PFC MegaPACTM Power Factor Corrected AC-DC Switchers

USER GUIDE | UG:105
PFC MegaPACTM
Power Factor Corrected AC-DC Switchers
May 2013
ContentsPage
Overview of Product
1
Mechanical3
Considerations
MegaPAC3
Do’s and Don’ts
Technical Description
4
Configuring and
Reconfiguring
MegaPACs
5
ConverterPAC6
Description
ConverterPAC10
Output and Connector
Pin Identification
Quick Install
Instructions
12
Mechanical Drawings
15
Interface Connections 16
Specifications23
Power Derating
25
Connector Kit Listing
25
Current Share Boards
26
Low Leakage Version
29
Output Sequencing
30
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 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 Vicor power
supplies) online.
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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 that is 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 400 V). The driver is to the left of
the boosters when looking at the output end of the supply. A user-friendly interface
provides control and output sequencing capability (see page 30 for more information
about this capability), in addition to useful status indicators. Please consult our
Applications Engineering Department if you have other special requirements.
Standard Features
n Power Factor 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
nPower 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
nOutputs:
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 for limiting inrush current
n Conducted EMI meets FCC class A and EN 55022 class A
Some configurations meet Class B. Consult Factory
n Harmonic Distortion to EN61000-3-2
n RoHS compliant available
n Output Sequencing and General Shutdown
(Refer pg. 25. Consult Applications Engineering for automatic sequencing circuitry.)
n Overcurrent protection on all outputs
n Overvoltage protection and Overtemperature limiting on all ConverterPAC outputs (not applicable with VI-J00)
n Size: 3.4”H x 6.0”W x 12.4”L (313,9mm x 152,4mm x 309,mm)
n Safety Agency Approvals: cURus, cTUVus, CE Mark
Optional Features
n DC OK status signal
n Current Share Boards - see pages 26 - 28
n Output voltage adjustment range with built-in potentiometer
n Low Leakage Version available upon request - see page 29
n -40C operation
n Conformal Coating (contact factory)
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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 0.15 in. (3.8mm).
When selecting a mounting location and orientation, the unit should be positioned
so air flow is not restricted. Maintain a 2" 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 30 CFM 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 45 lb-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 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, compatible connector kits can be ordered separately. Refer to page 25 for additional information regarding connector kits.
n To 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.
n 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.
n Do not insert or remove a ConverterPAC while the power supply is running. They are not designed for hot insertion or extraction.
n Wait 5 minutes after shutting off the power supply before inserting or removing a ConverterPAC.
n Do not restrict airflow to or from the supply as this can cause overheating damage.
n Booster ConverterPACs are available for power expansion. Refer to page 6 for additional information.
n Do Not use boosters as independent outputs. Operating boosters with disconnected bus bars will cause failures.
n Before turning on the unit ensure all input and output wire are properly connected and all hex nuts properly tightened.
n Keep output wires as short as possible and run the output (+/-) power cables next to each other. Use twisted pair wiring whenever possible.
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n Avoid running input and output wiring in close proximity as this may cause noise related problems.
n PFC MegaPACs are NOT user serviceable. Please contact our customer service department at 1-800-735-6200 for repair assistance. Please be advised that attempts to repair or modify the power supply will void the warranty.
n A proper fault protection device (fuse or breaker) should be used in series with the input terminals.
n Use proper size wires to avoid overheating and excessive voltage drop.
n NEVER loosen the inner nut on a ConverterPAC.
n 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.
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 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 to 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 lowpower 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 Vcc comes up within 2 s 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 Vcc output of 5 Vdc sourcing up to 0.3 A is provided for peripheral use.
An output Enable/Disable function is provided by using an optocoupler to control
the Gate In pins of the ConverterPAC assemblies. If the Enable/Disable control pin is
pulled low, the optocoupler turns on, pulling the Gate In pin low and disabling the
ConverterPAC output. The nominal delay for an output to come up when measured
from release of the Enable/Disable pin is 10-15 ms. The General Shutdown function
controls all outputs simultaneously and works in a similar manner.
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The ride-through (holdup) 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 1.2 seconds after initial power-up and can be used
to indicate an impending loss of power. At least 3 ms 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.
Input
PFC MegaPAC and PFC
MegaPAC-High Power
Architecture
Line Filter
Soft Start
Circuit
Rectifier
Boost Converter
High Voltage
DC Bus
Waveform
Sample
Current
Sample
ConverterPAC #1
Power
Output
ConverterPAC #2
Power
Output
ConverterPAC #3
Power
Output
ConverterPAC #8
Power
Output
PFC Control
Customer
Interface
E/D Control
Fan
Current
Monitor
Enable/Disable Control
Housekeeping
Power
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 4 kW MegaPAC.) For outputs greater than 200 Watts, a driver ModuPAC
and one or more booster ConverterPACs will be used. For outputs greater than 600 Watts, 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 5 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. Power and interface connections can
be made after the ConverterPAC has been installed.
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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 as viewed from the output end of the MegaPAC.
Figure 2 shows a driver placed in slots #1 and 3 boosters placed in slots # 2 to 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
400 V. For detailed guideline on how outputs should be placed in series, please refer to
the Applications note (Creating high voltage outputs) available on the website at www.vicorpower.com.
Figure 2.
Paralleling ConverterPACs
Bus Bars for Paralleling
Loosen screw to
remove ConverterPAC
1
2
3
4
5
6
7
8
Driver
Boosters
ConverterPAC Functional Description
ConverterPACs are the family of slide-in output assemblies 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
+
_
VI-200
ModuPAC
ModuPAC
The ModuPAC output assembly consists of a VI-200 DC to DC converter that converts
the high voltage bus to the desired regulated output voltage. Each ModuPAC can provide
up to 200 Watts of power. Multiple ModuPACs can be paralleled in a driver-booster
configuration
to provide more power. ModuPACs are fused with a PC-Tron, DC-rated,
+ Vout
Remote Sense fuse. A passive LC filter is used to reduce output ripple/noise down to 1%
fast-acting
Output Adjust
typical,
- Vout and 2% maximum peak-to-peak from 10% to 100% of rated load. An optional
DC OK (PowerGood
Good)
DC Power
signal, or output voltage Trim potentiometer can be specified. The
ModuPAC contains overvoltage protection (OVP), overcurrent protection (OCP), and
overtemperature limiting (OTL). The OCP has automatic recovery when the overcurrent
condition is removed. The OVP and OTL are latching functions and require recycling of
the AC input power to restart.
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+
_
VI-J00
JuniorPAC
JuniorPAC
The JuniorPAC consists of a VI-J00 DC to DC converter that converts the high voltage
bus to the desired regulated output voltage. JuniorPACs can provide up to 100 Watts of
+ Vout
output
power and are fused with a single PC-Tron, DC-rated, fast-acting fuse. A passive
Remote Sense
Output Adjust
LC filter
is used to reduce output ripple/noise down to 1% typical, and 2% maximum
- Vout
peak-to-peak
from 10% to 100% of rated load. An optional DC Power Good signal or
DC OK (Power Good)
output voltage Trim potentiometer can be specified. The JuniorPAC contains output
overcurrent protection, which recovers automatically when the overcurrent condition is
removed. Overvoltage protection and overtemperature limiting are not available.
Output #1
M1
VI-J00
VI-J00
M2
M1
M2
Remote Sense
DualPAC
Output #1 Adjust
This output assembly consists of two VI-J00 DC to DC converters that convert the high
#2
voltageOutput
bus
to the desired regulated output voltages as noted above. The outputs are
Remote Sense
electrically
isolated. For detailed pin out description, refer to page 10.
Output #2 Adjust
DualPAC
+
VI-J00
_
RAM
RAMPAC
RAMPAC
This +output
assembly consists of a VI-J00 DC to DC converter with a Ripple Attenuator
Vout
Remote Sense
Module
(RAM) and is designed for applications requiring low output ripple/noise. The
Output Adjust
RAMPAC
can attenuate the ripple/noise down to 10 mV peak-to-peak over a 20 MHz
- Vout
DC OK (Power Good)
bandwidth
from 10% to 100% of rated load of the converter. Outputs from 5 V to 50 V are available.
BatPAC
+
_
VI-200/BatMOD
BatPAC
+
_
Maxi
ModuPAC
The BatPAC output assembly consists of a VI-200 BatMod current source that converts
the high
+ Vout voltage bus to the desired regulated output voltage. The converter is fused with
Current Limit Adjust
a PC-Tron,
DC-rated, fast-acting fuse. The BatPAC is a 200 Watts programmable current
Voltage Limit Adjust
source
- Voutthat can be configured as a battery charger. Maximum current and voltage
Remote are
Interfacecontrolled using potentiometers that come as a standard feature, or through
settings
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 voltage. Each Maxi module
+ Vout
Remote
Sense
can provide up to 600 Watts of output power. Each FinPAC occupies 2 slots because
Output Adjust
it has
an extra large heatsink attached to dissipate the heat generated by this more
- Vout
DC OK (Power
Good)
powerful
Maxi
converter. Currently, the FinPAC is ONLY used in the high power (MX)
chassis. It cannot be used in any other member of the MegaPAC Family. Contact Vicor for future updates.
FlexPAC
The FlexPAC output assembly consists of from 2 to 4 discrete outputs that convert the
high voltage bus to the desired output voltage. Each FlexPAC output can be manually
trimmed from 2 V to 25 V and supports up to 5 amps with a maximum output power
of 50 W per output. All outputs maintain less than 50 mV noise over the entire output
range. All outputs support local sense only. For electrical trim options and specific
output sequencing contact the factory.
M-1 STATUS
M-2 STATUS
M-1 VOLTAGE ADJUSTMENT
M-2 VOLTAGE ADJUSTMENT
CONNECTOR
J1
M-3 VOLTAGE ADJUSTMENT
M-4 VOLTAGE ADJUSTMENT
M-3 STATUS
M-4 STATUS
FlexPAC
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List of ConverterPACs used in the PFC MegaPAC and
PFC MegaPAC-High Power and their features
ConverterPAC
OVP
OCP
OTL
RS/AS
LS/AS
PG
TrimPot
ModuPAC
Std
Std
Std
AS*
AS*
Opt
Opt
JuniorPAC
N/A
Std
N/A
AS*
AS*
Opt
Opt
DualPAC
N/A
Std
N/A
AS*
AS*
N/A
Opt
RAMPAC
N/A
Std
N/A
AS*
AS*
Opt
Opt
BatPAC
N/A
Std
N/A
N/A
N/A
N/A
Std
FinPAC**
Std
Std
N/A
AS*
AS*
Opt
Opt
FlexPAC
Std
Std
Std
LS
LS
N/A
Std
* See pages 12 and 13 for more information on Autosense.
** All the above mentioned ConverterPACs can be used in both the PFC MegaPAC and PFC MegaPAC-
High Power except the FinPAC which currently can only 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 outputs
b = number of DC-DC modules and FlexPACs
cccc = customer specific configuration code
v = optional revision code and may be blank (note: v = G for RoHS compatible
product)
xx = additional option codes
Note: xx = MI for rugged chassis, = MC for rugged chassis with conformal coating
ConverterPACXxDV/xEAxF
X = ConverterPAC type (For RoHS, add G to current prefix)
xD = Voltage out
xE = Current out (rounded to 1 decimal point)
xF = Can be multiple options* (see page 9)
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Part Numbering (Cont.)
* ConverterPAC options
B Booster module
D
F
S
1
Trimpot removed for external
BatPAC adjustment
DC OK or Power Good
2
Full 50-110% output adjustment
T
90-110% output adjustment4
F1
50-107.5% output adjustment
T1
90-107.5% output adjustment
F2
50-105% output adjustment
T2
90-105% output adjustment
F3
50-102.5% output adjustment
T3
90-102.5% output adjustment
F4
50-100% output adjustment
T4
90-100% output adjustment
F5
60-110% output adjustment
T5
98-105% output adjustment
F6
70-110% output adjustment
T6
100-110% output adjustment
80-110% output adjustment
V1
"VXI" low noise (150 mV or less)
F7
I
Industrial Grade module
K
Custom SRF module used
P
Preload
M
R
15V< VOUT ≤ 24 V5
V2
"VXI" low noise (50 mV or less)
VOUT ≤ 15 Vdc
Military Grade module
V3
RAM external3
“VXI” low noise (1% ripple or less)
VOUT > 24 V
Examples:
M15V/10A, M15V/10ADFI, D15V/6.7A-12V/8.3AT
M = ModuPAC (RoHS =GM)
D = DualPAC (RoHS = GD)
J = JuniorPAC (RoHS = GJ)
[1]
R = RAMPAC (RoHS = GR)
B = BatPAC (RoHS = GB)
PZ = PZ - FinPAC (RoHS = GPZ)
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, components such as autosense resistors and local sense
jumpers must be removed before turning on the supply. In addition, in order to insure proper operation,
sense pins must be connected either locally or remotely after the RAM's output. For further information,
contact Applications Engineering.
[4] T options: Optional for all ConverterPACs EXCEPT the BatPAC, DualQPAC, and FlexPAC. Trim Range
dependent on module type and voltage
[5]
V options: Optional ONLY on the ModuPAC, DualPAC and JuniorPAC. N/A on all other
ConverterPACs. Requires 15% minimum load.
FlexPACFxxaaa-bbb-ccc-ddd
F = FlexPAC
xx = pack chassis variations
aaa = voltage setting for output 1 with implicit factor of 10 (103 = 10.3 V)
bbb = output 2
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DUALPAC
ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC
ModuPAC
JuniorPAC
RAMPAC
J2 (REMOTE SENSE)
+ V0UT
J2-PIN1
OUTPUT ADJUST
1
2
3
MATING HDWR:
TRIM PIN ACCESS
HOUSING- MOLEX P/N: 50-57-9403
+ SENSE
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 11-01-0208
- SENSE
- VOUT
J3 DC OK (POWER GOOD)
J3-PIN1
DualPAC
J1-B-PIN1
J2-B-PIN1
OUTPUT ADJ. #1
HOUSING- MOLEX P/N: 39-01-0043
Vcc IN
4
3
2
1
MATING HDWR:
TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
POWER GOOD
POWER GOOD INVERTED
SIGNAL GROUND
J1 (OUTPUT CONNECTORS)
1 AND 4 +V OUT
4
5
1
2
2 AND 5 -V OUT
6
3
3 +R/SENSE 6 -R/SENSE
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-2060
TERMINALS- MOLEX P/N: 39-00-0039
CRIMP TOOL MOLEX P/N: 11-01-0197
J1-A-PIN1
J2 (REMOTE SENSE)
J2-A-PIN1
OUTPUT ADJ. #2
1
2
3
MATING HDWR:
TRIM PIN ACCESS
HOUSING- MOLEX P/N: 50-57-9403
+ SENSE
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 11-01-0208
- SENSE
20-130182-TAB
DUALPAC - COMPONENT SIDE VIEW
M2
Output A
48V/2.1A
M1
Output B
12V/8.3A
J1-B (M1)
J1-A (M2)
Example: D12V/8.3A-48V/2.1A
Note:
1. All ConverterPACs 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.
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ConverterPAC Output and Connector Pin Identification for the PFC MegaPAC
BatPAC
+ V0UT
J2 (BATPAC REMOTE INTERFACE)
CURRENT LIMIT ADJUST
VOLTAGE LIMIT ADJUST
- VOUT
4
3
2
1
MATING HDWR:
CURRENT LIMIT ADJUST
HOUSING- MOLEX P/N: 39-01-0043
VOLTAGE LIMIT ADJUST
TERMINALS- MOLEX P/N: 30-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
CURRENT MONITOR
- VOUT
J3-PIN1
FinPAC
+ 0UT
P2 REMOTE SENSE TRIM/SC & POWER GOOD
OUTPUT ADJUST
- OUT
4
3
2
1
P2-PIN1
HOUSING- MOLEX P/N: 39-01-0073
TRIM
Vcc IN
POWER GOOD
TERMINALS- MOLEX P/N: 39-00-0031
CRIMP TOOL MOLEX P/N: 57005-5000
POWER GOOD INVERTED
SIGNAL GROUND
M1
2
M2
3
M3
4
+
1
+
–
M4
MATING HDWR:
+
–
HOUSING MOLEX P/N 39-01-2120
n/a n/a
CRIMP TOOL MOLEX P/N 11-01-0197
6
+
n/a n/a
TERMINALS MOLEX P/N 39-00-0039
5
–
12
M-4 STATUS
10 11
M-3 VOLTAGE ADJUSTMENT
M-4 VOLTAGE ADJUSTMENT
M-3 STATUS
9
J1
8
M-2 STATUS
M-1 VOLTAGE ADJUSTMENT
M-2 VOLTAGE ADJUSTMENT
CONNECTOR
MATING HDWR:
-SENSE
7
M-1 STATUS
+SENSE
–
FlexPAC
7
6
5
Note:
1. All ConverterPACs 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.
UG:105
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Page 11
PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see page 15)
Mounting the PFC MegaPAC and PFC MegaPAC-High Power
n Mount the power supply on any of its four sides.
n Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15" (3,8mm). The maximum allowable torque is 5.5 lb-in.
n Maintain 2" (5,1cm) clearance at either end for airflow.
Input Connections
L2MODUPAC/JR.PAC/RAMPAC
L1
Input Power J9
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
INPUTS
115/230 VAC
47 TO 500 Hz
300VDC
n Apply input AC power to terminal block J9 using a pressure screw terminal.
n Strip length of AC power conductors to be 0.35 inches.
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
n Maximum torque is 4.4 lb-in.
LABEL NO: 94-00046 REV B
Input Panel Connectors
n Place a fuse or circuit breaker in the input line for safety reasons.
n Use a maximum wire size of 14 AWG with soldered terminals.
n The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix
P/N 32-00-58-0, purchased from other sources) can be used to prevent fraying.
Output Connections
+ Vout
Power Connections
J2 Pin 1
Vtrim Pot Adjust (Option)
- Vout
Installing ring lugs and/or bus bars on output studs:
n The upper stud is Positive and the lower stud is the Return.
J3 pin 1 (DC OK Option)
Single Output ModuPAC
n Newer outputs studs are 1/8th inch longer. See page 24 for more information.
n Remove nut.
n Place ring lug over output stud.
n Replace and tighten outer nut to a maximum torque of 45 lb-in.
Do Not Over-Tighten Nuts.
n Verify all output nuts are properly installed before turning on supply.
J1A
6 5 4
-RS +RS 3
2
J1B
6 5 4
+
-RS +RS -
+
1
3
1
+
2
+
DualPAC Output Connector
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 #11-01-0197.
Sense Connections
Note: Newer power supplies have the Autosense feature. For these units, if Remote
Sense connections are not made or needed, no Local Sense selection is necessary simply connect the output to the load and the unit will automatically operate in Local
Sense. If Remote Sense connections are made, the unit will operate in a Remote Sense
mode. Remote Sense terminals should be terminated to their respective output i.e. - RS
to - Output and + RS to + Output. See page 13 for more information on Autosense. For units without Autosense, sense connections must ALWAYS be made. Not
connecting sense lines to their respective output can cause failure to the unit.
UG:105
vicorpower.com Applications Engineering: 800 927.9474
Page 12
Sense Connector J2 (and P2 for the FinPAC):
J2 Sense Connector
J2
Pin
J2-1 Trim Pin Access
J2-2 +Sense
J3-3 -Sense
1
2
3
n Sense connections do not have to be made if the Local Sense option was ordered or if
Autosense is present (see above note on Autosense.)
n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided.
n J2-2 is the +Sense and J2-3 is the -Sense.
P2 Sense Connector
n Attach terminals to 22-24 AWG twisted pair wire using Molex tool #11-01-0208.
+SENSE
7
6
5
n Attach opposite ends of Sense lines to point where regulation is desired.
-SENSE
4
3
2
1
TRIM
Vcc IN
POWER GOOD
n Verify that Sense lines are not cross-connected before applying input power.
POWER GOOD INVERTED
n Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided
n For the FinPAC, P2-7 is the + Sense and P2-6 is the -Sense.
SIGNAL GROUND
n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.
6
J1A
5 4
-RS +RS 3
2
6
J1B
5 4
Sense Connections on DualPACs:
+
n Sense connections do not have to be made either if the Local Sense option has
+
-RS +RS -
+
been ordered or Autosense is present (refer to note on Autosense).
1
3
1
n Sense connections are available on the J2 connector (P2 for the FinPAC)
or the J1A and J1B connectors.
+
2
PIN
1 and 4 +V OUT
2 and 5 -V OUT
3 +REMOTE SENSE
6 -REMOTE SENSE
DualPAC Output Connector
n If using J2 or P2 connector, see instructions on page 10.
n On J1A and J1B, Pin 3 is the +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.
J2 Trim Pin Connector
J2
Pin
J2-1 Trim Pin Access
J2-2 +Sense
J3-3 -Sense
1
2
3
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 “F” in the ConverterPAC part number means the Trim option is
installed; e.g. M5V/40AT.)
n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided.
P2 Trim Pin Connector
7
6
5
4
3
2
1
+SENSE
-SENSE
TRIM
Vcc IN
POWER GOOD
POWER GOOD INVERTED
SIGNAL GROUND
n Attach terminals to 22-24 AWG stranded wire using Molex tool #11-01-0208.
n J2-1 provides Trim access.
n For the FinPAC, refer to P2 Connector. P2-5 provides Trim Access.
n Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.
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vicorpower.com Applications Engineering: 800 927.9474
Page 13
DC OK (Power Good)
DC OK (Power Good) Connection J3 (and P2 for FinPAC)
J3
n DC OK is only available as an option and is not always present.
4
3
2
1
Pin
J3-4
J3-3
J3-2
J3-1
Vcc
Power Good
Power Good Inverted
Signal Ground
P2 DC OK Connector
+SENSE
7
6
5
-SENSE
TRIM
Vcc IN
POWER GOOD
4
3
2
1
POWER GOOD INVERTED
SIGNAL GROUND
n J3-4 is Vcc In, J3-3 is Power Good, J3-2 is Power Good inverted, and J3-1
is Signal Ground.
n Use Molex mating receptacle #39-01-0043 with #39-00-0031 terminals provided.
n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.
n For the FinPAC, refer to the P2 Connector. P2-3 is Power Good.
n Use Molex mating receptacle #39-01-0073 with #39-00-0031
terminals provided.
n Attach terminals to 22-28 AWG stranded wire using Molex tool #57005-5000.
Interface Connections J10
J10
4
5
6
1
2
3
7
8
9 10 11 12
n Use Molex mating receptacle #39-01-2120 with #39-00-0039 terminals provided.
n J10-1 to 8 are Enable/Disable for slots 1-8.
J10 INTERFACE
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
J10-7
J10-8
J10-9
J10-10
J10-11
J10-12
E/D-7
E/D-8
Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
n J10-9 is Vcc, J10-10 is Signal Ground, J10-11 is AC Power OK, and J10-12 is General Shutdown.
n Attach terminals to 18-24 AWG stranded wire using Molex tool #11-01-0197.
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 only.
M4
5
7
8
9
10
11
12
–VOUT M1
–VOUT M2
–VOUT M3
–VOUT M4
DO NOT USE
DO NOT USE
1
2
3
4
5
6
+VOUT M1
+VOUT M2
+VOUT M3
+VOUT M4
DO NOT USE
DO NOT USE
6
n/a n/a
M3
4
+
n/a n/a
12
–
10 11
M2
3
+
–
9
2
+
–
8
UG:105
1
+
–
7
M1
vicorpower.com Applications Engineering: 800 927.9474
Page 14
4
5
6
47 TO 500 Hz
UG:105
vicorpower.com LABEL NO: 94-00046 REV B
47 TO 500 Hz
L2
LABEL NO: 94-00046 REV B
FAN
.25 [6.35]
.21 [5.33]
2.92 [74.17]
.47 [11.94]
5.10 [129.54]
(DIRECTION OF AIR
FLOW OPTIONAL)
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
300VDC
L2
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
INPUTS
115/230 VAC
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1
L1
300VDC
14 AWG WIRE
INPUTS
115/230 VAC
CLAMPING SCREWS
6.04 [153.42]
3.37 [85.60]
MATING HDWR:
HOUSING-MOLEX P/N: 39-01-2120.
TERMINALS-MOLEX P/N: 39-00-0039
CRIMP TOOL-MOLEX P/N: 11-01-0122
L1
INPUT CONNECTIONS
3
9 10 11 12
2
8
1
7
J10
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
E/D-7
E/D-8
Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
J10 INTERFACE
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
J10-7
J10-8
J10-9
J10-1O
J10-11
J10-12
2.92 [74.17]
.21 [5.33]
2.75 [69.85]
(T0P AND BOTH SIDES)
CUSTOMER MOUNTING HOLES (16X)
M4 OR #8-32 THREAD MAXIMUM
SCREW PENETRATION .150 [4.00 MM]
FROM OUTSIDE SURFACE.
6.75 [171.45]
(ORIGINAL LENGTH)
12.24 [310.83]
6.75 [171.45]
(RE-DESIGNED LENGTH)
12.36 [313.87]
6.75 [171.45]
11.93 [302.90]
.53 [13.39]
2.77 [70.23]
FLANGED
NUT
RE-DESIGNED
BRASS
INSERT
.47 [11.94]
5.10 (129.5 MM)
7 SP. @ .7285
(18.5 MM)
STUD IS 1/8 INCH LONGER. (SEE SHEET ONE FOR DIMENSIONAL DATA).
MAY BE PRESENT. THE NEW OUTPUT PANEL HAS A BRASS INSERT AND THE
NOTE: EITHER THE ORIGINAL OR RE-DESIGNED OUTPUT STUD AND PANEL COMBINATION
ORIGINAL
1.40 [35.56]
.73 [18.52]
1.46 [37.03]
3.28 [83.19]
OUTPUT PANEL AND STUDS
1/4 - 20 SERRATED FLANGED
NUT ZINC PLATED STEEL
WITH OPTIONAL BUSS BARS
ORIGINAL STUD AND PANEL
.41 [10.35]
RE-DESIGNED STUD AND PANEL
PFC MegaPAC Mechanical Drawing
Applications Engineering: 800 927.9474
Page 15
Interface Connections
Chassis Input Power Terminals (J9)
Input AC power is applied to terminal block J9 using a pressure screw terminal that
accepts a maximum wire size of 14 AWG. The insulation should be stripped .35 inches
and the maximum torque applied to the screws should not exceed 4.4 lb-in. The
connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N
32-00-58-0, purchased from other sources) can be used to prevent fraying. J9-1 (GND) is
Earth Ground for safety; J9-2 (L2) and J9-3 (L1) are the other Hot connections. For Input
DC power, L2 is (+) and L1 is (-).
A fault clearing device, such as a fuse or circuit breaker with a maximum 15A rating at
the power supply input is required for safety agency compliance. It should be sized to
handle the start-up inrush current of 25A pk at 115 Vrms and 230 Vrms.
Figure 3.
Input Panel Connectors
L1
INPUTS
115/230 VAC
47 TO 500 Hz
300VDC
L1
L2
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
LABEL NO: 94-00046 REV B
u
INPUTS
115/230 VAC
47 TO 500 Hz
300VDC
L2
DO NOT
OPERATE
WITHOUT
EARTH
GROUND
INPUT CONNECTIONS
J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
LABEL NO: 94-00046 REV B
Output Power Connections (+P, -P for Single Output, or J1A/J1B for Dual Outputs)
For single output ConverterPACs, these terminals are two 1/4-20 plated steel studs. The
upper stud is positive with respect to the lower stud. For dual output ConverterPACs,
there is a 6-pin Molex connector for each output. J1A pins 1 and 4 are the +Output,
and J1A pins 2 and 5 are the -Output. Pins 3 and 6 are duplicates of the Remote Sense
terminals present on J2A and J2B. Use appropriate wire size rated to handle the full
output current, including short circuit levels. Avoid large current loops in output cables;
run power 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 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. FlexPAC is local sense only.
If units do not have Autosense, sense connections must be made. When making
sense connections, keep in mind that although all outputs are open-Sense protected,
the +/-Sense terminals must be connected to their respective outputs before the PFC
MegaPAC and PFC MegaPAC-High Power are powered up. Regardless of the output
polarity configured, the +Sense should always connect to the +Power output. The
-Sense connects to the -Power output. Sense connections are not required on booster
ConverterPACs, BatPACs, or if the Local Sense option is specified. Local Sense mode
means that the Remote Sense lines are not connected. Sense pins can be accessed on
J1A/J1B or J2A/J2B on dual output units.
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Page 16
Signal Ground (J10-10)
Signal Ground (see Figure 4 and Connector Pin Identification on page 14) is an isolated
ground reference for all J10 interfacing signals, and can be used for ConverterPAC
output status signals such as Power Good. This is not the same as Earth Ground on input
power connector J9.
Figure 4.
Interface Connector
J10
4
5
6
1
2
3
7
8
9 10 11 12
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
J10-7
J10-8
J10-9
J10-10
J10-11
J10-12
E/D-7
E/D-8
Vcc +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
Enable/Disable (J10-1 to J10-8)
The Enable/Disable control pins allow ConverterPAC outputs to be sequenced either
on or off. J10-1 through J10-8 are the control pins for output positions 1 through 8,
respectively (see Figure 5 and Connector Pin Identification on page 14). For DualPACs
and FlexPACs, all outputs are sequenced. In parallel array using VI/VE modules only
the driver ConverterPAC 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 the
effects of switch bounce.
Figure 5.
Enable/Disable and
General Shutdown
A TTL "1" applied to the base of the transistor turns
output OFF. Pin 1 (or Pin 12 for GSD) is pulled Low
with respect to Signal Ground.
Enable/Disable Output 1
TTL "1" (OFF)
TTL "0" (ON)
1
0
General Shutdown
Signal Ground
UG:105
vicorpower.com J10
9
PFC MegaPAC
Vcc
1
12
10
Applications Engineering: 800 927.9474
Page 17
Enable/Disable control of Maxi/Mini/Micro Module Arrays
When using the Enable/Disable function on an output that consists of two or more Maxi
modules, it is necessary to connect the E/D pins of the corresponding module locations
together such that both modules are commanded to turn ON or OFF simultaneously.
Example:
Slots 2, 4 and 6 have been configured as a single output parallel array (see Figure 6)
In order to disable the 48 V output, E/D 2, E/D 4 and E/D 6 should be shorted together
as shown in Figure 6. With E/Ds connected together, a single switch can then be used to
remotely enable and disable the output.
**Note: For single output power supply configurations, the simplest method of remotely enabling and disabling the output is to use the General Shutdown (GSD) function.
Figure 6.
Enable/Disable Control
of Maxi Arrays
J10
Slot# 8 M3.3V/40A
2
4
6
Slot# 7 M5V/40A
MegaPAC
Power Factor Corrected
J1
123
Slot# 6 PZ48V/12.5AJS1
10
Slot# 5
Slot# 4 PZ48V/12.5AJS1
Slot# 3
Slot# 2 PZ48V/12.5AN
Slot# 1
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 allowed to exceed 4.5 V when not in use, or when
the outputs are to be enabled. Do not apply more than 6 V to this input at any time.
Normal open circuit voltage is 1.5 to 3 V with respect to Signal Ground. If driven from
an electromechanical switch or relay, a capacitor should be connected to eliminate the
effects of switch bounce.
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Page 18
AC OK / Power Fail (J10-11)
This is an active high TTL compatible signal and provides a status indication of the AC
input power (see Figure 7 and Connector Pin Identification on page 14). It is capable
of sourcing 0.5 mA at >3.2 V and sink 16mA at < 0.5 V. This signal switches to a TTL “1”
when the high voltage bus exceeds low-line condition during turn-on, and switches
to a TTL “0” 3 ms (minimum) before loss of output regulation due to the loss of input
AC power. This signal can be used to warn external control circuits of an
impending loss of power.
Figure 7.
AC OK Power Fail
J10
+5V
10K
2.49K
PN2222
11 AC Power OK
10 Signal Ground
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
circuitry or is used with the Power Good circuitry to provide a pull-up reference for the
outputs of the DC Power Good circuit on a ConverterPAC. If used for this purpose, the
Signal Ground on J10-10 must also be connected to the J3-1 Signal Ground pin
of the ConverterPAC.
Figure 8.
Auxiliary Vcc
78M05
+5V/300 mA
J10
9 Auxiliary Vcc
0.1 µF
10 Signal Ground
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Page 19
Power Good (J3-3)
The optional Power Good signal on J3-3 is referenced to Signal Ground on J3-1, and
indicates the status of the output voltage. This signal is asserted a TTL “1” when the
output voltage is above 95% of nominal. It is a TTL “0” when the output voltage is
below 85% of nominal. If the Trim option is also used, the Power Good trip points
DO NOT track with the trimmed voltage. It is possible to trim the output below the fixed
setpoints of the Power Good circuit and cause a negative Power Good signal.
Figure 9.
ConverterPAC
Power Good and Vcc
2.49K
2.49K
10K
2N2222
J3
4
Vcc In
3
Power Good
2
1
Power Good Inverted
Signal Ground
Power Good Inverted (J3-2)
This is the inverse of the Power Good signal and is referenced to Signal Ground on J3-1.
Signal Ground (J3-1)
Signal Ground on J3-1 is an isolated secondary ground reference for J3 status signals. It
is used to provide a reference point for the Power Good circuitry and is not the same as
Earth Ground on input power connector J9.
Vcc In (J3-4)
The Vcc In on J3-4 is an input that requires +5 V either from the J10 Auxiliary Vcc, or
from another source. Input current to this pin is limited by an internal resistor to 3 mA.
If the J10 Auxiliary Vcc is connected to Vcc In on J3-4, then the J10 Signal Ground must
be connected to Signal 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 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, this termination should be made close
to the output load. Compensation of up to 0.5 V (0.25 V per lead) can be obtained. Use
twisted pair 22-24 AWG wire for this purpose.
For DualPACs, the +Sense pins are available on connectors designated as J2A-2 and
J2B-2 for outputs A and B, respectively. –Sense pins are on J2A-3 and J2B-3, respectively.
These pins are also duplicated on the power connectors J1A and J1B.
Reminder: Only units with Autosense will automatically operate in Local Sense mode if no sense
connections are made. It will operate in remote sense mode if remote sense connections are made.
Units without Autosense MUST have sense connections (Local or Remote) terminated to their respective
output for the unit to operate properly.
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vicorpower.com Applications Engineering: 800 927.9474
Page 20
Figure 10.
Sense Leads
+P +Out
(Local Sense)
(Remote Sense)
+Sense
Load
Use 22-24 AWG
Twisted Pair Wires
-Sense
-P -Out
External Trim (J2-1)
Output voltage can be trimmed using an optional factory-installed Trim potentiometer
or with the Trim pin (see Figure 11). The Trim potentiometer is located on the
ConverterPAC. If the Trim potentiometer has not been ordered, the Trim pin must be
used. When using the Trim pin, the Trim limits are determined by the DC/DC converter
used on the ConverterPAC. Maximum Trim ranges are 10% above the nominal
converter voltage and 50% below the nominal converter voltage (except 10 V, 12 V and
15 V outputs which are 10% below nominal) as measured from the output studs or
output connector of the power supply.
Note: The combined effects of module trim up, remote sense and 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 reference voltage (Vref). The
reverse is true to decrease an output voltage.
Note: Converters are sometimes pre-trimmed at the factory if a nonstandard output voltage is
requested. Standard voltages include 2 V, 3.3 V, 5 V, 10 V, 12 V, 15 V, 24 V, 28 V, and 48 V. If using a
nonstandard voltage, or if a ConverterPAC is ordered with a Trim option, the resistor calculations will
differ from those on page 22. Please consult the factory for assistance.
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Page 21
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 (Pre-Defined)
1.23 V
1.0 kW
Maxi/Mini/Micro (User Defined)
1.23 V
Consult Factory
Figure 11.
Use 22-24 AWG
Twisted Pair Wires
External Trim
+P +Out
(Remote Sense)
R1
J2-2 +Sense
To Error
Amplifier
+ RTH R5
V1
V Ref
-
R8
R2
J2-1
R3
R6
+
V2
R7
Load
-
J2-3 -Sense
R4
-P -Out
Use 22-24 AWG Twisted Pair Wires
Example:
±10% Trim adjust on a 12 V nominal output.
Figure 11 shows a typical variable Trim circuit. Using a 10k 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)
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
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 Guide or consult the factory for assistance.
CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS BELOW 5 V.
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Specifications
Input Characterisitcs
Input Voltage
85-264 Vac, 47-500 Hz 100-380 Vdc
Power Factor
0.99 @ 115 Vac ; 0.95 @ 230 Vac - both at full load (47-63 Hz)
Inrush Current
25A pk @ 115 Vrms and 230 Vrms
Ride Through Time
>20 ms at nominal line, full load
Power Fail
>3 ms warning
Conducted EMI
Surge Immunity
FCC Class A; EN55022 Class A (Certain configurations meet B. Contact Factory)
Mil-STD 461 CE 101 and 102 require external filtering
EN 61000-4-5 Installation Class 3, Performance Criteria B
(Temporary loss of output power may occur which is self recoverable)
Primary to Chassis GND = 2,121 Vdc
Dielectric Withstand
Primary to Secondary = 4,242 Vdc
Secondary to Chassis GND = 750 Vdc
Overvoltage and Transients
Per Mil-STD 704 and 1399 (MI rugged chassis only
Ouput Characterisitcs
Line/Load Regulation
Ist Gen: ± 0.2% max.10% to full load
± 0.5% max. No load to 10% load
Line Regulation*
Maxi: ± 0.20% max. to 0.3% max LL to HL, Full Load
Load Regulation*
Maxi: ± 0.1% No load to full load
VI-200/VI-J00 Setpoint
Accuracy*
Maxi Setpoint Accuracy
1% for standard voltages; 2% for special or adjustable voltages
1% for standard voltages;
2% for special, adjustable voltages and 48 Vdc outputs
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
V2 = (50 mVp-p or less) Vout < 15 Vdc
V3 = (1% ripple or less) Vout > 24 V
Ripple and Noise
(VXI options require 15% minimum load)
RAMPAC: 10 mVp-p or 0.15% whichever is greater
FlexPAC 50 mV p-p
10% -110% of nominal voltage Maxi modules
External Output Trim Range
50% -110% of nominal voltage VI-200/VI-J00 modules
(Using Trim/Sc pin)
90% -110% of nominal voltage VI-200/VI-J00 modules 10-15 V
2-25 V FlexPAC
105-125% of full load capability of VI-200/VI-J00 modules
Overcurrent Trip Point
115% typical of full load capability of Maxi modules
135% FlexPAC
Overvoltage Protection
115-135% on VI-200 and Maxi modules only
Efficiency
80% typical
MP Prefix
Output Power
MX Prefix
1,600 W at 230 Vac
1,200 W at 115
Vac+
2,400 W at 230 Vac
1,200 W at 115 Vac+
*Note: Not to exceed an input current of 15 A.
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Specifications (Cont.)
Environmental Characteristics
Storage Temperature
-40°C to 85°C
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.
-20°C to 40°C full power; -20°C to 60°C half power
Operating Temperature**
-40°C optional with rugged chassis (-MI or -MC suffix)
Shock and Vibration
Mil-STD 810 (MI rugged chassis ONLY)
Humidity
0 to 95% non-condensing
cURus – UL 60950-1, CSA 60950-1
cTUVus – EN 60950-1, UL 60950-1, CSA 60950-1
Safety Agency Approvals
CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC
Note: some MI chassis will not carry all safety approvals
Product Weights
MP Chassis
MX Chassis
(fully configured)
9.75 lbs (4,42 kgs)
10 lbs (4,54 kgs)
2 years limited warranty.
Warranty
See www.vicorpower.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 than 500 Watts.
Output Studs
New, more robust output studs (with a 3 to 1 safety margin @ 45 in. lbs.) were installed
in ConverterPACs, the slide-in assemblies used in the MegaPAC Family. These new
outputs studs are 1/8" longer to allow for multiple lugs. They are fully compatible with
the original flanged nut ConverterPACs for use in parallel arrays.
Other advantages include:
n Inner nut (that might become loose) replaced by a brass insert
n Stronger connection to the PCB
n Improved conductivity (less voltage drop and heating)
n Both the stud and panel are less likely to break due to over torqueing
Shown below are the original and re-designed studs.
Original
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Redesigned
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PFC MegaPAC Output Power Derating
Output Power vs Input Voltage (Vac) (47-500 HZ)
2,400W @ 200 Vac
Output Power (Watts)
2400
2200
Derate at 12W/volt
Power Exceeded
2000
1800
1600
1400
Safe Operating Area
1200
1000
85
95
105 125 145 165 185 200 215 235 255 265
Input Voltage (Vac or Vdc)
(For VDC, 100V min applies)
PFC MegaPAC Connector Kit (19-130040) Listing
Item
Qty
1
1
12
2
**
3
8
Description
Vendor #1
Part #
HOUSING 12 POS.165 CTR W/LATCH
MOLEX
39-01-2120
TERMINAL FEM CRIMP 18 - 24 AWG TIN
MOLEX
39-00-0039
CRIMP TOOL FOR ITEM 2
MOLEX
11-01-0197
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
00-01-0197
**
6
8
HOUSING 3 POS.1 CTRS W/LATCH
MOLEX
50-57-9403
7
27
TERMINAL FEM CRIMP 22 - 24 AWG SEL/GLD
MOLEX
16-02-0103
CRIMP TOOL FOR ITEM 7
MOLEX
11-01-0118
**
** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT)
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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 +/-1mV 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 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 Hotswap Applications.
Figure 12.
D*
CSB Interconnect Expample
+OUT
+VOUT
+S
Power Supply 1
24V@1kW
TRIM
Yellow
-S
-OUT
Brown
D*
+OUT
T1
-V1
T2
-V2
Power
Red
CSB02
-VOUT
+S
Power Supply 2
24V@1kW
TRIM
White
Black
-S
-OUT
(Requirements on page 27.)
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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 12. 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 12.
7.For paralleling more than 2 supplies consult factory for assistance.
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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
T1
3
-V1
4
T2
5
-V2
6
No Connection
0.12"
(3.0mm)
0.12"
(3.0mm)
0.900"
(22.9mm)
1.14"
(29.0mm)
Figure 13. 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 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.CSB02 MUST be used for current sharing Maxi/Mini/Micro converters
(Maxi, Mini and Micros).
PLEASE NOTE, THE CSB IS NOT INTENDED FOR HOTSWAP APPLICATIONS
Contact your Regional Applications Engineer at 1-800-927-9474 for additional information.
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Page 28
Low Leakage Version
If Low Leakage is required, the MegaPAC Family of Power Supplies has a model
variant (must be requested). This model enables the user to meet various additional
specifications. Presently, the PFC MegaPAC, Mini MegaPAC and Autoranging MegaPAC
are available in Low Leakage versions. Other models can be made available. The MegaPAC Family of Power Supplies consist of:
n PFC MegaPAC
n PFC MegaPAC-High Power
n PFC MegaPAC-EL (Low Noise)
n Mini MegaPAC
n Autoranging MegaPAC
n 4 kW MegaPAC
n 4 kW MegaPAC-EL (Low Noise)
The advantage of the Low Leakage MegaPAC power supply is in multiple power supply
systems that have one AC input. This option will lower the input leakage current for
these products to 500 µA or less. An additional external EMI filter may be required.
How Low Leakage is obtained
Low Leakage for the MegaPAC Family 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 may no longer meet Vicor’s published specifications for conducted EMI. In
order to reduce the EMI to within an acceptable limit, an additional external EMI filter
maybe required. All safety agency certifications for the MegaPAC Power Supplies
remain intact. Contact Applications Engineering for more information.
Vicor currently has the following ConverterPACs (See ConverterPAC information sheet
and/or Design Guide for more information):
VI-200/VI-J00
Maxi/Mini/MicroOther
ModuPAC (M)
FinPAC (PZ)
JuniorPAC (J)
UniPAC (XU)
DualPAC (D)
QPAC (XQ)
RamPAC (R)
FinQPAC (PZL)
FlexPAC (FSS)
BatPAC (B)
QPAC (L)
DualQPAC (LD)
Junior QPAC (LJ)
Please note: The MegaPACs (including Low Leakage versions) are not UL 2601 or EN60601 compliant.
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Output Sequencing
Using the MegaPAC's standard Input Interface Connector (J10) along with the
ConverterPAC's optional DC OK Option*, it is possible to implement unique output
voltage power up and power down sequences. Below is an example showing how this
may be done.
* DC OK Option is not available for VI-J00 dual output DualPACs
Requirement: 5 V must start before the 3.3 V output. If the 5 V output is lost, the 3.3 V
output must turn off.
The first step in meeting this requirement 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 Vicor's customer service department
for assistance. The DC OK option monitors the output voltage of a given ConverterPAC
and provides a TTL logic signal depending on its output voltage.
Figure 15.
ModuPAC Pinout
+ Vout
J2 Pin 1
Vtrim Pot Adjust (Option)
- Vout
J3 pin 1 (DC OK Option)
Figure 16.
J3 DC OK Connector
DC OK (Power Good)
J3
4
3
2
1
Pin
J3-4
J3-3
J3-2
J3-1
UG:105
Vcc
Power Good
Power Good Inverted
Signal Ground
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Page 30
Figure 17.
Output Sequencing
Wire Interconnect
1
2
3
4
5
6
7
8
6
12
5
11
4
10
3
9
2
8
1
7
L
L
1
2
3.3V Output
5V with "D" option (DC OK)
Figure 17 shows the correct wiring connections between the Power Good Connector (J3)
of a 5 V ModuPAC and the Input Interface Connector (J10) of a typical PFC MegaPAC
configuration. In this example, the 3.3 V ModuPAC is located in the slot #7 and the
5 V ModuPAC (with the DC OK option) is located in slot #8. In order for the Power
Good option to properly function, it requires a 5 V source 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 until its output has reached
approximately 95% of its nominal output voltage. This will keep the 3.3 V output in
disabled mode, allowing the 5 V output to reach regulation first. In addition, should
the 5 V output drop below 85% the Power Good signal will drop low and disable the 3.3
V output. Figures 18 and 19 show the startup and shutdown waveforms for the circuit
shown in Figure 17.
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Output Sequencing (Cont.)
Channel #1: 5 V Output
Channel #2: 3.3 V Output
Channel #3: 5 V DC OK signal
Figure 18.
Startup Waveforms
5V Output
3.3V Output
5V DC OK
Figure 18. Startup Waveforms
Figure 19.
Shutdown Waveforms
5V Output
3.3V Output
5V DC OK
Figure 19. Shutdown Waveforms
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NOTES:
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vicorpower.com Applications Engineering: 800 927.9474
Page 33
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 Vicor’s 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
• 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, PFC MegaPAC,
Standard MicroPAC and Conduction Cooled MicroPAC.
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
The Power Behind Performance
Rev 1.3
03/2015 P/N 07-130243-01A
vicorpower.com Applications Engineering: 800 927.9474
Page 34