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MM2-12501: DescriptionMultichip Packages Mini MegaPac; Categorysemiconductor Memory IC Multichip packaging; File Size1MB，28 Pages; ManufacturerVICOR; Websitehttp://www.vicorpower.com/

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USER GUIDE | UG:110

Mini MegaPAC™

AC-DC Switcher

Contents

Overview

Standard Features

Optional Features

Mechanical Considerations

MegaPAC Dos and Don’ts

Technical Description

Page

Configuring and

Reconfiguring MegaPACs

ConverterPAC Functional

Description

Part Numbering

Overview

The Mini MegaPAC AC-DC switcher allows users to instantly configure high-efficiency, off-line power

supplies that operate on either 115 or 230V

(47 – 500Hz) or 260 – 380V

. Although small in size

(3.4 x 6.0 x 9.5in [85,8 x 153,4 x 241,3mm]), the Mini MegaPAC provides up to 1,000W of output

power. The chassis has five slots and can provide up to ten isolated outputs.

A complete power supply is configured at the factory by selecting and inserting up to five same-length,

slide-in output assemblies called ConverterPACs™. ConverterPACs incorporate one or two

VI-200™ / VI-J00™ and/or Maxi Vicor DC-DC converters and are available in a wide array of output

voltages 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 the

ConverterPACs, refer to the ConverterPAC data sheets. The ConverterPACs used in the Mini MegaPAC

use VE-2xx and VE-Jxx modules.

Manufactured at 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 one of the

same length and 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 400V). 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.

ConverterPAC Output and

Connector Pin Identification

for the Mini MegaPAC

Mini MegaPAC

Quick Install Instructions

PFC MegaPAC

Mechanical Drawing

Interface Connections

Specifications

New Output Studs

MegaPAC Family Connector Kit

(43075) Listing

Current Share Boards -

Optional Feature

Current Share Boards -

Optional Feature Diagram

Low-Leakage Version

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:110

Page 1

Technical Description

The Mini MegaPAC™ chassis consists of an off-line single phase AC front end, EMI filter, cooling fan,

customer interface and associated housekeeping circuits. Input AC mains voltage (L1/N, L2 and GND) is

applied to a terminal block. The input current is passed through an EMI filter designed to meet EN55022

Class A and B. At start up, inrush current is limited by an NTC thermistor prior to being passed to the

power rectifiers. The power rectifiers and filter capacitors are arranged in a conventional full-wave

bridge rectifier / voltage-doubler configuration. This operates as a full-wave bridge rectifier on 230V

or can be manually strapped for operation as a voltage doubler on 115V

, delivering unregulated

300V

to a high-voltage backplane. The backplane supplies power to a variety of ConverterPAC™

assemblies that provide the desired low-voltage, regulated outputs.

Voltage conversion in the output assemblies is achieved by the Vicor 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 emission and high efficiencies.

At initial power-up, the Mini 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. When operating on 115V

the internal housekeeping V

comes up within two seconds after the application of input power.

On 230V

, it comes up within 500ms. Once the bus potential is within operating parameters, the

AC Power OK signal asserts to a TTL "1" indicating that the input power is OK and allows the power

outputs to come up within <50ms later. An auxiliary V

output of 5V

sourcing up to 0.3A is provided

for peripheral use on interface connector J10-9.

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 output. The typical delay associated for an output to

come up when measured from release of the Enable / Disable pin is 5 – 10ms. The General Shut Down

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

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. A minimum of 3ms

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

voltage falls below its operating threshold.

Figure 1

Mini MegaPAC architecture

Power

Input

EMI Filter

AC/DC Power Rectification,

Input Voltage Strapping,

Inrush Current Limiting

High Voltage

Unregulated Bus

DC/DC Output

ConverterPAC #1

Power Output

DC/DC Output

ConverterPAC #2

Power Output

Fan

Logic Power

Supply

DC/DC Output

ConverterPAC #3

Power Output

Housekeeping

Circuits

DC Bus Sense

Control

DC/DC Output

ConverterPAC #4

Power Output

Customer Interface

(Optoisolators)

DC/DC Output

ConverterPAC #5

Power Output

UG:110

Page 4

Configuring and Reconfiguring MegaPACs™

Most ConverterPACs™ of the same length can be easily added, replaced or moved by sliding the

assemblies in or out of a MegaPAC chassis. (Currently, the exceptions are the FinPACs™ which can

only be used in the PFC MegaPAC-High Power and the UniPACs™ which can only be used in the 4kW

MegaPAC). They are driver ConverterPACs and can be inserted into any available slot. For outputs

greater than 200W, a driver ConverterPAC 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 air flow 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.

Installing Booster ConverterPACs to Increase Output Power

ConverterPACs can be paralleled for more power. Additional power to an output is obtained by

connecting one or more boosters in parallel with a single driver. The driver can be placed in any open

slot. All boosters should be inserted in the slots to the immediate right of the driver when viewed from

the output end of the MegaPAC. Figure 2 shows a driver placed in slots #1 and 3 boosters placed

in slots #2 – 4. After inserting the driver and boosters, they are paralleled using bus bars across the

positive and negative output studs. Drivers should not be paralleled with each other. Bus bars between

a driver and booster(s) should never be disconnected. (For help in identifying boosters and drivers, refer

to the Part Numbering section on Page 8). Please note that total output voltage should not exceed the

converter baseplate-output isolation rating of 400V. For a detailed guideline on how outputs should be

placed in series, please refer to:

AN:204 Creating High-Voltge Outputs.

Figure 2

Paralleling ConverterPACs

Bus Bars for Paralleling

Loosen screw to

remove ConverterPAC

Driver

Boosters

UG:110

Page 5

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