

Applications Engineering: 800 927.9474 

Page 1

Autoranging MegaPAC

TM

 

AC-DC Switcher

USER GUIDE  |  UG:106 

June 2013

Overview 

The Autoranging MegaPAC AC-DC switcher allows users to instantly configure high 
efficiency, off-line power supplies that operate on either 115 or 230 Vac (47-500 Hz), or 
260-380 Vdc. The Autoranging MegaPAC provides up to 1,600 W of output power with a 
power density of 6.6 W per cubic inch. The chassis has 8 slots and can provide up to 16 
isolated outputs. Its dimensions are 3.4"H x 6.0"W x 11.9"L (86,4 x 152,4 x 302,3).
A complete power supply is configured at the factory by selecting and inserting up to 
eight same length slide-in output assemblies called ConverterPACs. ConverterPACs 
incorporate one or two VI-200/VI-J00 and/or Maxi Vicor DC to DC converters and are 
available in a wide array of output voltage and power levels. The net result is a power 
supply that offers the advantages of a custom supply, but is assembled from standard 
and modular building blocks. For detailed information about ConverterPACs, refer 
to the ConverterPAC information sheets. Currently, the ConverterPACs used in the 
Autoranging MegaPAC only use VI-200/VI-J00 Vicor DC to DC converters.  

 

Refer to page 6 for a brief overview of the ConverterPACs used.
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 different output voltage is needed, upgrading is easy: simply unlock a 
single screw and replace the slide-in ConverterPAC assembly with a same length 
ConverterPAC and one that 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 left 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.

Contents Page

 

Overview  

1

of Product 
 
Mechanical 2
Considerations 

 

 
MegaPAC 3 
Do’s and Don’ts 

 

 
Technical Description 

 
Configuring and 

5

Reconfiguring 

 

MegaPACs
 
ConverterPAC 6 
Description

Part Numbering 

7

ConverterPAC Output 

9

and Connector Pin 

 

Identification

Quick Install 

10 

Instructions
 
Mechanical Drawings 

13

 
Interface Connections  14

Specifications 20

Current Share Boards 

21

Low Leakage Version 

23

Summary of Contents for UG:106

Page 1: ...00 VI J00 Vicor DC to DC converters Refer to page 6 for a brief overview of the ConverterPACs used 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 different output voltage is needed upgrading is easy simply unlock a single screw and replace the slide in ConverterPAC assembly wi...

Page 2: ...derations The Autoranging 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 20 lb in The maximum penetration is 0 15 in 3 8mm When selecting a mounting location and orientation the unit should be positioned so air flow is not restricted Maintain a 2 inch 5 1cm minimum clearance at...

Page 3: ...bles next to each other to minimize inductance n Wait 5 minutes after shutting off power before inserting or removing ConverterPACs n Do not attempt to repair or modify the power supply in any manner other than the exchange of ConverterPACs as described in this Design Guide There are no user serviceable components n Insert proper fault protection at power supply input terminals i e a fuse n Use pr...

Page 4: ...come up typically within 15 30 ms later 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 If the Enable Disable control pin is pulled low the optocoupler turns on pulling the Gate In pin low and disabling the ConverterPAC output The typ...

Page 5: ... will provide an airflow escape and can cause failure to the power supply 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 pa...

Page 6: ...down to 1 typical and 2 maximum peak to peak from 10 to 100 of rated load An optional DC Power Good signal or output voltage Trim potentiometer can be specified The JuniorPAC contains output overcurrent protection which recovers automatically when the overcurrent condition is removed Overvoltage protection and overtemperature limiting are not available DualPAC This output assembly consists of two ...

Page 7: ...d in the Autoranging MegaPAC and their features ConverterPAC OVP OCP OTL RS AS LS AS PG TrimPot ModuPAC Std Std Std AS AS Opt Opt JuniorPAC N A Std N A AS AS Opt Opt DualPAC N A Std N A AS AS N A Opt RAMPAC N A Std N A AS AS Opt Opt BatPAC N A Std N A N A N A N A Std FlexPAC Std Std Std LS LS N A Std See page 11 and 14 for more information on Autosense OVP Overvoltage Protection latching OCP Overc...

Page 8: ...ut adjustment F5 60 110 output adjustment T3 100 110 output adjustment F6 70 110 output adjustment T4 90 100 output adjustment F7 80 110 output adjustment T5 98 105 output adjustment F8 90 110 output adjustment T6 100 110 output adjustment F9 100 110 output adjustment V1 VXI low noise 150 mV 15 V VOUT 24 V output I I Grade module V2 VXI low noise 50 mV VOUT 15 Vdc K Custom SRF module used V3 1 rip...

Page 9: ...0208 3 SENSE SENSE 1 TRIM PIN ACCESS 2 OUTPUT ADJUST J1 B PIN1 J1 A PIN1 OUTPUT CONNECTORS 1 AND 4 V OUT 3 3 R 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 11 01 0197 MATING HDWR 6 5 4 2 AND 5 V OUT DUALPAC 20 130182 TAB J1 B M1 J1 A M2 M2 M1 Output A 48V 2 1A Output B 12V 8 3A Example D12V 8 3A 48V 2 1A DUALPAC COMPONENTSIDEVIEW VOLTAGE L...

Page 10: ...Connections Installing ring lugs and or bus bars on output studs n The upper stud is Positive and the lower stud is the Return n Remove outer nut Do not remove or loosen inner nut n Place ring lug over output stud n Replace and tighten outer nut to a maximum torque of 45 lb in Do Not Over Tighten Nuts n Verify all output nuts are properly installed before turning on supply Installing power connect...

Page 11: ... connected before applying input power Sense Connections on DualPACs n Sense connections do not have to be made if the Local Sense option has been ordered An L in the ConverterPAC part number means the Local Sense option has been installed e g D5V 20AL 12V 4 2AL n Sense connections are available on the J2 connector or the J1A and J1B connectors Either can be used n If using J2 connector see instru...

Page 12: ...7005 5000 Interface Connections J10 n Use Molex mating receptacle 39 01 2120 with 39 00 0039 terminals provided n J10 1 to 8 are Enable Disable for slots 1 8 n J10 9 is Vcc J10 10 is Signal Ground J10 11 is AC Power OK and J10 12 is General Shutdown n Attach terminals to 18 24 AWG stranded wire using Molex tool 11 01 0197 12 11 10 9 8 7 6 5 4 3 2 1 J10 J10 9 J10 10 J10 11 J10 12 Vcc 5V 0 3A SIGNAL...

Page 13: ...TABLE OUTPUT OPTION IS SPECIFIED INPUT LEGEND NOTE THIS POWER SUPPLY CAN BE CONNEC TED TO ANY SINGLE PHASE AC SOURCE OPERATING AC INPUTS AUTO MAX TORQUE ON SET SCREWS 10 IN LBS DO NOT RUN W O EARTH GROUND HERE L2 100 120 VAC 200 240 VAC SCALE NONE AUTO RANGING MegaPAC J9 INPUT CONNECTIONS J9 1 EARTH GROUND J9 2 AC HOT J9 3 AC NEUTRAL R12 R4 WESTCOR C L L C J2A PIN1 SAME AS J2 SAME AS J2 J2B PIN1 1...

Page 14: ... 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 See page 9 for additional information on Autosense Newer power supplies may have some outputs configured with the Autosense feature that automatically locally senses the output if remote sense is not used To check...

Page 15: ...d be controlled The Enable Disable pins should be pulled low to less than 0 7 V with respect to Signal Ground to disable the outputs They will sink 10 mA maximum These pins should be open circuited or allowed to exceed 4 5 V when enabled Do not apply more than 6V to these inputs at any time If driven from an electromechanical switch or relay a capacitor should be connected to eliminate the effects...

Page 16: ...ding loss of power Auxiliary Vcc 5V 0 3A J10 9 The Vcc on J10 9 is an auxiliary 5V regulated power source see Figure 7 and Connector Pin Identification on Page 12 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 The Auxiliary Vcc typically powers user circuitry or is us...

Page 17: ...d Inverted J3 2 This is the inverse of the Power Good signal and is referenced to Signal Ground on J3 1 Signal Ground J3 1 Signal Ground on J3 1 is an isolated secondary ground reference for J3 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 Vcc In J3 4 The Vcc In on J3 4 is an input that requires 5...

Page 18: ...optional factory installed Trim potentiometer or with the Trim pin 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 Maximum Trim ranges are 10 above the nominal converter voltage and 50 below the nominal converter volta...

Page 19: ... 90 kW V2 V1 VR6 2 75 V 2 25 V 5 V IR7 V2 R7 5 V 10 kW 500 mA IR8 IR7 IR6 525 mA VR8 Vnom 10 V2 13 2 V 5 V 8 2 V Given Vnom 12 V R8 VR8 IR8 8 2 V 525 mA 15 62 kW Using the above resistor combination a 12 V output can be trimmed externally up to 13 2 V and down to 10 8 V For further information on external trimming refer to Chapter 5 of the Applications Manual or consult the factory for assistance ...

Page 20: ...Output Trim Range 50 110 of nominal voltage VI 200 VI J00 modules 90 110 of nominal voltage VI 200 VI J00 modules 10 15 V 2 V 25V FlexPACs Overcurrent Trip Point 105 125 of full load capability of VI 200 VI J00 modules Dependent on voltage set for FlexPAC contact factory Overvoltage Protection ModuPACs 115 135 FlexPACs 125 set voltage Efficiency Up to 82 typical Output Power 1 600 W at at 230 Vac ...

Page 21: ... an output voltage up The benefit is that only the supply that is supporting less current is adjusted up This action balances the currents 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 ...

Page 22: ...s Molex CT43045F surface mountable connector 390 height above board Pin Description 1 Power 2 T1 3 V1 4 T2 5 V2 6 No Connection J1 Pinout Figure 11 Mechanical Drawing Specifications 1 Power 2 50 Vdc at 5 mA maximum 2 Accuracy 1 mV between Vout connections 3 Output current when not trimming up 1 uA VI 200 J00 5 uA Maxi 4 Use 4 non plated through holes with standoffs for mounting 5 CSB01 MUST be use...

Page 23: ...d with the removal of the Y capacitors from within 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 500 mA 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 Westcor s ...

Page 24: ...UG 106 vicorpower com Applications Engineering 800 927 9474 Page 24 NOTES ...

Page 25: ...FC Micro PFC Mini MEGAPAC FAMILY PFC MegaPAC 4kW MegaPAC 4kW MegaPAC EL Low Noise PFC MegaPAC High Power PFC MegaPAC Low Noise High Power PFC MegaPAC EL Low Noise Mini MegaPAC Autoranging MegaPAC ConverterPACs OTHERS FlatPAC EN PFC FrontEnd MicroPAC Conduction Cooled MicroPAC Rugged COTS versions MI are available for the PFC Micro PFC MicroS PFC Mini and PFC MegaPAC Information furnished by Vicor ...

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