FlatPAC-EN Design Guide

USER GUIDE | UG:120
FlatPAC-ENTM and FlatPAC-EN MI
EN Compliant Autoranging Switchers
October 2012
ContentsPage
Overview of Product
1
Standard Features 2
Optional Features 2
Part Numbering 2
Mechanical Considerations 3
Do's and Don'ts 4
Technical Description 4
Configuration Layout 6
"Quick Install"
Instructions
7
Mechanical Drawings 10
Output Connectors 12
FlatPAC-EN Connector Kit
12
Power Connections 13
User Interface Connections
14
Specificaitons 20
Output Power Derating
22
Thermal Curves
24
Current Share Boards
28
Overview
The FlatPAC-EN/EN MI is an ultra low profile switching power supply that provides up
to 500 Watts from up to 4 isolated outputs. It operates on either 115 or 230 Vac nominal
(47-63 Hz), or 250-380 Vdc. It can be populated with either VI-200/VI-J00 or Maxi/Mini/
Micro Vicor converters. The use of these converters gives the FlatPAC-EN/EN MI the
inherent power flexibility typical of all Vicor products. With dimensions of
1.4" H (35,6 mm) x 5.0" W (127 mm) x 9.2" L (233,7 mm), the FlatPAC-EN/EN MI
provides a power density greater than 7W/in3. It is factory configured to meet user
output requirements.
Note: The FlatPAC-EN/EN MI does not have an internal fan.
The MI version is a rugged chassis designed specifically for COTS and harsh environment applications.
Using the PowerBench configurator tool available on vicorpower.com, anybody can
now configure a FlatPAC-EN (and other Vicor power supplies) online.
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Page 1
Standard Features
n Power Factor Correction (passive): Power Factor (Typical) 0.70 (>75% Load)
n Input Voltage: 90-132/180-264 Vac[1], 47-63 Hz, or 250-380 Vdc
nMaximum Power Output: 500 W (105/190Vac min.)
425 W for EN61000-3-2 compliance
n Up to 4 isolated user specifiable outputs
n Conducted EMI: FCC Class A
EN 55022 Class A
FCC Class B EN 55022 Class B
Mil-STD 461 may require external filter
n Harmonic Attenuation to EN61000-3-2/A14[2]
n Compliant to EN61000-4-4
(Electrical Fast Transient/Burst) and EN61000-4-5 (Surge Immunity)
n MI version meets Mil-STD 810 for Shock and Vibration with extended temp range
n MI version also available with -40°C temp rating
n Efficiency (typical) > 70%
n Autosense[3]
n RS-232 microcontroller interface
n Output overcurrent protection on all outputs
n Size: 1.4" H (35,6 mm) x 5.0" W (127,0 mm) x 9.2" L (233,7 mm)
n Safety Agency Approvals: cURus, cTUVus, CE Mark
[1] Derates
[2] For
to 260 W @ 90 Vac, 400 W @ 180 Vac.
output power £ 425 W, not to exceed an input current of 3.33 A rms at 230 Vac, 50 Hz.
[3] This
feature is implemented in all converter slots (except with Micro modules). Autosense allows automatic local sensing when remote sense connections are not made. The FlatPAC-EN/EN MI will operate in remote sense mode when remote sense connections are made. Refer to Page 18 for more information on Autosense.
Optional Features
n Current Share Board for unit to unit power sharing - See Pages 28 - 30
n Connector kits (# 19-130044)
n Conformal coating available on select MI models - contact factory
n -40°C Operation, Mil-STD 810 Shock and Vibration (MI rugged chassis only)
Part Numbering
FlatPAC-EN/EN MI
FLx1-x2 x3 -xxxx (-x4)(-x5)
ex. FL4-13-6544
x1 = number of outputs
x2 = number of VI-200/VI-J00 modules
x3 = number of Maxi/Mini/Micro modules
xxxx = sequential number assigned by Vicor
(-x4 ) = optional Factory assigned: G - RoHS
(-x5 ) = optional versions
xB = Number of modules
Note: x5 = MI for rugged chassis, = MC for rugged chassis with conformal coating
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Mechanical Considerations
The FlatPAC-EN/EN MI is mounted on the bottom surface using standard 8-32 or 4 mm
screws (cannot be mounted from the front.)
C1
A1
A3
B1
Identical mounting
holes (C1 & C2)
to Vicor's
2 UP FlatPAC
B2
A4
C2
A2
Maximum allowable torque is 5 in. lbs.. The maximum penetration for mounting holes
A1, A2, A3 and A4 is 0.125 in. (3 mm) and for mounting holes B1, B2, C1 and C2 is 0.250
in. (6 mm). The minimum recommended mounting holes are as follows:
1. For standard mounting (forced air cooling), use A1, A2, A3, A4 mounting holes.
2. For standard mounting (conduction cooling), use A1, A2, A3, A4, B1 and B2
mounting holes.
3. For a Vicor 2 Up FlatPAC retrofit replacement, use C1 and C2 as these two are identical to the recommended mounting holes on the FlatPAC.
For increased ruggedness, additional mounting holes can be used to secure the
power supply.
The FlatPAC-EN/EN MI does not have an internal fan. It can be either conduction or
convection cooled (same model).
Avoid excessive bending of output power cables after they are connected to the output
terminals. For high-current outputs, use cable ties to support heavy cables and minimize
mechanical stress on connectors. Be careful not to short-out to neighboring outputs. The
maximum torque recommended on output nuts is 10 in. lbs.
For applications that require vibration levels above MIL-STD-810E, minimum integrity
test, a shock absorbing mount design is required.
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Page 3
FlatPAC-EN/EN MI Do’s and Don’ts
n Do not exceed an operating case temperature of 90°C. To prevent an overtemperature condition, an external fan may be required.
n Run the output (+/–) power cables next to each other to minimize inductance.
n Always turn the power supply off before disconnecting input or output wires.
n When using the remote sense feature, the +Out and -Out load wires should never be disconnected while the supply is operating. Failing to do so could damage the
power supply.
n Do not attempt to repair or modify the power supply in any manner as this action will void the warranty. In the event of problems, contact Applications Engineering
at 1-800-927-9474.
n Insert proper fault protection at power supply input terminals (i.e., a fuse). Refer to Page 13 for more information.
n Use proper size wires to avoid overheating and excessive voltage drop.
n Output voltages over 60 Vdc, 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 FlatPAC-EN/EN MI consists of an off-line single phase autoranging front end, EMI
filter, customer interface, power supply control circuit, associated housekeeping circuits,
a MiniHAM module and a selection of Vicor’s VI-200/VI-J00 and/or
Maxi/Mini/Micro DC-DC converters.
The MiniHAM was specifically designed for EN compliance using passive filtering.
Unlike active PFC solutions, the MiniHAM generates no EMI, greatly simplifying and
reducing system noise filtering requirements. It is also considerably smaller and more
efficient than active alternatives and improves the unit’s MTBF. It will provide harmonic
current compliance at 230 Vac input up to 425 W of output power. Input AC mains
voltage is applied to input connector MBJ1 (see Page 7) and the input current is passed
through an EMI filter designed to meet conducted noise limit of EN 55022, Classes A and
B specifications (certain configurations meet EN55022 Class B. Consult Factory.)
At start-up, the microcontroller verifies that the input voltage is within the specified
operating range. Once this occurs, the microcontroller closes the safety relay and puts
the autoranging front-end in the correct mode (closing or opening the Doubler relay).
The autoranging front-end has two modes, the doubler mode (90 Vac - 132 Vac) or
bridge rectifier mode (180 Vac-264 Vac, 250 Vdc-380 Vdc). Inrush current is limited by
a PTC thermistor. The PTC is shunted out (by closing the Inrush relay) when the output
voltage has charged up the bus capacitors within the specified range (205 Vdc-390 Vdc).
Approximately one second after the application of the input voltage, the bus voltage 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 300 Vin family of Zero-CurrentSwitching (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.
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At initial power-up, all outputs are disabled to limit the inrush current and to allow
the DC bus potential to settle to the correct operating level. A low-power transformer
flyback circuit converts the high voltage DC bus into regulated low voltage to power the
internal housekeeping circuits as well as the auxiliary +5 Vs located in the
interface connector.
An output Enable/Disable function is provided to control Vicor’s DC-DC converters.
If the Enable/Disable control pin is pulled low, the modules output is disabled. The
nominal delay associated for an output to come up when measured from release of
the Enable/Disable pin is 9-12 ms. The General Shutdown function controls all outputs
simultaneously and works in a similar manner.
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UG:120
vicorpower.com VI-200
Maxi
M2
CBJ1
Interface Conn.
Applications Engineering: 800 927.9474
VI-J00
or
Mini
M2
VI-J00
or
Mini
M3
CBJ1
Interface Conn.
(Two 18 pin Molex Connectors)
(assumes only half bricks are used)
Single, Dual orTriple Outputs
VI-J00
or
Mini
M1
MiniHAM
MBJ1
Input Conn.
Micro
M3
(Two 18 pin Molex Connectors)
(assumes only half and/or
quarter bricks are used)
Micro
M2
VI-J00
or
Mini
M4
CBJ1
Interface Conn.
Single, Dual, Triple or Quadruple Outputs
Micro
M1
MiniHAM
MBJ1
Input Conn.
Note: The type of output connector a FlatPAC-EN has depends on which modules are used. E.g. if a two output configuration uses
two half bricks (instead of a full brick and half brick) this two output configuration will have the 18 pin molex connectors,
not stud connectors.
For a single output configuration,
either M1or M2 is used
(Stud Connectors)
(assumes either a full brick
and/or half brick is used)
Single or Dual Outputs
VI-J00
or
Mini
M1
MiniHAM
MBJ1
Input Conn.
FlatPAC-EN/EN MI Configuration Layout
Page 6
FlatPAC-EN/EN MI “Quick Install” Instructions
(For Mechanical Drawing, see Page 10)
A3
Mounting the FlatPAC-EN/EN MI
A4
n Mount the FlatPAC-EN on the bottom (cannot be mounted from the front).
n For standard mounting (forced air cooling), use A1, A2, A3, A4 mounting holes.
C1
C2
B2
B1
n For standard mounting (conduction cooling), use A1, A2, A3, A4, B and B2 mounting holes.
n For a Vicor two Up FlatPAC retrofit replacement, use C1 and C2 as these two are identical to the mounting holes on the FlatPAC.
n For increased ruggedness, use additional mounting holes to secure the power supply.
Identical mounting
holes (CI & C2) to Vicor's
2 UP FlatPAC
n Use #8 - 32 or 4mm mounting screws. For mounting holes A1, A2, A3 and A4, the maximum penetration should not exceed 0.125 in. (3 mm). For mounting holes B1, B2, C1 and C2, do not exceed maximum penetration of 0.250 in. (6 mm).
A2
A1
Note: The maximum allowable torque is 5 in. lbs.
Input Connections
MBJ1
Input Power MBJ1
GND
N/C
n Apply input AC power connector MBJ1 using a maximum torque of 5 in. lbs.
N/C
n Place a fuse or circuit breaker in the input line for safety requirements (9 A).
L2/N
L1
n Use Molex mating receptacle 39-01-4051, terminals 39-00-0090 and crimp tool
Molex # 11-01-0199.
Output Connections
(Refer to Page 6 for more information on configuration layout and output connector type)
Note: The type of output connector a FlatPAC-EN has depends on which modules are used. Also,
outputs with molex connectors are limited to 9A/pin (27A per output).
STUD OUTPUT CONNECTORS
M1
+
+
-
-
J1
Power Connections
Installing power connectors on outputs with 10-32 stud connectors (only full and/or half bricks used):
10-32 STUDS
J2
n Install #10 ring lugs on output studs
Note: The right stud is positive and the left stud is the return when viewed from the output end.
OUTPUT M1
OUTPUT M2
n Remove the nut and place ring lug over output stud.
n Replace and tighten the nut to a torque of 10 inch pounds. Do Not Over-Tighten Nuts.
18 PIN MOLEX OUTPUT CONNECTOR
Installing power connectors on outputs with 18 pin Molex connectors (only half bricks used):
J3
10
1
9
J3
18
OUTPUTS M2 & M3
PIN DESCRIPTION PIN DESCRIPTION
1
2
3
4
5
6
7
8
9
+V OUT M3
-V OUT M3
-V OUT M3
+ SENSE M3
- SENSE M3
TRIM M2
+V OUT M2
+V OUT M2
-V OUT M2
10
11
12
13
14
15
16
17
18
+V OUT M3
+V OUT M3
-V OUT M3
+ SENSE M2
TRIM M3
- SENSE M2
+V OUT M2
- V OUT M2
- V OUT M2
J2
18
9
OUTPUT M1
10
1
J2
PIN DESCRIPTION PIN DESCRIPTION
1
2
3
4
5
6
7
8
9
10
N/C
11
N/C
12
N/C
13
N/C
14
N/C
15
TRIM M1
+V OUT M1 16
+V OUT M1 17
-V OUT M1 18
N/C
N/C
N/C
+ SENSE M1
N/C
- SENSE M1
+V OUT M1
- V OUT M1
- V OUT M1
n 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.
n J2-1, J2-2, J2-3, J2-4, J2-5, J2-10, J2-11, J2-12 and J2-14 are not connected.
n The output M2 slot accepts either a Mini or a Junior module. J3-7, J3-8, and J3-16 are positive while pins J3-9, J3-17 and J3-18 are the returns.
n The output M3 slot accepts either a Mini or a Junior module. J3-1, J3-10, J11 are positive while pins J3-2, J3-3, J3-12 are the returns.
n For this 18 pin housing, use Molex mating receptacle #39-01-2180 with
#39-00-0039 terminals.
n Attach 18-24 AWG stranded wire using Molex tool #11-01-0197.
Note: The molex connectors are limited to 9A/pin (27 A per output)
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18 PIN MOLEX OUTPUT CONNECTORS
OUTPUTS M3 & M4
OUTPUTS M1 & M2
18
10
18
10
9
1
9
1
J2
+V OUT M2
-V OUT M2
-V OUT M2
+V OUT M2
- VOUT M2
TRIM M1
+V OUT M1
+V OUT M1
-V OUT M1
10
11
12
13
14
15
16
17
18
PIN DESCRIPTION PIN DESCRIPTION
+V OUT M2
+V OUT M2
-V OUT M2
+ VOUT M1
TRIM M2
- VOUT M1
+V OUT M1
- V OUT M1
- V OUT M1
1
2
3
4
5
6
7
8
9
+V OUT M4
-V OUT M4
-V OUT M4
+ SENSE M4
- SENSE M4
TRIM M3
+V OUT M3
+V OUT M3
-V OUT M3
10
11
12
13
14
15
16
17
18
+V OUT M4
+V OUT M4
-V OUT M4
+ VOUT M3
TRIM M4
- VOUT M3
+V OUT M3
- V OUT M3
- V OUT M3
n The output M2 slot only accepts a Micro module. J2-1, J2-4, J2-10, J2-11
are positive, while pins J2-2, J2-3, J2-5 and J2-12 are the returns.
n The output M3 slot only accepts a Micro module. J3-7, J3-8, J3-13 and J3-16
are positive, while pins J3-9, J3-15, J3-17 and J3-18 are the returns.
n The output M4 slot only accepts either a Mini or a Junior module. J3-1, J3-10
and J3-11 are positive while pins J3-2, J3-3, and J3-12 are the returns.
n For this 18 pin housing, use Molex mating receptacle #39-01-2180
with #39-00-0039 terminals.
n Attach 18 - 24 AWG stranded wire using Molex tool #11-01-0197
Note: The molex connectors are limited to 9A/pin (27 A per output)
See Page 11 for detailed diagrams of output connections.
Sense Connections
The FlatPAC-EN/EN MI is shipped with Autosense installed
(For more information on Autosense, refer to Page 18)
STUD OUTPUT CONNECTORS
10-32 STUDS
-
J1
+
+
-
1
2
3
4
5
6
7
8
9
n The output M1 slot only accepts a Micro module. J2-7, J2-8, J2-13 and J2-16
are positive, while pins J2-9, J2-15, J2-17 and J2-18 are the returns.
J3
PIN DESCRIPTION PIN DESCRIPTION
Installing power connectors on outputs with 18 pin Molex connectors
(only half and/or quarter bricks used):
J2
M1
OUTPUT M2
OUTPUT M1
Pin
1 Trim Pin
2 + Remote Sense
3 - Remote Sense
3 2 1
Sense Connections for stud outputs (only full and/or half bricks used):
M2
n For Remote Sense, connect Remote Sense wires to Remote Sense/Trim Pin Access
Connector J1 or J2 for single output and J1/J2 for dual outputs.
Note: Connector pins J1-2 and J2-2 are the + Senses and J1-3 and J2-3 are the -Senses.
n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
n Attach terminals to 24-30 AWG stranded twisted pair wire using
Molex tool # 11-01-0208.
n Attach opposite end of sense lines to their respective outputs to point where
regulation is desired. Verify that sense lines are not cross-connected.
Sense Connections on 18 pin molex output connectors (only half bricks used):
18 PIN MOLEX OUTPUT CONNECTORS
OUTPUT M1
+S
-S
18
9
OUTPUTS M2 & M3
18
9
10
1
-S
nFor Output M2, J3-13 is the +Sense andJ3-15 is the -Sense.
J3
J2
J2-13 + SENSE M1
J2-15 - SENSE M1
nFor Output M1, J2-­13 is the +Sense and J2-15 is the -Sense.
10
1
+S
-S +S
n If Remote Sense is desired, connect Remote Sense wires to the sense lines of
Connector J2 for output 1 and J3 for outputs 2 and 3.
J3-4 + SENSE M3 J3-13 + SENSE M2
J3-5 - SENSE M3 J3-15 - SENSE M2
nFor Output M3, J3-4 is the +Sense and J3-5 is the -Sense.
n Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
n 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 bricks used):
18 PIN OUTPUT CONNECTORS
OUTPUTS M3 & M4
OUTPUTS M1 & M2
18
10
18
9
1
9
J2
M1, M2, M3 accept Micro modules
No sense connections are available
for Micro modules
10
-S +S
1
J3
M4 accepts 1 Mini or 1
Junior
J3-4 + SENSE M4
J3-5 - SENSE M4
n If Remote Sense is desired (available only on output M4), connect Remote Sense
wires to sense lines of Connector J3.
nRemote Sense is NOT available for Micro modules and hence is not available on outputs M1, M2 and M3.
nOn output M4, 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
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Trim Connections
TRIM: STUD OUTPUT CONNECTORS
M1
M2
-
OUTPUT M1
+
-
J1
+
10-32 STUDS
J2
M2
n For output M1, J1-1 provides Trim Access.
n For output M2, J2-2 provides Trim Access.
n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
OUTPUT M2
3 2 1
Trim Connections on stud output connectors (when full and/or half brick used):
Pin
1 Trim Pin
2 + Remote Sense
3 - Remote Sense
n Attach 24 - 30 AWG stranded wire using Molex tool #11-01-0208.
Trim Connections for 18 pin Molex output connectors (when half bricks used):
n For output M1, J2-6 provides Trim access
18 PIN MOLEX OUTPUT CONNECTORS
10
1
T
n For output M2 and M3, J3-6 and J3-14 provides Trim access respectively.
OUTPUTS M2 & M3
OUTPUT M1
18
9
18
9
10
T
T
n Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
1
J2
J3
J3-6
J2-6 TRIM M1
TRIM M2 J3-14 TRIM M3
n Attach 18 - 24 AWG stranded wire using Molex tool #11-01-0197.
Trim Connections for 18 pin Molex output connectors (when half and/or quarter bricks used):
n For outputs M1 and M2, J2-6 and J2-14 provide Trim access respectively.
18 PIN MOLEX OUTPUT CONNECTORS
OUTPUTS M1 & M2
18
9
T
T
18
1
9
J2
J2-6 TRIM M1
OUTPUTS M3 & M4
10
J2-14 TRIM M2
n For outputs M3 and M4, J3-6 and J3-14 provide Trim access respectively.
10
T
n Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
1
T
J3
J3-6 TRIM M3
J3-14 TRIM M4
n Attach 18 - 24 AWG stranded wire using Molex tool #11-01-0197.
Interface Connections
PIN DESCRIPTION
CBJ1-1
CBJ1-2
CBJ1-3
CBJ1-4
CBJ1-5
CBJ1-6
CBJ1-7
CBJ1-8
CBJ1-9
CBJ1-10
CBJ1-11
CBJ1-12
SGND
N/C
ACOK
TX
RX
E/D-4
E/D-3
E/D-2
E/D-1
GSD
N/C
+5VS
n CBJ1-1 is Signal Ground and CBJ1-3 is AC OK.
n CBJ1-4 is the Transmit and CBJ1-5 is the Receive functions for the RS-232
command protocol.*
n CBJ1-4 thru 9 are Enable/Disable,CBJ1-10 is General Shutdown and CBJ3-12 is +5 VS.
n For the FlatPAC-EN, CBJ1-2 and CBJ1-11 are not connected.
n Use Molex mating receptacle #50-57-9412 with #16-02-0097 cinch pins.
n Attach 24 - 30 AWG stranded wire using Molex tool #11-01-0209.
*These functions are part of the RS-232 Command Protocols. See Page 14 for detailed information.
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Page 9
2
3
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vicorpower.com SIGNAL GROUND
N/C
AC POWER OK
TRANSMIT
4
RECEIVE
ENABLE/DISABLE
ENABLE/DISABLE
ENABLE/DISABLE
ENABLE/DISABLE
GENERAL SHUTDOWN
N/C
+5V@300mA
CBJ1-1 SGND
CBJ1-2 N/C
CBJ1-3 ACOK
CBJ1-4 TX
CBJ1- 5 RX
CBJ1-6 E/D-4
CBJ1-7 E/D-3
CBJ1- 8 E/D-2
CBJ1-9 E/D-1
CBJ1-10 GSD
CBJ1-11 N/C
CBJ1-12 +5VS
8.500
147.96
138.43
5.825
3
MATING CONNECTOR: 2
HOUSING: MOLEX (50-57-9412)
SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0097)
CRIMP TOOL: MOLEX (11-01-0209)
CBJ1 E/D INTERFACE CONNECTOR
5.450
215.90
5
AIR
FLOW
4.563
.219
115.89
3
MOTHER BOARD
CONTROL BOARD
DESIGNATION
J3
J2
J1
M2
J2
M2
M1
+
-
+
-
depends on which modules are used.
Note: The type of output connector a FlatPAC-EN has
CBJ4 AND CBJ5 ARE PART OF THE RS-232 MICROCONTROLLER FUNCTIONS. SEE PAGE 12 INFORMATION.
FOR A VICOR 2 UP FLATPAC RETROFIT, USE MOUNTING HOLES C1 AND C2. SEE PAGE 4 OR 7 FOR MOUNTING DETAILS.
5
A COMPLETE SET OF MATING CONNECTORS CAN BE PURCHASED FROM VICOR BY SPECIFYING
CONNECTOR KIT P/N 19-130044.
CONNECTOR PART NUMBERS SPECIFIED ARE MOLEX OR EQUIVALENT
MB
CB
REFERENCE
5.56
J3
J2
M1
4
2
1
NOTES: UNLESS OTHERWISE SPECIFIED
C2
C1
See page 11 for detailed
output connection information
OUTPUTS M3 & M4
.38 9.53
101.60
5
CUSTOMER MOUNTING HOLES
4X #8-32 x .250 OR M4 x 6mm MAX LG
FROM OUTSIDE OF POWER SUPPLY
35.59
OUTPUT M2 & M3
1 CB J1 (12 PIN)
.50 12.70
4.000
CUSTOMER MOUNTING HOLES
4X #8-32 x .125 OR M4 x 3mm MAX LG
FROM OUTSIDE OF POWER SUPPLY
1.40
OUTPUT M1
PIN 1
L1
N/C
N/C
.03 0.77
233.69
OUTPUTS M1 & M2
OUTPUT M2
DESCRIPTION
L2/N
GND
MBJ1
9.20
OUTPUT M1
PIN REF
1
MATING CONNECTOR:
HOUSING: MOLEX (39-01-4051)
SOCKET CRIMP 16 AWG: MOLEX (39-00-0090)
CRIMP TOOL: MOLEX (11-01-0199)
MBJ1 A/C INPUT
Measurement tolerances are
Fractions
+/- 1/32
Decimals
.xx +/- .01
.xxx +/- .005
Angles
+/- 1/2o
FlatPAC-EN/EN MI Mechanical Drawings
Applications Engineering: 800 927.9474
Page 10
Refer to page 6 to review configuration layout of FlatPAC-EN
A. STUD OUTPUT CONNECTOR - when configured with full brick and/or half brick
-V OUT
10-32 OUTPUT STUDS
SxJ2 REMOTE SENSE/TRIM
PIN CONNECTOR
+V OUT
3
2
1
- SENSE
+ SENSE
TRIM
MATING CONNECTOR:
HOUSING: MOLEX (50-57-9403)
TERMINAL FEM CRIMP 24-30 AWG: MOLEX (16-02-0103)
USE CRIMP TOOL: MOLEX (11-01-0208)
B. 18 PIN MOLEX CONNECTORS - when configured only with half bricks
(Note: The Molex connectors are limited to 9A/pin (27A/output)
9 18
OUTPUT M1
J2
8 17
7 16
6 15
5 14
OUTPUT M2 & M3
J3
4 13
3 12
2 11
1 10
Outputs M1
Outputs M2 and M3
PIN DESCRIPTION
PIN DESCRIPTION
1
2
3
4
5
6
7
8
9
N/C
N/C
N/C
N/C
N/C
TRIM M1
+V OUT M1
+V OUT M1
-V OUT M1
10
11
12
13
14
15
16
17
18
N/C
N/C
N/C
+ SENSE M1
N/C
- SENSE M1
+V OUT M1
-V OUT M1
-V OUT M1
1
2
3
4
5
6
7
8
9
+V OUT M3 10
-V OUT M3 11
-V OUT M3 12
+ SENSE M3 13
- SENSE M3 14
TRIM M2 15
+V OUT M2 16
+V OUT M2 17
-V OUT M2 18
+V OUT M3
+V OUT M3
-V OUT M3
+ SENSE M2
TRIM M3
- SENSE M2
+V OUT M2
-V OUT M2
-V OUT M2
MATING CONNECTOR:
18 PIN HOUSING: MOLEX (39-01-2180)
TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039)
USE CRIMP TOOL: MOLEX (11-01-0197)
C. 18 PIN MOLEX CONNECTORS - when configured with half and/or quarter bricks
(Note: The Molex connectors are limited to 9A/pin (27A/output)
OUTPUTS M1 & M2
J2
9 18
8 17
7 16
1
2
3
4
5
6
7
8
9
6 15
5 14
4 13
OUTPUTS M3 & M4
J3
Outputs M3 and M4
Outputs M1 and M2
3 12
2 11
1 10
+V OUT M2
-V OUT M2
-V OUT M2
+V OUT M2
-V OUT M2
TRIM M1
+V OUT M1
+V OUT M1
-V OUT M1
10
11
12
13
14
15
16
17
18
+V OUT M2
+V OUT M2
-V OUT M2
+V OUT M1
TRIM M2
-V OUT M1
+V OUT M1
- V OUT M1
- V OUT M1
1
2
3
4
5
6
7
8
9
+V OUT M4
-V OUT M4
-V OUT M4
+SENSE M4
-SENSE M4
TRIM M3
+V OUT M3
+V OUT M3
-V OUT M3
10
11
12
13
14
15
16
17
18
+V OUT M4
+V OUT M4
-V OUT M4
+V OUT M3
TRIM M4
-V OUT M3
+V OUT M3
- V OUT M3
- V OUT M3
MATING CONNECTOR:
18 PIN HOUSING: MOLEX (39-01-2180)
TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039)
USE CRIMP TOOL: MOLEX (11-01-0197)
Note: The type of output connector a FlatPAC-EN has depends on which modules are used. E.g. if a two output configuration uses two half bricks
(instead of a full brick and half brick) this two output configuration will have the 18 pin molex connectors, not stud connectors.
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Page 11
Output Connectors for FlatPAC-EN/EN MI
Item
Qty
1
3
8
2
**
Description
Vendor #1
Part #
HOUSING 3 POS .100 CTR W/LATCH
MOLEX
50-57-9403
TERMINAL FEM CRIMP 22 - 24 AWG SEL GOLD
MOLEX
16-02-0103
CRIMP TOOL FOR ITEM 2
MOLEX
11-01-0208
3
4
2
HOUSING 16 POS .165 CTRS W/LATCH
MOLEX
39-01-2160
5
2
HOUSING 18 POS .165 CTRS W/LATCH
MOLEX
39-01-2180
6
40
TERMINAL FEM CRIMP 18 - 24 AWG SEL GOLD
MOLEX
39-00-0039
CRIMP TOOL FOR ITEM 6
MOLEX
11-01-0197
7
1
HOUSING 5 POS .165 CTRS W/LATCH
MOLEX
39-01-4051
8
5
TERMINAL CRIMP 16 AWG 9 A GOLD
MOLEX
39-00-0090
CRIMP TOOL FOR ITEM 8
MOLEX
11-01-0199
9
1
HOUSING 12 POS .10 CTRS W/LATCH
MOLEX
50-57-9412
10
14
TERMINAL FEM CRIMP 24 - 30 AWG SEL GOLD
MOLEX
16-02-0097
CRIMP TOOL FOR ITEM 10
MOLEX
11-01-0209
**
**
**
** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT)
FlatPAC-EN - Connector Kit listing
Connector Kit 19-130044 - Available for purchase from Vicor
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Interface Connections
Chassis Input Power Terminals (MBJ1)
Input AC power is applied through connector MBJ1 using Molex mating connector
39-01-4051. Use 16 AWG wire with Molex Socket Pin 39-00-0090 and
Crimp Tool 11-01-0199.
A fault clearing device, such as a fuse or circuit breaker, with a maximum 9 A rating at
the power supply input is required for safety agency compliance. It should be sized to
handle the start-up inrush current of 8.5 A peak at 115 Vac or 17 A peak at 230 Vac.
Figure 1.
Input Power Terminal MBJ1
MBJ1
MBJ1 A/C INPUT
GND
MATING CONNECTOR:
N/C
L2/N
HOUSING: MOLEX (39-01-4051)
N/C
L1
SOCKET CRIMP 16 AWG: MOLEX (39-00-0090)
CRIMP TOOL: MOLEX (11-01-0199)
Output Power Connections
There are two types of output power terminals available in the FlatPAC-EN. Each slot has
one of the following configurations: either 10 - 32 plated steel bolts or an 18 pin Molex
connector (The type of output connector a FlatPAC-EN has depends on which modules
are used. See Pages 7 and 11. Molex connectors are limited to 9 A/pin, 27 A per output)
The positive polarity of the stud output termination is the right bolt when viewed from
the output end. Each power output is isolated, so outputs of positive or negative polarity
can be configured through proper selection of the output reference terminal.
In order to minimize parasitic cable inductance and reduce EMI, the output power
cables should be routed in close proximity to one another, and large current loops
should be avoided. To avoid excessive voltage drop, do not undersize power cables,
especially for high current outputs. Do not bulk input AC wires with the output
wires because this can couple output noise into the input wires which can increase
EMI. Excessive cable inductance coupled with large capacitive loading can introduce
instability in switching power supplies. This problem can be avoided with proper
system design. Consult Vicor’s Applications Engineering Department for assistance with
applications that use long cable lengths and excessive load capacitance.
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Figure 2.
Output Power Connections
A. STUD OUTPUT
10-32 OUTPUT STUDS
-V OUT
B. 18 PIN MOLEX OUTPUT CONNECTOR
J2/J3
9 18
8 17
+V OUT
7 16
6 15
J1/J2 SENSE/TRIM
PIN CONNECTOR
1
2
3
TRIM
+ SENSE
- SENSE
5 14
4 13
3 12
2 11
1 10
Output M1 (Using 1 Mini or 1 Junior)
PIN
1
2
3
4
5
6
7
8
9
J2 (18 PIN OUTPUT, SENSE
AND TRIM PIN CONNECTOR)
DESCRIPTION
PIN DESCRIPTION
N/C
10 N/C
N/C
11 N/C
N/C
12 N/C
N/C
13 + SENSE M1
N/C
14
N/C
TRIM M1
15 - SENSE M1
+V OUT M1
16 +V OUT M1
+V OUT M1
17 - V OUT M1
-V OUT M1
18 - V OUT M1
Outputs M2 and M3 (Using 2 Minis or 2 Juniors)
PIN
1
2
3
4
5
6
7
8
9
J3 (18 PIN OUTPUT, SENSE
AND TRIM PIN CONNECTOR)
DESCRIPTION
PIN DESCRIPTION
+V OUT M3
10 +V OUT M3
-V OUT M3
11 +V OUT M3
-V OUT M3
12 -V OUT M3
+ SENSE M3
13 + SENSE M2
- SENSE M3
14 TRIM M3
TRIM M2
15 - SENSE M2
+V OUT M2
16 +V OUT M2
+V OUT M2
17 - V OUT M2
-V OUT M2
18 - V OUT M2
B. 18 PIN MOLEX OUTPUT CONNECTOR
J2/J3
9 18
8 17
7 16
6 15
5 14
4 13
3 12
2 11
1 10
Outputs M1 and M2 (Using 2 Micros)
PIN
1
2
3
4
5
6
7
8
9
J2 (18 PIN OUTPUT, SENSE
AND TRIM PIN CONNECTOR)
DESCRIPTION
PIN DESCRIPTION
+V OUT M2
-V OUT M2
-V OUT M2
+V OUT M2
- VOUT M2
TRIM M1
+V OUT M1
+V OUT M1
-V OUT M1
10
11
12
13
14
15
16
17
18
+V OUT M2
+V OUT M2
-V OUT M2
+ VOUT M1
TRIM M2
- VOUT M1
+V OUT M1
- V OUT M1
- V OUT M1
Outputs M3 and M4 (Using 1 Micro
and 1 Mini or 1 Junior)
PIN
1
2
3
4
5
6
7
8
9
J3 (18 PIN OUTPUT, SENSE
AND TRIM PIN CONNECTOR)
DESCRIPTION
PIN DESCRIPTION
+V OUT M4
10 +V OUT M4
-V OUT M4
11 +V OUT M4
-V OUT M4
12 -V OUT M4
+ SENSE M4
13 + VOUT M3
- SENSE M4
14 TRIM M4
TRIM M3
15 - VOUT M3
+V OUT M3
16 +V OUT M3
+V OUT M3
17 - V OUT M3
-V OUT M3
18 - V OUT M3
(Note: The Molex connectors are limited to 9A/pin (27A/output)
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.
AC OK (CBJ1-3)
AC OK is an active high TTL compatible signal and provides a status indication of the AC
input power. It is on pin CBJ1-3 and is capable of sinking 16 mA maximum. This signal
switches to a TTL "1" when the high voltage bus exceeds low-line condition during turnon. Upon loss of input power, the bus voltage will drop, causing the AC OK signal to go
low. Typically, a 2.5 ms holdup time is provided for a 500 W load following the loss of
the AC OK signal.
TRANSMIT/RECEIVE RS-232 Command Protocol (CBJ1-4 and CBJ1-5)
The FlatPAC-EN/EN MI incorporates a microprocessor for communicating status and
allowing user control. A suitable Terminal Emulator must be used to communicate
with this circuit. A free emulator can be downloaded from the Vicor website at
www.vicorpower.com (FlatPAC-EN page). Operation in the remote mode requires
commanding the Power Supply to be a slave via the RS-232 interface.
Operating Modes
The FlatPAC-EN has two operating modes, Remote and Manual, which can be set using
the RS-232 interface feature. The operating mode setting is stored in a non-volatile
EEPROM and requires an REON or REOFF command in order to switch modes. The
default mode setting from the factory is in Manual mode. The FlatPAC-EN has an
operating mode indicator LED, which is viewable through the left side vent hole nearest
the CBJ1 E/D Interface Connector. When this LED is ON, the power supply is operating
in Remote Mode.
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Figure 3.
CBJ1
Interface
Connector
LED Indicator
Output
Connections
LED Indicator inside
Communications Protocol
The protocol is an ASCII character stream that will be sent back and forth between
the power supply and the user. The FlatPAC-EN/EN MI in the remote mode will be
considered a slave in that it will only respond to commands and requests and will
not initiate conversations. Communications are half-duplex in that only the FlatPACEN/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 format of 1 start bit, 8
data bits, 1 stop bit and no parity at 9600 Baud.
Commands, Status Requests and Module Replies
All commands and requests will have a reply. The reply will be one of the following
character strings followed by a CR/LF character pair. "OK"- Issued when a command
has been received and acted upon and the command has no return data associated
with it. "Inv Command"- Issued when an unrecognized command has been received
or a command cannot be executed at this time. "Inv Range"- Issued when a command
argument is not within a valid range.
The following is the list of commands and their definitions. All commands must be
followed with a CR/LF character pair.
PUP - Power Up
This command starts the automatic turn on timed sequence for the modules. If a Power
Down sequence is active at the time this command is received, a reply of
"Inv Command" is returned; otherwise "OK" is returned.
PDN - Power Down
This command starts the automatic turn off timed sequence for the modules. This
command can be given at any time and will cancel any uncompleted automatic power
up sequences. "OK" is returned.
EMO - Emergency Off
This command turns all modules off. If either a Power Up or Power Down sequence is
active at the time, it will be terminated immediately. A response of "OK" is returned.
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TON1, TON2, TON3, TON4
Turn On commands for modules 1, 2, 3, or 4.
These commands turn on the module identified by the trailing digit. If an automatic
sequence is in effect at the time this command is received, a reply of "Inv Command" is
returned; otherwise "OK" is returned.
TOFF1, TOFF2, TOFF3, TOFF4
Turn Off commands for modules 1, 2, 3, or 4.
These commands turn off the module identified by the trailing digit. If an automatic
sequence is in effect at the time this command is received, a reply of "Inv Command" is
returned; otherwise "OK" is returned.
SDON1, SDON2, SDON3, SDON4
Set Delay On Time for modules 1, 2, 3 or 4.
These commands set the associated time delays for the DC-DC converters to be activated
via "PC" pin release. There is an additional delay of up to 7 ms inherent in the DC-DC
converters. These commands are entered with a trailing argument. The valid range of
the argument is from 1 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 seconds. 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 power up of the unit or from
receipt of the Power Up command. If these commands are entered without an argument
then the unit will report the present settings of these variables.
SDOFF1, SDOFF2, SDOFF3, SDOFF4
Set Delay Off Time for modules 1, 2, 3, or 4.
These commands set the associated time delays for the DC-DC converters to be
deactivated via "PC"pin release. These commands are entered with a trailing argument.
The valid range of the argument is from 1 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
seconds. 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 argument then the unit will report the present settings of
these variables.
BV - Bus Voltage Readback
This command returns the current Bus Voltage reading.
MS - Module Status
This command returns the module status as shown: MS=X1 X2 X3 X4 X5
X1 indicates the status of module output 1.
X2 indicates the status of module output 2.
X3 indicates the status of module output 3.
X4 indicates the status of module output 4.
A "1" indicates the output is up/on and ok and a "0" indicates the output is down/off.
X5 indicates the status of the power supply Bus. A "1" indicates BUS OK and a "0"
indicates BUS NOT OK.
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SN - Serial Number
This command returns the serial number as set by factory (available only on request.)
REON - Remote Mode ON
This command put the power supply into the slave mode. In this mode the power
supply will only respond when commanded.
REOFF - Remote Mode OFF
This command put the power supply into the manual mode. In this mode the power
supply will only respond to the following commands via the RS-232 interface: REON,
SN, SDON1, SDON2, SDON3, SDON4, BV, MS, HST.
HST - Heat Sink Temperature
This command returns Temperature of the Heat Sink in degrees Celsius. Heat Sink
Temperature is measured frequently and stored into EEPROM memory. Upon loss of
power last measured value in stored in EEPROM.
Enable/Disable Mode (CBJ1-8 and CBJ1-9)
The Enable/Disable control pins allow outputs to be sequenced either on or off.
CBJ1-4 through CBJ1-9 are the control pins for outputs 1 through 4. 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 source 9 mA maximum. These pins should be open circuited or
allowed to exceed 4.5 V when enabled. Do not apply more than 5 V to these inputs.
Figure 4.
Enable/Disable Mode
J1
FlatPAC-EN
A TTL "1" applied to the base of the transistor turns
output OFF. Pin 1 (or Pin 7 for GSD) is pulled Low
with respect to Signal Ground.
5
Vcc
Enable/Disable Output 1
1
Enable/Disable Control
General Shutdown
TTL "1" (OFF)
TTL "0" (ON)
7
1
0
Signal Ground
4
The correspondence between a module and its E/D line as seen from the output end of
the power supply goes from left to right.
General Shutdown /GSD (CBJ1-10)
The GSD control pin on CBJ1-10 allows simultaneous shutdown of all outputs. This pin
must be pulled down to less than 0.7 V, and will source 9 mA maximum to shut down all
outputs. The GSD pin should be open circuited or allowed to exceed 4.5 V when not in
use, or when the outputs are to be enabled. Do not apply more than 5 V to this input at
any time. Normal open circuit voltage is 1.5 to 4 V with respect to Signal Ground.
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Auxiliary Vcc +5V/300mA (CBJ1-12)
Figure 5.
Auxiliary Vcc
78M05
+5V/300 mA
CBJ1
CBJ1-12 Auxiliary Vcc
0.1 µF
CBJ1-1 Signal Ground
The Vcc on CBJ1-12 is an auxiliary 5V regulated power source. It is +5 Vdc +/–5%
with respect to Signal Ground and can supply 300 mA maximum. It is capable of
withstanding a short, but shorted user interface functionality will be lost.
+Sense/­–Sense ( J2) (Not applicable when using BatMod current source.)
The sense lines for the outputs are shipped from the factory with Autosense. Autosense
provides the user with automatic sensing of the outputs. With Autosense, the FlatPACEN/EN MI will automatically operate in a Remote Sense mode when the Remote Sense
connections are made. But in the event that the Remote Sense is not connected or
needed, no Local Sense selection is necessary - simply hook up the outputs and the
FlatPAC-EN will automatically 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 and does not
require local sense jumpers. When using the remote sense feature, the +Out and -Out
load wires should never be disconnected while the supply is operating. Failing to do so
could damage the power supply.
In the local sense mode (Remote Sense lines not connected), the power supply will
regulate the output at the output terminals. The voltage appearing at the load may
drop slightly due to voltage drop in the power cables. If it is necessary to compensate
for voltage drop along the output power cables, the output can be trimmed up or
configured for Remote Sense. Use stranded twisted pair 24 - 30 AWG wire for the Remote
Sense lines. Remote Sense can compensate for a voltage drop of up to 0.5 V, or 0.25 V
on each leg.
The Sense connector for outputs with stud connectors is a 3 pin connector providing
the +Sense connection on J1/ J2-2 and the - Sense connection on J1/J2-3. The Sense
connector for outputs with 18 pin Molex connectors is provided on the 18 pin output
connector that also provides the output and trim connections. See Page 11 for details.
Figure 6.
+Out
Remote Sense
+Sense
Load
Use 24-30 AWG
Twisted Pair Wires
-Sense
-Out
Note: Remote sense is not available for output configurations using the Micro modules. network
or an external voltage source. To increase an output voltage above its nominal, it is
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External Trim (Not applicable when using BatMod current source)
The Trim pin can be used for external control of the output voltage. Trim connections on
single and dual output connector for output M1 is J1-1 while for output M2 is J2-2. Trim
connections on triple output connectors for output M1 is J2-6, for output M2 is J3-6, and
for output M3 is J3-14. Trim connections for quadruple output connectors on outputs
M1 and M2 is J2-6 and J2-14 respectively, and for outputs M3 and M4 is J3-6 and J314 respectively. A 10% increase to the trim pin voltage will result in a 10% increase in
output voltage. Reducing the trim pin voltage by 10% will result in a 10% decrease in
output voltage.
Table 1.
Module Internal Reference
Voltages and Thevenin
Resistances
Output Module
Vref
RTH
VI-200/VI-J00 ³3.3 V
2.50 V
10.0 kW
VI-200/VI-J00 < 3.3 V
0.97 V
3.88 kW
Maxi/Mini/Micro (Predefined)
1.23 V
1.0 kW
Maxi/Mini/Micro ( User defined)
1.23 V
Consult Factory
Figure 7.
External Trim
(Remote Sense)
+Out
R1
Use 24-30 AWG
Twisted Pair Wires
+Sense
To Error
Amplifier
+ RTH R5
V1
-
V Ref
R8
R2
Trim
R3
R6
R7
-Sense
R4
-Out
+
V2
Load
Use 24-30 AWG
Twisted Pair Wires
Example:
±10% Trim adjust on a 12 V nominal output.
Figure 7 shows a typical variable trim circuit. Using a 10 k trimpot (R7), the resistor
values for R6 and R8 can be calculated as follows:
V1= Vref + 10% = 2.75 V
IR5 = (2.75 V - Vref)/RTH = (2.75 V - 2.5 V)
/10 kW = 25 mA
Given: Vref = 2.5 V (see Table 1)
Given: RTH = 10 kW (see Table 1)
Setting the bottom limit:
VR6 = 2.5 V - 10% = 2.25 V
And since 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
R8 = VR8/IR8 = 8.2 V/525 mA = 15.62 kW
Given: Vnom = 12 V
CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS BELOW 5 V.
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Specifications (Typical at 25°C, nominal line and 75% load, unless otherwise specified)
General
Number of Outputs
1-4
Modules
VI-200/VI-J00, VE-200/VE-J00: Maxi/Mini/Micro
Efficiency
Typically > 70%
cURus – UL 60950-1, CSA 60950-1
Safety Agency Approvals
cTUVus – EN 60950-1, UL 60950-1, CSA 60950-1
CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC
Vibration
Mil-STD 810 Minimum Integrity (MI chassis only)
Shock
Mil-STD 810 40G Functional Shock (MI chassis only)
Maximum Output Power
Up to 500 Watts; 425 Watts for EN 61000-3-2/A14 compliance
(not to exceed input current of 9 A)
(105/190 Vac minimum input)
Input
90-132/180-264 Vac 47-63Hz
Input
90-132/180-264 Vac 47-63Hz
Inrush Current
8.5 A peak @ 115 Vac and 17 A peak at 230 Vac
Line/Load Regulation
VI200/VI-J00:± 0.2% max.10% to full load; ± 0.5% max. No load to 10% load
Line
Regulation[4]
Maxi/Mini/Micro:± 0.20% max. to 0.3% max LL to HL, Full Load
Ride Through Time:
500W
400W
@ 115Vac (typical)
12 ms
15 ms
@ 230Vac (typical)
16 ms
18 ms
Harmonic Distortion
Conducted EMI
EN61000-3-2 A/14 (For output power £ 425 W or input current not in excess of
3.33 A rms at 230 Vac, 50 Hz.)
FCC and EN 55022 Class A(certain configurations meet EN 55022 Class B)
Mil-STD 461 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
Primary to Chassis GND = 1,500 VRMS
Dielectric Withstand
Primary to Secondary = 3,000 VRMS
Secondary to Chassis GND = 500 VRMS
Output (VI-200/VI-J00 Modules)
Parameter
Min
Setpoint Accuracy[5]
Typ
Max
Units
0.5
1
%
of VNOM
Load/line Regulation
±0.2
%
10% to full load
Load/line Regulation
±0.5
%
Load to 10%
Temperature Regulation
0.01
Long Term Drift
0.02
0.02
%/°C
See module
VI/E-200
100
mV p-p
VI/E-J00
100
mV p-p
Voltage Trim Range:
VI-200/VI-J00 Slots
Total Remote Sense
Compensation
Over rated temp.
%/K hours
Output Ripple & Noise:
Notes
50-110
0.5
% VOUT
Volts
design guide
for exact
specifications
± 10% on
10-15 VOUT
Autosense.
See Page18
OVP Set Point[6]
115
125
%VOUT
Recycle Power
Current Limit
105
115
% of I max
Auto Recovery
UG:120
vicorpower.com Applications Engineering: 800 927.9474
Page 20
Specifications (Cont.)
Output (Cont.) (VI-200/VI-J00 Modules)
Parameter
Min
Short Circuit Current
(105[7])
20
Typ
Max
Units
130
%
Notes
Not available on
Overtemperature Limiting
VI-J00
Setpoint Accuracy[8]
±0.5
±1
% of VNOM
See module
Load Regulation
±0.01
% of VNOM
design guide
for exact
specifications
Temperature Regulation
0.002
Long Term Drift
0.02
0.005
%/K hours
%/°C
-20 to 100°C
Maxi
75
mV p-p
design guide
Mini
100
mV p-p
for exact
Micro
125
mV p-p
specifications
10-110
% Vout
See module
Output Ripple and noise:
Voltage Trim Range:
Preload may be
Maxi/Mini/Micro Slots
Total Remote Sense
0.5
Compensation
OVP Set Point
112
Current Limit
102
Volts
115
required
Autosense.
See Page18
135
% of VOUT
Recycle power
135
% of I max
Auto Recovery
Overtemperature Limiting
Not available
Enviornmental
Storage Temperature [9]
-40°C to +100°C
Operating Temperature [9]
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)
Derate 2.6% total output power for each 1,000 ft to a maximum operating
Altitude
altitude of 15,000 ft. Non-operating storage maximum altitude is 40 K.
Humidity
0 to 95% non condensing
Product Weight
3.4 lbs. (1,5 kg)
Dimensions
1.4" H (35,6 mm) x 5.0" W (127,0 mm) x 9.20" L (233,7 mm)
Warranty[10]
2 years limited warranty. See vicorpower.com for complete warranty statement.
[4] See
Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal output voltage.
[5] For
special and adjustable voltages, maximum setpoint accuracy is 2% of VNOM.
[6] 131%
Nominal for Booster Modules. No OVP for VI-J00.
[7] VI-J00
modules only.
[8] For special, adjustable voltages and 48 Vdc outputs, maximum setpoint accuracy is 2% of V
NOM.
Note: See individual module datasheets for specific module specifications.
[9] Specific
temperature data on all module configurations can be obtained by contacting
Applications Engineering.
[10] Opening,
repairing or modifying the unit will void the warranty. If you have any problem with the
power supply, please contact Customer Service at 1-800-735-6200. If the unit needs to be returned
for inspection/analysis, an RMA number will be issued. All units must have a RMA number
prior to return.
UG:120
vicorpower.com Applications Engineering: 800 927.9474
Page 21
Output Power Derating
FlatPAC-EN
Output Power vs. Input Voltage
500
Outp u t Po wer
(W atts)
450
400
Safe
Operating Range
Safe
Operating Range
350
300
265
255
245
235
225
215
205
200
200
195
190
185
180
175
165
155
145
132
132
125
115
105
95
100
90
260
250
Input Voltage (VAC)
FlatPAC-EN
Output Power vs. DC Input Voltage
600
550
500
Ou tpu t Powe r
(W atts )
450
400
Safe
Operating Range
350
300
250
200
150
100
50
0
250
260
270
280
290
300
310
320
330
340
350
360
370
380
Input Voltage (VDC)
UG:120
vicorpower.com Applications Engineering: 800 927.9474
Page 22
Output Power Derating (Cont.)
Vicor DC-DC Converters - 300 VIN Family Avilable Power (W)
Output
Voltage
VI/-200
VI-J00
Maxi
Mini
Micro
2 Vdc
80
40
160
100
50
3.3 Vdc
132
66
264
150
75
5 Vdc
200
100
400
200
100
200
100
500
250
150
12 Vdc
15 Vdc
24 Vdc
28 Vdc
48 Vdc
All module configurations: The FlatPAC-EN/EN MI or an individual output may be
limited by module power limitations.
1. One cannot exceed the output power rating of the FlatPAC-EN regardless of the
module capability.
2. Also see Output Power vs. Input Voltage charts on Page 22.
3. Please note that FlatPAC-EN configurations that uses Molex outputs connectors are
limited to 9 A/pin (27 A per output). This is a Molex connector limitation, NOT a
module power limitation. Vicor’s online configuration tool (VSPOC) will not provide a FlatPAC-EN/EN MI solution for requirements that exceed the 27 A limitation.
UG:120
vicorpower.com Applications Engineering: 800 927.9474
Page 23
Thermal Curves for FlatPAC-EN/EN MI
Output Power vs. Operating Temperature
Low Line (105 VAC) 5 V Modules
Left to Right Air Flow
Output Power (Watts)
500
Òê
450
400
ê
Ò
350
300
Òê
250
Òê
200
150
100
Òê
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
100 LFM
250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Output Power vs. Operating Temperature
High Line (190 VAC) 5 V Modules
Left to Right Air Flow
Output Power (Watts)
500
Ò
ê
450
400
Ò
ê
350
300
Ò
ê
250
200
Òê
150
100
Ò
ê
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
UG:120
100 LFM
vicorpower.com 250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Applications Engineering: 800 927.9474
Page 24
Thermal Curves for FlatPAC-EN/EN MI (Cont.)
Output Power vs. Operating Temperature
Low Line (105 VAC) 5 V Modules
Right to Left Air Flow
Output Power (Watts)
500
450
Ò
400
ê
350
300
Ò
ê
250
200
ê
Ò
150
Òê
100
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
100 LFM
250 LFM
Ò
500 LFM
750 LFM
ê
1000 LFM
Output Power vs. Operating Temperature
High Line (190 VAC) 5 V Modules
Right to Left Air Flow
Output Power (Watts)
500
ê
450
400
Ò
ê
350
300
ê
Ò
250
200
Ò
ê
150
Òê
100
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
UG:120
100 LFM
vicorpower.com 250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Applications Engineering: 800 927.9474
Page 25
Thermal Curves for FlatPAC-EN/EN MI (Cont.)
Output Power vs. Operating Temperature
Low Line (105 VAC) 12 V Modules
Left to Right Air Flow
Output Power (Watts)
ê
Ò
500
450
ê
Ò
400
350
Ò ê
300
250
Òê
200
150
100
Òê
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
100 LFM
250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Output Power vs. Operating Temperature
High Line (190 VAC) 12 V Modules
Left to Right Air Flow
Output Power (Watts)
ê
Ò
500
450
400
Ò ê
350
Ò ê
300
250
Òê
200
150
Òê
100
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
UG:120
100 LFM
vicorpower.com 250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Applications Engineering: 800 927.9474
Page 26
Thermal Curves for FlatPAC-EN/EN MI (Cont.)
Output Power vs. Operating Temperature
Low Line (105 VAC) 12 V Modules
Right to Left Air Flow
Output Power (Watts)
ê
Ò
500
450
Òê
400
350
Òê
300
250
Òê
200
150
Ò
ê
100
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
100 LFM
250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Output Power vs. Operating Temperature
High Line (190 VAC) 12 V Modules
Right to Left Air Flow
Output Power (Watts)
ê
Ò
500
450
Ò
400
ê
350
Òê
300
250
Ò
ê
200
150
100
Ò
50
0
0
10
20
30
40
50
60
70
80
90
Ambient Temperature (°C)
0 LFM
UG:120
100 LFM
vicorpower.com 250 LFM
Ò
500 LFM
ê
750 LFM
1000 LFM
Applications Engineering: 800 927.9474
Page 27
Current Share Boards - Optional Feature
"Current sharing" also known as Load Sharing, is the ability to divide the output current
evenly across all active power supplies. This greatly reduces stresses on each power
supply and allows them to run cooler, resulting in higher reliability. Standard "current
sharing" techniques typically utilize shunt resistors or Hall Effect devices to measure
the current from each power supply. Power shunt resistors continually dissipate power
and require cooling especially when dealing with high output currents of >100 Amps.
Hall Effect devices measure magnetic fields generated by current flowing through a
conductor and, although they dissipate no power, they tend to be large and expensive.
First developed by Vicor Engineering for paralleling MegaPAC supplies, the Box-to-Box
Current Share Board or CSB allows two or more Vicor power supplies to current share
by utilizing the inherent voltage drop produced in the negative output return cable. This
eliminates the need for additional shunt resistors or expensive Hall Effect devices and
provides a simple 5 wire connection method to achieve a +/-1 mV accuracy between the
Negative Output power rails. This accuracy translates to a 1% current sharing if there is a
total of 100 mV 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 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 the circuit also offers simple redundancy. In addition, because CSB functions as
a current source, the Trim outputs (T1 and T2) of the CSB can be placed in parallel to
create a summing node. This allows current sharing between more than two supplies by
paralleling the T2 output of one CSB circuit with the T1 output of the next CSB.
Please Note: The CSB is not intended for use in Hot-swap Applications.
Figure 8.
CSB Interconnect Expample
D*
+OUT
Supply # 1
5 V @ 120 A
+VOUT
+S
TRIM
Yellow
-S
-OUT
Brown
D*
+OUT
Supply # 2
5 V@120 A
+S
TRIM
-S
T1
-V1
T2
-V2
Power
Red
CSB02
-VOUT
White
Black
-OUT
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vicorpower.com Applications Engineering: 800 927.9474
Page 28
Current Share Boards - Optional Feature (Cont.)
Requirements:
1.For proper operation, the power supplies being paralleled should be enabled at the
same time.
2.-Out conductors must be of equal length and wire gauge.
Separate -Out conductors must be used from each supply to the load, or the use of
a "Y" connection to a common point must be used as shown in Figure 8. Each leg of
the "Y" must have 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.When using D*, the Power input should be connected on the cathode side of the
paralleling diodes as shown above.
6. Terminate Sense Leads either locally or remotely as shown in Figure 8.
UG:120
vicorpower.com Applications Engineering: 800 927.9474
Page 29
Current Share Boards - Optional Feature (Cont.)
0.13" (3.3mm) Dia Non
Plated thru hole 4
places
1.74"
(44.2mm)
2
1
4
3
6
5
Molex CT43045F surface mountable
connector. .390" height above board.
1.500"
(38.1mm)
J1 Pinout
Pin
Description
1
Power
2
1T
3
-V1
4
2T
5
-V2
6
No Connection
0.12"
(3.0mm)
0.12"
(3.0mm)
0.900"
(22.9mm)
1.14"
(29.0mm)
Figure 9. Mechanical Drawing
24.0" +/- 1.0"
Red, 22 AWG
P1
Power
Yellow, 22 AWG
T1
Brown, 22 AWG
-V1
White, 22 AWG
T2
Black, 22 AWG
-V2
Figure 10. 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 µA (VI-200/J00), +/–5 µA (Maxi/Mini/Micro).
4.Use four non-plated through holes with standoffs for mounting.
5.CSB01 MUST be used for current sharing VI-200/VI-J00 converters.
6.CSB02 MUST be used for current sharing Maxi/Mini/Micro converters.
PLEASE NOTE, THE CSB IS NOT INTENDED FOR HOT-SWAP APPLICATIONS
Contact your Regional Applications Engineer at 1-800-927-9474 for additional information.
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Page 30
NOTES:
UG:120
vicorpower.com Applications Engineering: 800 927.9474
Page 31
For Vicor Global Office Locations, please go to: www.vicorpower.com/contact-us
or call 800-735-6200.
For more information about this or other Vicor products, or for assistance with component-based power
system design, contact the Vicor office nearest you. Vicor's comprehensive line of power solutions includes
modular, high-density DC-DC converters and accessory components, configurable power supplies, and custom
power systems. Vicor, designs and builds configurable power supplies incorporating high density DC-DC
converters and accessory components.
This product line includes:
LoPAC FAMILY:
• PFC MicroS
• PFC Micro
• PFC Mini
MegaPAC FAMILY:
• PFC MegaPAC
• 4kW MegaPAC
• PFC MegaPAC (High Power)
• PFC MegaPAC-EL
• Mini MegaPAC
• ConverterPACs
OTHERS:
• FlatPAC-EN
Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini and PFC MegaPAC.
INFORMATION FURNISHED BY VICOR IS BELIEVED TO BE ACCURATE AND RELIABLE. HOWEVER, NO RESPONSIBILITY IS ASSUMED BY VICOR FOR ITS USE. NO LICENSE IS GRANTED BY IMPLICATION OR OTHERWISE
UNDER ANY PATENT OR PATENT RIGHTS OF VICOR. VICOR COMPONENTS ARE NOT DESIGNED TO BE USED
IN APPLICATIONS, SUCH AS LIFE SUPPORT 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
The Power Behind Performance
Rev 1.0
11/2014
P/N 03-000050
vicorpower.com Applications Engineering: 800 927.9474
Page 32