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M5V_30AD: DescriptionMultichip Packages MODUPAC; Categorysemiconductor Memory IC Multichip packaging; File Size1MB，35 Pages; ManufacturerVICOR; Websitehttp://www.vicorpower.com/

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USER GUIDE | UG:105

PFC MegaPAC

Power Factor Corrected AC-DC Switchers

Contents

Overview

Standard Features

Optional Features

Mechanical Considerations

MegaPAC Dos and Don’ts

Technical Description

Configuring and

Reconfiguring MegaPACs

ConverterPAC Functional

Description

Part Numbering

Page

ConverterPAC Output and

Connector Pin Identification

for the PFC MegaPAC

PFC MegaPAC

Quick Install Instructions

PFC MegaPAC

Mechanical Drawing

Interface Connections

Output Studs

PFC MegaPAC

Output Power Derating

Overview

The PFC MegaPAC family of supplies combine Power Factor Correction (PFC) with the inherent

configurability of all Vicor MegaPAC products. This design guide covers four model variations:

PFC MegaPAC

PFC MegaPAC MI

PFC MegaPAC High Power

PFC MegaPAC High Power MI

1600W max, standard chassis

1600W max, rugged COTS chassis

2400W max, standard chassis

2400W 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-DC converters 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

ConverterPACs with VI-200™ / VI-J00™ Vicor DC-DC converters while the high-power chassis accepts

ConverterPACs with both VI-200 / VI-J00 and / or Maxi module. (Refer to Page 7 for a brief overview of

the ConverterPACs used).

PFC MegaPAC Connector Kit

(43075) Listing

Current Share Boards -

Optional Feature

Current Share Boards -

Optional Feature Diagram

Low Leakage Version

Output Sequencing

Note:

This user guide contains references to parts and products that are no longer available for new designs.

They remain included for reference only.

UG:105

Page 1

Mechanical Considerations

The PFC 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 5.5 lb.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 2in minimum clearance at both ends of the PFC MegaPAC and route all cables so

airflow is not obstructed. The standard unit draws air in at the fan side / AC input side and exhausts air

out the load side. If airflow ducting is used, use caution, as sharp turns could present back pressure to

the PFC MegaPAC. The fan moves approximately 30CFM of air.

Avoid excessive bending of output power cables after they are connected to the PFC MegaPAC. For

high-current outputs, use cable ties to support heavy cables in order to minimize mechanical stress on

output studs. Be careful not to short-out to neighboring output studs. The PFC MegaPAC units are

supplied with serrated, flanged hex nuts on all output studs. Therefore, thread-locking compounds or

lock washers are not required. The maximum torque recommended on flanged nuts is 45lb.in. Never

loosen the inner nut on a ConverterPAC™. This nut supports the hardware inside the ConverterPAC and

is factory torqued.

Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such

applications, a shock-absorption mounting design is required.

MegaPAC Dos and Don’ts

Remote sense should be used:

n to

improve poor output regulation.

n when

using older ConverterPACs that do not have the autosense feature.

NEVER

connect the remote-sense wires in reverse. To avoid failures,

always terminate the +Sense to the +Out and the –Sense to the –Out.

needed, compatible connector kits can be ordered separately.

Refer to Page 25 for additional information regarding connector kits.

avoid overheating,

NEVER

operate the supply with an open output slot. Open slots should always

be filled with a ConverterPAC or a plastic airblock designed for the PFC MegaPAC.

Always turn the power supply

OFF

before disconnecting any input or output wires.

Failure to do so may lead to an electrical shock hazard and or damage to the power supply.

NOT

insert or remove a ConverterPAC while the power supply is running.

They are not designed for hot insertion or extraction.

Wait five minutes after shutting off the power supply before inserting or removing a ConverterPAC or

to clear on OVP fault condition.

NOT

restrict airflow to or from the supply as this can cause overheating damage.

Booster ConverterPACs are available for power expansion. Refer to Page 6 for additional information.

not use boosters as independent outputs. Operating boosters with disconnected bus bars will

cause failures.

Before turning on the unit, ensure all input and output wires are properly connected and all hex nuts

properly tightened.

Keep output wires as short as possible and run the output (+/–) power cables next to

each other. Use twisted-pair wiring whenever possible.

UG:105

Page 3

AVOID

running input and output wiring in close proximity, as this may cause noise-related problems.

MegaPACs are

NOT

user serviceable. Please contact our customer service department at

PFC

1-800-735-6200 for repair assistance. Please be advised that attempts to repair or modify the power

supply will void the warranty.

proper fault protection device (fuse or breaker) should be used in series with the input terminals.

proper size wires to avoid overheating and excessive voltage drop.

Use

NEVER

loosen the inner nut on a ConverterPAC™.

FinPAC ConverterPACs can only be used with a high-power chassis. A high-power chassis is identified

by an “MX” prefix code in the specific model number.

Output voltages over 60V

, whether from individual modules or series arrays, are considered

as hazardous secondary outputs under UL 60950. Appropriate care must be taken in design

implementation of the supply.

Technical Description

The PFC MegaPAC™ chassis consists of an off-line single phase, power-factor-corrected front end, EMI

filter, cooling fan, customer interface and associated housekeeping circuits. Input AC mains voltage

(L1, L2 and GND) is applied to a terminal block. The input current is passed through an EMI filter

designed to meet conducted noise limit “B” specifications of FCC Part 15, VDE 0871, and EN55022

Class A. At start up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after

initial power up by a DC bus voltage-sense circuit driving a relay. After rectification, the input voltage

is put through a boost converter that keeps the AC input current sinusoidal and synchronized with the

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-DC converters. These are forward converters in which the main switching element switches

at zero current. This patented topology has a number of unique attributes: low-switching losses;

high-frequency operation resulting in reduced size for magnetics and capacitors; excellent line and load

regulation; wide adjustment range for output; low EMI / RFI emissions and high efficiencies.

At initial power up the PFC MegaPAC outputs are disabled to limit the inrush current and to allow the

DC bus potential to settle out to the correct operating level. A low-power flyback converter operating

with PWM current-mode control converts the high-voltage DC bus into regulated low voltage to power

the internal housekeeping circuits and DC cooling fan. The internal housekeeping V

comes up within

2s 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 V

output of 5V

sourcing up to 0.3A 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 nominal delay for an output to

come up when measured from release of the Enable / Disable pin is 10 – 15ms. The General Shutdown

function controls all outputs simultaneously and works in a similar manner.

UG:105

Page 4

The ride-through (hold-up) time is the amount of time the load can be supported before loss of output

regulation after the loss of input power. Detecting the loss of input power takes a finite time period

after which the AC Power OK signal goes from a TTL “1” to “0." This signal is available for use within

1.2s after initial power up and can be used to indicate an impending loss of power. At least 3ms of

warning time is given. Following the loss of input power, the outputs are disabled when the bus voltage

drops below its operating threshold.

Figure 1

PFC MegaPAC™ and

PFC MegaPAC

high-power architecture

Input

Line Filter

Rectifier

Waveform

Sample

Current

Sample

Soft Start

Circuit

Boost Converter

High Voltage

DC Bus

ConverterPAC #1

Power

Output

ConverterPAC #2

PFC Control

ConverterPAC #3

Power

Output

Power

Output

Customer

Interface

E/D Control

Enable/Disable Control

Fan

Current

Monitor

Housekeeping

Power

ConverterPAC #8

Power

Output

Configuring and Reconfiguring MegaPACs

Most ConverterPACs™ of the same length can be inserted into any available slot of a MegaPAC chassis.

They can also be easily added, replaced or moved by sliding the assemblies in or out of a MegaPAC

chassis. (Currently, two exceptions are the FinPACs™ which can only be used in the high-power chassis

and the UniPACs™ which can only be used in the 4kW MegaPAC.) For outputs greater than 200W, a

driver ModuPAC and one or more booster ConverterPACs will be used. For outputs greater than

600W, a driver FinPAC and one or more booster ConverterPACs will be used. Arrays of drivers 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 five minutes. Failure to do so can result in personal injury or damage to the supply.

Take standard ESD precautions when handling ConverterPACs.

Removing ConverterPACs

ConverterPACs can be removed by loosening the captive screw at the base. Once this screw has been

loosened, the ConverterPAC will slide out of the chassis.

Once a ConverterPAC has been removed,

the empty slot MUST be filled with either another ConverterPAC or an airblock.

If the slot is left

empty, it will provide an airflow escape and 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. 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.

UG:105

Page 5

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