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UG:105

vicorpower.com

Applications Engineering: 800 927.9474

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Westcor PFC MegaPAC

TM

Power Factor Corrected AC-DC Switchers

USER GUIDE | UG:105

May 2013

Overview

The PFC MegaPAC family of supplies combine power factor correction (PFC) with the
inherent configurability of all Westcor MegaPAC products. This design guide covers 4
model variations:

1.

PFC MegaPAC

1600 W max, standard chassis

2.

PFC MegaPAC MI

1600 W max, rugged COTS chassis

3.

PFC MegaPAC High Power

2400 W max, standard chassis

4.

PFC MegaPAC High Power MI

2400 W max, rugged COTS chassis

All PFC MegaPACs have the same input and output connections, mounting points, and
the same dimensions:
The extended length (-EL) chassis is covered in a different design guide
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 more) VI-200/VI-J00), Maxi Vicor DC to DC converters and/or
FlexPACs and are available in a wide selection 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. Currently, the standard power
chassis uses only FlexPACs and ConverterPACs with VI-200/VI-J00 Vicor DC to DC
converters while the high power chassis accepts FlexPACs and ConverterPACs with
both VI-200/VI-J00 and/or Maxi module. (Refer to page 6 for a brief overview of the
ConverterPACs used.)

Using the PowerBench configurator tool available on

www.vicorpower.com

, anybody can now configure a PFC MegaPAC (and other Westcor

power supplies) online.

Contents Page

Overview

1

of Product

Mechanical 3
Considerations

MegaPAC 3
Do’s and Don’ts

Technical Description

4

Configuring and

5

Reconfiguring

MegaPACs

ConverterPAC 6
Description

ConverterPAC 10
Output and Connector
Pin Identification

Quick Install

12

Instructions

Mechanical Drawings

15

Interface Connections 16

Specifications 23

Power Derating

25

Connector Kit Listing

25

Current Share Boards

26

Low Leakage Version

29

Output Sequencing

30

1
2
3
...
»

Содержание PFC MegaPAC

Страница 1: ... DC to DC converters and or FlexPACs and are available in a wide selection 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 Currently the standard power chassis uses only FlexPACs and ConverterPACs with VI 200 VI J00 Vicor DC to DC converters while the high power chassis acce...

Страница 2: ...actor Correction 0 99 at 115 Vac 0 95 at 230 Vac both at full load 47 63Hz n Universal Input 85 264 Vac 47 500 Hz or 100 380 Vdc n Power Outputs Standard Chassis 1 600W at 230 Vac High Power Chassis 2 400W at 230 Vac 1 200W at 115 Vac 1 200W at 115 Vac n Outputs Standard Chassis Up to 32 outputs High Power Chassis Up to 32 outputs n Fan Cooled n Full power to 40 C half power to 60 C n Soft start f...

Страница 3: ...e shock or vibration levels In such applications a shock absorption mounting design is required MegaPAC Do s and Don ts n Remote sense should be used To improve poor output regulation When using older ConverterPACs that do not have the autosense feature n NEVER connect the remote sense wires in reverse To avoid failures always terminate the Sense to the Out and the Sense to the Out n If needed com...

Страница 4: ... AC input voltage in compliance with EN61000 The boost converter delivers regulated high voltage DC to the hold up capacitors and backplane The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired regulated outputs Voltage conversion in the output assemblies is achieved by Vicor s family of Zero Current Switching ZCS DC to DC converters These are forward conver...

Страница 5: ...ivers and boosters should be configured so all boosters are placed in the slots to the immediate right of the driver when looking at the output end of the MegaPAC Prior to removing or installing ConverterPACs you must remove power from the MegaPAC and wait 5 minutes Failure to do so can result in personal injury or damage to the supply Take standard ESD precautions when handling ConverterPACs Remo...

Страница 6: ...blies used in MegaPAC power supplies Most ConverterPACs of the same length are interchangeable within a MegaPAC and between different AC input MegaPAC chassis Exceptions are the FinPAC and UniPAC They can be added moved or changed as necessary The following ConverterPACs can be used in the PFC MegaPAC and or PFC MegaPAC High Power Spec sheets for ConverterPACs are available at www vicorpower com M...

Страница 7: ...at can be configured as a battery charger Maximum current and voltage settings are controlled using potentiometers that come as a standard feature or through Trim pin access as an option BatPACs are available for 12 V 24 V and 48 V battery systems FINPAC The FinPAC output assembly consists of a Maxi DC to DC converter that converts the unregulated high voltage bus to the desired regulated output v...

Страница 8: ...nly be used in the PFC MegaPAC High Power The UniPAC not listed above cannot be used either in the PFC MegaPAC or the PFC MegaPAC High Power Currently the UniPAC is only used in the 4 kW MegaPAC Note All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC JuniorPAC and RamPAC Part Numbering PFC MegaPAC Mpaa 7bcccc v xx p P for standard chassis p X for high power chassis aa number of...

Страница 9: ...10A M15V 10ADFI D15V 6 7A 12V 8 3AT M ModuPAC RoHS GM R RAMPAC RoHS GR D DualPAC RoHS GD B BatPAC RoHS GB J JuniorPAC RoHS GJ PZ PZ FinPAC RoHS GPZ 1 D option Optional for all ConverterPACs EXCEPT the DualPAC BatPAC and RamPAC 2 F options Optional for all ConverterPACs EXCEPT the BatPAC DualQPAC and FlexPAC Trim range dependent on module type and voltage 3 R option When using an external RAM compo...

Страница 10: ...PAC J2 B PIN1 OUTPUT ADJ 1 J2 A PIN1 J2 REMOTE SENSE MATING HDWR HOUSING MOLEX P N 50 57 9403 TERMINALS MOLEX P N 16 02 0103 CRIMP TOOL MOLEX P N 11 01 0208 3 SENSE SENSE 1 TRIM PIN ACCESS 2 OUTPUT ADJ 2 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...

Страница 11: ...s except the FinPAC occupy one slot The FinPAC occupies two slots 2 New output studs were installed on the ConverterPACs and are 1 8th inch longer Refer to page 24 for more information FlexPAC P2 REMOTE SENSE TRIM SC POWER GOOD POWER GOOD INVERTED TRIM 5 3 2 4 1 SIGNAL GROUND POWER GOOD Vcc IN 7 6 SENSE SENSE TERMINALS MOLEX P N 39 00 0031 HOUSING MOLEX P N 39 01 0073 CRIMP TOOL MOLEX P N 57005 50...

Страница 12: ...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 connectors on DualPACs J1A and J1B n Use Molex mating receptacle 39 01 2060 with 39 00 0039 terminals provided n Pins 1 and 4 are Positive while pins 2 and 5 are the Return n Attach terminals to 18 24 AWG stranded wire using Molex tool 11 01 0...

Страница 13: ... Sense and Pin 6 is the Sense n Use Molex mating receptacle 39 01 2060 with 39 00 0039 terminals provided n Attach terminals to 18 24 AWG twisted pair wire using Molex tool 11 01 0197 n Verify that Sense lines are not cross connected before applying input power Trim Pin Connection J2 and P2 for FinPAC n The Trim J2 connection should only be made if the Trim option has not been installed A T or an ...

Страница 14: ... 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 FlexPAC Connections J1 n Use Molex mating receptacle 39 01 2120 with 39 00 0039 terminals provided n Attach terminals to 18 24 AWG stranded wire using Molex tool 11 01 0197 n J1 pins 11 5 12 and 6 are for special trim options Contact factory for use n Local Sense o...

Страница 15: ...RATE GROUND EARTH WITHOUT DO NOT MATING HDWR TERMINALS MOLEX P N 39 00 0039 CRIMP TOOL MOLEX P N 11 01 0122 RE DESIGNED STUD AND PANEL ORIGINAL STUD AND PANEL T0P AND BOTH SIDES RE DESIGNED LENGTH ORIGINAL LENGTH FAN DIRECTION OF AIR FLOW OPTIONAL 6 04 153 42 3 37 85 60 6 75 171 45 2 92 74 17 21 5 33 25 6 35 5 10 129 54 47 11 94 41 10 35 2 75 69 85 6 75 171 45 11 93 302 90 2 92 74 17 21 5 33 6 75 ...

Страница 16: ... 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 automatically locally senses the output if remote sense is not used To check if an output has the Aut...

Страница 17: ...rPAC need 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 6 V to these inputs at any time If driven from an electromechanical switch or relay a capacitor should be connected to eliminate th...

Страница 18: ...t method of remotely enabling and disabling the output is to use the General Shutdown GSD function General Shutdown GSD J10 12 The GSD control pin on J10 12 allows simultaneous shutdown of all ConverterPAC outputs see Connector Pin Identification on page 9 This pin must be pulled down to less than 0 7 V and will sink 13 mA maximum to shut down all outputs The GSD pin should be open circuited or al...

Страница 19: ...of an impending loss of power 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 14 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 circui...

Страница 20: ...gnal Ground on J3 1 Sense Sense J2 2 and J2 3 See page 10 and 13 for information on Autosense The Sense on J2 2 should be connected to the Power Out and the Sense on J2 3 to the 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 volta...

Страница 21: ...nd dynamic load step may cause the module to trip OVP See page 6 for information on restart 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 ref...

Страница 22: ...e IR5 IR6 25 mA R6 VR6 IR6 2 25 V 25 mA 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 Design...

Страница 23: ... 0 3 max LL to HL Full Load Load Regulation Maxi 0 1 No load to full load VI 200 VI J00 Setpoint Accuracy 1 for standard voltages 2 for special or adjustable voltages Maxi Setpoint Accuracy 1 for standard voltages 2 for special adjustable voltages and 48 Vdc outputs Ripple and Noise Std outputs 2 or 100 mV p p whichever is greater 75 min load VXI options V1 150 mVp p or less 15 V Vout 24 V outputs...

Страница 24: ...r com for complete warranty statement See Vicor module specifications A preload may be necessary for modules trimmed down below 90 of normal output voltage The maximum operating temperature is 40 C If using a VI 200 with output voltage less than 12 V and more than 150 Watts the operating temperature decreases to 35 C This also applies when using a FinPAC with output voltage less than 24 V and more...

Страница 25: ...19 130040 Listing Item Qty Description Vendor 1 Part 1 1 HOUSING 12 POS 165 CTR W LATCH MOLEX 39 01 2120 2 12 TERMINAL FEM CRIMP 18 24 AWG TIN MOLEX 39 00 0039 CRIMP TOOL FOR ITEM 2 MOLEX 11 01 0197 3 8 HOUSING 7 POS 098 CTR L PROFILE MOLEX 39 01 0073 4 8 HOUSING 4 POS 098 CTR L PROFILE MOLEX 39 01 0043 5 94 TERMINAL FEM CRIMP 22 18 AWG PH BRNZ MOLEX 39 01 0031 CRIMP TOOL FOR ITEMS 3 4 MOLEX 00 01...

Страница 26: ...V accuracy between 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 ...

Страница 27: ... a minimum of a few millivolts of drop in order for proper operation 50 mV to 100 mV 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 Wh...

Страница 28: ... V 1 4 T2 5 V 2 6 No Connection J1 Pinout Figure 13 Mechanical Drawing Figure 14 Cable 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 Mini Micro 4 Use 4 non plated through holes with standoffs for mounting 5 CSB01 MUST be used for current sharing VI 200 VI J00 converters VI 200 J00 6 C...

Страница 29: ...ly of power supplies is obtained 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 µA 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...

Страница 30: ...ement is to configure the 5 V ModuPAC with the DC OK Option which is indicated by a D designator in the M oduPAC s part number located on the top surface of each ModuPAC above the Vout Any ModuPAC that has the DC OK option will also have the 4 pin J3 DC OK connector installed To order a ModuPAC with the DC OK option please contact Westcor s customer service department for assistance The DC OK opti...

Страница 31: ... to provide the necessary Vcc pull up This 5 V source is conveniently available using the 5 V aux source from the Input Interface Connector J10 9 and J10 10 With a Vcc voltage properly applied to the 5 V ModuPAC s Power Good Connector J3 1 and J3 4 the Power Good signal J3 3 can now be connected to the Enable Disable control pin for slot 7 J10 7 The 5 V ModuPAC s Power Good signal will remain low ...

Страница 32: ...Output Sequencing Cont Channel 1 5 V Output Channel 2 3 3 V Output Channel 3 5 V DC OK signal 5V Output 5V DC OK 3 3V Output 5V Output 5V DC OK 3 3V Output Figure 18 Startup Waveforms Figure 19 Shutdown Waveforms Figure 18 Startup Waveforms Figure 19 Shutdown Waveforms ...

Страница 33: ...UG 105 vicorpower com Applications Engineering 800 927 9474 Page 33 NOTES ...

Страница 34: ...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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