28 Vdc MIL-COTS DESIGN GUIDE VIPAC ™ Contents 2– 3PRODUCT OVERVIEW 4FEATURES 5INPUT / OUTPUT OPTIONS 6SPECIFICATIONS 7 – 8 TECHNICAL OVERVIEW 9INPUT CONNECTIONS 10 – 12 OUTPUT CONNECTION OPTIONS 13CHASSIS CONFIGURATIONS 14 – 15 MOUNTING OPTIONS v i c o r p o w e r . c o m 16MECHANICAL DRAWINGS 16MECHANICAL INFORMATION 17THERMAL MANAGEMENT 18GENERAL INFORMATION 19APPLICATION TIPS 1 Product Overview Vicor’s 28 V MIL-COTS VIPAC™ is an integrated power system leveraging the latest advances in DC-DC converter technology and modular front ends. VIPAC combines application specific PPU power processing units (PPU) and a choice of chassis styles to provide fast, flexible and highly reliable power solutions for a wide range of demanding applications. The PPU is the core element of the system and incorporates either Vicor’s M-FIAM5B or M-FIAM9 to provide transient protection, EMI filtering and inrush current limiting. The web-based VCAD tool enables designers to configure the PPU with up to three independently regulated outputs having power levels from 50 to 400 W. Vicor’s Maxi, Mini, Micro Series DC-DC converters, in industry standard quarter, half and full brick packages, are used to deliver output voltages from 3.3 to 48 Vdc. Additionally, the wide trim range of the modules can provide operating voltages as low as 500 mV. The PPU is comprised of: • DC input modular front end • Vicor’s Maxi, Mini, Micro Series high density DC-DC converters • Interface board • Coldplate or finned chassis • Choice of output termination styles The VIPAC is offered in several chassis configurations facilitating its use in a variety of applications using either conduction, convection or forced convection cooling. The low profile, conduction cooled version may be mounted to an existing cabinet wall, coldplate or heat sink. The 0.5” or 1” finned versions, available in longitudinal or transverse configurations, are ideal for use in free or forced convection environments. The use of standard chassis footprints allows different input voltage configurations of the VIPAC to be used interchangeably depending on system and market requirements. v i c o r p o w e r . c o m 2 Input Options 28 Vdc MIL-COTS version Control Interface Output Sequencing BUS-OK /Bus Voltage Monitor Output Enable / Disable Pre-assembled and Tested Front Ends M-FIAM5B – Filter Input Attenuator Module M-FIAM9 – Filter Input Attenuator Module Rugged Interconnect Board Selectable for Single, Multiple or Parallel Outputs Protective Features Auto Restart Inrush Current Limiting EMI Filtering Input Transient Protection Vicor’s Maxi, Mini, Micro Series DC-DC Converters Output Voltages 0.5 – 48 Vdc 50 – 400 W / Output (1/4 Brick Modules Shown) Platform Options Low Profile Coldplate 0.5” and 1” Optional Finned Configurations Choice of Output Termination (LugMate Shown) DC Input 18 – 36 Vdc; 28 V nom. v i c o r p o w e r . c o m 3 FEATURES • Control Interface Power Up / Down control Output sequencing for Turn-on, Turn-off BUS-OK 1k Error Amp 1.23 V 0.033 F Maximizes packaging flexibility Enhanced reliability Wide operating temperature range Load +S 1.23 V RD Trim Down +Out –40˚ to +95˚C chassis H-Grade –55˚ to +95˚C chassis M-Grade –S SC • Partitioned Power Architecture –Out 1k Error Amp 0.033 F –Out –S RD Trim Down SC Load +S +Out Micro 1.23 V • Secondary Control Output voltage trimming 10 – 110% Vout 1k Error Amp 1k Error Amp 0.033 F 1.23 V 0.033 F –Out SC –Out +Out –S SC RD Trim Down RD Trim Down Load Load +S +Out Mini and Maxi 1.23 V 1k Error Amp 0.033 F –Out –S SC RD Trim Down Load +S +Out 1.23 V 1k Error Amp v i c o r p o w e r . c o m 0.033 F –Out SC RD Trim Down Load +Out 4 INPUT / OUTPUT OPTIONS Output Voltage Selection 3.3 V VIPAC Configuration 5 V 12 V 15 V 24 V 28 V 36 V 48 V Total MicroMaximum Output Power (W)* # Outputs Single 75 100100100100100100100100 Single ll 150200200200200200200200200 Dual 75 100100100100100100100200 75 100100100100100100100 Dual ll 150200200200200200200200 75 100100100100100100100 Triple 75 75 75 MVC-G / MVX-G MVC-D / MVX-D MVC-A / MVX-A 300 100100100100100100100 100 100 100 100100100100300 100 100100 100100100100 Maximum Output Power (W)* Mini # Outputs Single 150 200200200200200200200200 MVC-E / MVX-E 300 400400400400400400400400 Single ll 150 200200200200200200200 400 150 200 200 200 200 200 200 200 MVC-B / MVX-B MaxiMaximum Output Power (W)* # Outputs Single 264 400400400400400400400400 MVC-F / MVX-F *Model numbers and total output power capability are application specific. Component tolerances may effect total output power (±5%) in parallel (//) configurations. See VIPAC configuration tool at: vicorpower.com/vcad MVC-xxx refers to M-FIAM5B MVX-xxx refers to M-FIAM9 v i c o r p o w e r . c o m 5 SPECIFICATIONS 28 Vdc Input MIL-COTS Version Parameter Min Typ Max UnitNotes Operating input voltage 18 28 36 Vdc Continuous Turn-on 18Vdc Inrush current 5.0 A pk Inrush limiting 0.007 A µF Transient immunity (M-FIAM5B) 50 Vdc 12.5 ms per MIL-STD-704E/F Transient immunity (M-FIAM9) 100 Vdc 50 ms per MIL-STD-1275A/B/D 250 Vdc 70 ms per MIL-STD-1275A/B/D 70 Vdc 20 ms per MIL-STD-704A 50 Vdc 12.5 ms per MIL-STD-704E/F EMI MIL-STD-461E Conducted emissions: CE101, CE102 Conducted susceptibility: CS101, CS114, CS115, CS116 Reverse Polarity Protection Internally fused Environmental Parameter Min Typ Max UnitNotes Dielectric withstand Input to chassis 1,500 / 2,121 Vrms / Vdc Operating chassis temperature H-Grade -40 95 °C M-Grade -55 95 °C Shock Method 516.5, Procedure 1 MIL-STD-810F (40 g for 15–23 ms, 75 g for 8–13 ms) Vibration MIL-STD-810F Method 514.5, Procedure 1 (20–2000 Hz at 5 g) Humidity 5 95 % Non-condensing Output Specifications - General at 25°C, nominal line and nominal load, per module unless otherwise specified Parameter Min Typ Max UnitNotes Output voltage set point ±1 % Vout nom Line regulation ±0.02 ±0.2 % Low line to high line; full load Temperature regulation ±0.002 ±0.005 %/˚C Over operating temp. range Over temperature shut down 115 ˚C Power sharing accuracy ±2 ±5 % 10% to 100% of full load Programming range 10 110 % Of nominal output voltage. (For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required) Current limit 115 % Iout max. Output voltage 95% of nominal Short circuit current 115 % Iout max. Output voltage <250 mV Interface Control Functions Type Master Enable Local Remote Output Enable / Disable √ √ √ Output Sequencing Bus OK Emergency Off √ √ √ √ √ Output Sequencing Power up will always occur in the defined sequence stored within the device. Any preprogrammed power down sequence, except the default, will not be in effect upon loss or removal of the VIPAC source voltage. Sequenced power down can only be achieved by issuing the requisite commands through the interface before removing the source voltage. v i c o r p o w e r . c o m 6 TECHNICAL OVERVIEW Overview Vicor’s 28 Vdc for MIL-COTS VIPAC front-end section utilizes either Vicor’s M-FIAM5B or M-FIAM9 input module to provide EMI filtering, transient protection, inrush current limiting and rectification as appropriate. The front end also contains input connectors, fusing and control circuitry to which the user can interface discrete circuitry. Up to three Maxi, Mini, Micro Series DC-DC converters are combined with the front end in an integrated mechanical assembly providing a high efficiency power supply delivering up to 400 W of output power. Circuit Operation The VIPAC utilizes either the M-FIAM5B or M-FIAM9 module which provides inrush current limiting, transient protection and EMI filtering. The DC voltage is applied via an agency approved 3-pin connector; a fuse in the the “+” lead protects the VIPAC from damage due to internal shorts. At start up, inrush current is limited by a FET. This FET serves as both an inrush current limiter at power up and a voltage limiting device in the event of an input transient overvoltage condition. The FET, driven by a DC bus voltage sense circuit, is brought to a low impedance after initial power up. The 28 V is applied to one or more Vicor Maxi, Mini, Micro DC-DC converters which deliver the selected output voltage and current levels. The DC-DC converters provide output over voltage protection, output current limiting, voltage regulation trim capability and input to output isolation. Vicor’s VCAD configuration tool selects standard 24 V in Maxi, Mini, and Micro modules for use within the VIPAC based on the application requirements. The modules are chosen based on the input and output requirements and the closest, but higher power level that is available to that specified. Specifications for these can be found on their respective data sheets. VIPAC BLOCK DIAGRAM - DC INPUT 18 – 36 Vdc Input + GND -DC + Transient Protection Inrush Current Limiting Reverse Polarity Protection Line Filter J1 PC PR – + DC-DC Converter Output #1 SC DC-DC Converter Output #2 SC DC-DC Converter Output #3 SC – +DC _ M-FIAM5B / M-FIAM9 + PC PR Remote RS232 User Interface Logic Control OR J3 – Master Disable (Local mode) – Output Sequencing – Module Status – BUS-OK Local Control v i c o r p o w e r . c o m Control 1 – + Output – Control 2 Control 3 + PC PR – + – 7 TECHNICAL OVERVIEW VIPAC Control MOD-DIS+, MOD-DIS– The VIPAC provides the user with choices with respect to how The MOD-DIS input is an optically coupled input and allows for the unit is operated. It can be controlled locally by applying remote disabling of the output(s) of the VIPAC. Applying current the appropriate “digital” signals to the device. to the MOD-DIS+, MOD-DIS– input disables the supply. The minimum input current for disabling the supplies is 3 mA. BUS-OK The maximum allowable current is 20 mA. An internal replica of BUS-OK is wired to the PC pin of all internal DC-DC converter modules. The modules will be Electrical Connections disabled (no DC output) during initial power up of the VIPAC Status output pair BUS-OK+, BUS-OK– are the collector (+) until the internal DC input bus voltage to the DC-DC converters and emitter (–) of an NPN optoisolator output transistor. In a is sufficient to support full load operation. The BUS-OK status typical application, the collector terminal BUS-OK+ of the output reflects the status of this inhibit function. This same optocoupler can be connected via current limiting resistors to a logic circuit will shut down the converters when the internal source no greater than 70 Vdc. These resistors should limit the DC bus voltage is insufficient to support proper operation. maximum current to the optocoupler output transistors to 1.5 mA. The emitter terminal BUS-OK– is connected to the return This shut down will occur during normal power down, line of the external source. The status OK condition will set the dropouts exceeding the hold up time, or internal faults optocoupler output transistors in saturation and are capable causing the internal DC bus voltage at the input of the of sinking up to 1.5 mA with a Vce saturation voltage of 0.4 converters to collapse. The BUS-OK output provides the user V. Users should be cautioned that although the output of the with an optically isolated status indication of the internal VIPAC can be used as the pull-up source, shortly after BUS-OK DC bus. This output, in AC powered system applications, can changes from OK (saturated) to NOT OK (high Z), the pull-up provide power supply status, switch in backup (standby) voltage will be shut down. If the pull-up source is one of the sources or initiate “power down” sequences to save volatile VIPACs outputs, it is advisable to provide a capacitive reservoir memory contents in the event of a power loss. The time from in order to maintain the pull-up potential after loss of DC current BUS-OK deassertion to output shut down is dependent upon output. Use edge sensing logic to detect assertion of logic outputs, the value of hold up capacitors used. The VIPAC online design or a separate source of bias supply voltage (i.e., backup batteries) tool contains a hold up capacitor calculator which provides to provide a safe pull-up voltage source regardless of the line appropriate values. status. 20 mA max. MOD-DIS Input Apply a current of 3–20 mA to disable output. V + 3 MOD-DIS v i c o r p o w e r . c o m V J3 Disable + BUS-OK – Status Output Transistor on when OK. Vce sat. = < 0.4 V @ 1.5 mA maximum external pull-up is 70 Vdc. BUS–OK signal is isolated VIPAC + r – 2 1.5 mA max. + 7 BUS-OK – 6 8 INPUT CONNECTIONS 28 Vdc Input Conn. Pin # Funct. Mating Conn. J1 1 2 3 GND – Vin + Vin 28 Vdc Input P/N 21394 I/O Interface Removable Jumper IN= Local Control P/N 22988 7 J3 I/O Interface* 1 Conn.Pin # Funct. J3 Mating Conn. 1NC 2 MOD-DIS– 3 MOD-DIS+ 4GND 5NC 6BUS-OK– 7 BUS-OK+ P/N 22988 J1 P/N 21394 * See detailed description on Pgs 7– 8 v i c o r p o w 1 2 3 GND e r . c o m –Vin +Vin 9 OUTPUT CONNECTION OPTIONS Discrete Output Configurations LugMate Ring Lugs (Factory Installed Option) LugMate Pin Out Micro LugMate Pin # 1 Solder Pad 1 3 Function – Vout Rd Trim-Down SC Secondary Control Ru Trim-Up 3 + Vout 1 3 Micro LugMate - with Rd/Ru trim resistor solder pads. (Design calculator for trim resistors located at vicorpower.com) 1 3 1 #4-40 Torque 4 in. lbs. Rd Ru SC 3 Mini/Maxi LugMate Pin # Conn. Function 1 1 J4 1 5 5 P/N 16385 5 Mating Conn. – Vout J4-1 – Vout J4-2 – Sense J4-3 Secondary Control J4-4 + Sense J4-5 + Vout Jumper *Removable Jumper P/N 16385 *Removable + Vout *Removable jumper is factory installed for local sensing. See Pg 22 for details 1 J4 1 5 **For units configured in parallel, one module will have the SC jumped to the –S and –Out. 5 #10-32 Torque 16 in. lbs. v i c o r p o w e r . c o m 10 OUTPUT CONNECTION OPTIONS Parallel Output Configurations Shown with the output of two modules connected in parallel using BUS BARS. LugMate Ring Lugs (Factory Installed Option) LugMate Pin Out Micro LugMate Pin # 1 Solder Pad 1 3 Function – Vout Rd Trim-Down SC Secondary Control Ru Trim-Up 3 + Vout 1 Micro LugMate - with Rd/Ru trim resistor solder pads. (Design calculator for trim resistors located at vicorpower.com) 3 1 3 1 #4-40 Torque 4 in. lbs. Rd Ru SC 3 Mini/Maxi LugMate Pin # Conn. Function 1 1 1 5 J4 5 P/N 16385 5 Mating Conn. – Vout J4-1 – Vout J4-2 – Sense J4-3 Secondary Control** J4-4 + Sense J4-5 + Vout Jumper *Removable Jumper P/N 16385 *Removable + Vout *Removable jumper is factory installed for local sensing. See Pg 22 for details 1 1 5 J4 **For units configured in parallel, one module will have the SC jumped to the –S and –Out. 5 #10-32 Torque 16 in. lbs. v i c o r p o w e r . c o m 11 OUTPUT CONNECTION OPTIONS Mating Connector Kits PlugMate PlugMate Pin Micro PlugMate PinOut Out MAXI PlugMate Pin Out Item (Looking into PlugMate) (Factory Installed Option) 1 13 Micro PlugMate Vicor P/N 25073 Pin # 1 2 3 4 1 5 12 24 4 8 +Vout +Vout –Vout –Vout 5 6 7 8 +Vout N/C SC –Vout Mini PlugMate Tyco Elect. P/N Vicor P/N 9 18 Note: VIPACs that contain multiple modules configured as a single output (paralleled for power or redundancy) MUST have their Outputs and Sense connected to each other at the load. DO NOT OPERATE A PARALLEL CONFIGURATION WITH ONLY ONE MODULE CONNECTED. v i c o r p o w e r . c o m 1 2 3 4 5 6 7 8 9 10 11 12 25049 M/C 25050 Function +Vout +Vout +Vout N/C N/C N/C –Vout –Vout –Vout 10 11 12 13 14 15 16 17 18 +Vout +Vout +Vout +S SC –S –Vout –Vout –Vout Item Vicor P/ N Vicor P/N Header 25050 25055 24796 M/C Item 25056Vicor P/ N 25067 12 24 1 13 Pin # 25073 Header Pin # Housing TYC1-794657-8 1 4 5 1-106529-2 8 Pin MAXI PlugMate Pin Out Kit Vicor P/N 25061 25056 24796 Vicor P/ N Item Function PlugMate Pin P/N Out Mating Connector MicroTyco Elect. Maxi PlugMate M/C 25056 25044 Function 1 10 Vicor P/N 25067 M/C Pin # Housing TYC-794657-8 Pin Out Pin Mini PlugMate 1-106529-2 Kit 1 2 3 4 5 6 7 8 9 HeaderHeader 25055 25043 Function Mating Connector Pin # ItemVicor P/ Vicor N P/ N Function Pin # +Vout 13 +Vout 14 +Vout 15 +Vout 16 +Vout 17 N/C 18 SC 19 –Vout 20 –Vout 21 Mini PlugMate Pin Out –Vout 22 –Vout 23 –Vout 24 1 10 Mating Connector 9 18 Tyco Elect. P/N Housing TYC2-794657-4 Pin 1-106529-2 Kit Header 25043 M/C 25044 Function +Vout +Vout +Vout +Vout +Vout +S –S –Vout –Vout Item –Vout Vicor P/ N –Vout 25049 Header –Vout M/C 25050 Vicor P/N 25044 24796 25061 12 CHASSIS CONFIGURATIONS MVC-A / MVX-A MVC-B / MVX-B MVC-D / MVX-D 3 MICRO 2 MINI 2 MICRO 4.96” x 6.8” (126,0 x 172,7 mm) • Dual or Triple Output • Up to 300 W 4.96” x 6.8” (126,0 x 172,7 mm) • Single or Dual Output • Up to 400 W • 3.15” x 6.8” (80,0 x 172,7 mm) Single or Dual Output • Up to 200 W • • • MVC-E / MVX-E MVC-F / MVX-F MVC-G / MVX-G 1 MINI 1 MAXI 1 MICRO 3.15” x 6.8” (80,0 x 172,7 mm) • Single Output • Up to 200 W 3.15” x 9.15” (80,0 x 232,4 mm) • Single Output • Up to 400 W • 3.15” x 6.8” (80,0 x 172,7 mm) Single Output • Up to 100 W • • • Finned Chassis Configurations Coldplate Longitudinal Optional 0.5” Fin Optional 1” Fin Transverse v i c o r p o w e r . c o m 13 MOUNTING OPTIONS Through-hole Mounting Surface Mounting Thermal compound both sides VIPAC with integral finned heat sink through-hole mounted External user supplied heat sink VIPAC with external user supplied heat sink VIPAC with integral finned heat sink through-hole mounted v i c o r p o w e r . c o m 14 Coldplate VIPAC Coldplate VIPAC mounted to custom thermal interface Thermal compound VIPAC with integral finned heat sink (down) For proper clearance use: Long standoff (P/N 23709) for mounting 1” heat sink fins down. VIPAC with integral finned heat sink (up) Short standoff (P/N 23710) for mounting 0.5” heat sink fins down or either heat sink fins up. v i c o r p o w e r . c o m 15 0.56 0.75 (14,2) (19,1) 1.37 (34,8) 0.81 (20,6) 0.50 (12,7) MECHANICAL DRAWINGS 0.22 (5,6) 0.08 (2,0) 1.31 (33,3) 0.32 (8,1) 1.87 (47,5) 1.00 (25,4) Please reference the mechanical drawings on the MIL-COTS VIPAC Power System web page at www.vicorpower.com. Heat Sink Options 0.56 0.75 (14,2) (19,1) 1.37 (34,8) 0.81 (20,6) 0.50 (12,7) 0.22 (5,6) Coldplate 0.08 (2,0) 1.31 (33,3) 0.32 (8,1) 1.87 (47,5) 1.00 (25,4) 0.5” Fin Option 1” Fin Option Fin spacing and relief are the same for both Fin options. MECHANICAL INFORMATION VIPAC Product Weight Chassis Configuration VIPAC Chassis Coldplate 0.5” Fins 1” Fins Model Prefix Configuration Pounds Grams Pounds Grams Pounds Grams MVC-G / MVX-G 1 Micro 0.9 411 1.4 640 1.6731 MVC-D / MVX-D 2 Micro 1.0 457 1.5 686 1.7 777 MVC-A / MVX-A 3 Micro 1.4 640 2.2 1006 2.5 1143 MVC-E / MVX-E 1 Mini 1.0 457 1.4 640 1.6 731 MVC-B / MVX-B 2 Mini 1.4 640 2.2 1006 2.6 1189 MVC-F / MVX-F 1 Maxi 1.3 594 2.0 914 2.31051 VIPAC Standoff Mounting Kits v Vicor Kit P/N i c o Kit Description For use with: 23709 Qty. 6-#23655 long standoff 1” finned heat sinks 23710 Qty. 6-#23656 short standoff 1/2” finned heat sinks or coldplate r p o w e r . c o m 16 THERMAL MANAGEMENT Thermal Impedance Specifications (˚C/W) Airflow VIPAC Model Prefix Chassis Natural 200 400 600 800 10001200 Config. Heat Sink Convection (LFM) (LFM) (LFM) (LFM) (LFM) (LFM) MVC-A / MVX-A 3 Micro 0.5” L 1.98 0.77 0.53 0.45 0.39 0.36 0.33 0.5” T 1.71 0.68 0.48 0.40 0.36 0.33 0.30 1.0” L 1.68 0.58 0.42 0.36 0.32 0.30 0.28 1.0” T 1.27 0.46 0.33 0.28 0.25 0.23 0.21 MVC-B / MVX-B 0.5” L 1.90 0.77 0.53 0.44 0.39 0.36 0.33 2 Mini 0.5” T 1.67 0.69 0.48 0.41 0.37 0.33 0.31 1.0” L 1.49 0.54 0.39 0.34 0.31 0.28 0.27 1.0” T 1.22 0.47 0.33 0.28 0.25 0.23 0.21 MVC-D / MVX-D 2 Micro 0.5” L 3.13 1.28 0.89 0.74 0.66 0.59 0.54 0.5” T 2.40 1.02 0.73 0.63 0.56 0.51 0.47 1.0” L 2.81 0.97 0.70 0.60 0.54 0.50 0.46 1.0” T 1.87 0.75 0.55 0.47 0.42 0.39 0.35 MVC-E / MVX-E 1 Mini 0.5” L 3.11 1.26 0.88 0.74 0.65 0.59 0.54 0.5” T 2.39 1.01 0.73 0.62 0.56 0.51 0.47 1.0” L 2.51 0.87 0.64 0.56 0.51 0.48 0.45 1.0” T 1.76 0.70 0.52 0.44 0.40 0.37 0.33 0.5” L 2.42 1.02 0.69 0.57 0.50 0.45 0.41 0.5” T 1.72 0.77 0.55 0.47 0.42 0.38 0.37 MVC-F / MVX-F 1 Maxi v 1.0” L 2.01 0.72 0.52 0.45 0.41 0.38 0.36 1.0” T 1.26 0.53 0.38 0.33 0.29 0.27 0.25 MVC-G / MVX-G 1 Micro 0.5” L 3.13 1.28 0.89 0.74 0.66 0.59 0.54 0.5” T 2.40 1.02 0.73 0.63 0.56 0.51 0.47 1.0” L 2.81 0.97 0.70 0.60 0.54 0.50 0.46 1.0” T 1.87 0.75 0.55 0.47 0.42 0.39 0.35 i c o r p o w e r . c o m 17 GENERAL INFORMATION Input Mating Connector Kits Part Number Description 23487 For use with: 28 Vdc Input VIPACs Kit Contains: One 3-pin DC Input mating connector, Vicor P/N 21394 One I/O Interface mating connector, Vicor P/N 22988 Output Mating Connector Kits Suggested Wire Gauge Part Number Description Function 23488 For use with: Mini or Maxi LugMate #20 0A–3A Kit Contains: One control connector, Vicor P/N 16385 DC Input/Output Leads #18 4A–6A #16 7 A – 10 A Two ring lugs Wire Gauge Application 23489 For use with: Micro LugMate #14 11 A – 15 A Kit Contains: Two ring lugs #12 16 A – 25 A #10 26 A – 40 A #8 41 A – 65 A #6 66 A – 104 A #4 105 A – 160 A 25061 For use with: Maxi PlugMate Kit Contains: One 24 pin housing, Vicor P/N 25044 24 pins, Vicor P/N 24796 25067 For use with: Mini PlugMate Kit Contains: One 18 pin housing, Vicor P/N 25050 18 pins, Vicor P/N 24796 25073 For use with: Micro PlugMate Kit Contains: One 8 pin housing, Vicor P/N 25056 8 pins, Vicor P/N 24796 Mating Connector Cross Reference Manufacturer Part Number Crimping Tools Designator Description Vicor P/N AMP Pin & Housing Manufacturer Pin Housing Wire Size Hand Die Set Tool P/N P/N J1 VIPAC DC Input - 3 Pin 21394 J3 VIPAC I/O Interface - 7 Pin 22988 J4 VIPAC Output Control - 5 Pin 16385 Micro PlugMate mating connector 25073 8 pin Mini PlugMate mating connector 25067 18 pin Maxi PlugMate mating connector 25061 24 pin Tyco Electronics JST Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics 193842-1* 770018-1 14 AWG 12 AWG 07KR-6S 91506-1 69710-1 N/A 58380-1 N/A 644083-5N/A 1-106529-2 794657-8 18-20 AWG 734202-2N/A 1-106529-2 1-794657-8 18-20 AWG 734202-2N/A 1-106529-2 2-794657-4 18-20 AWG 734202-2N/A * 770251-3 is an acceptable alternative v i c o r p o w e r . c o m 18 APPLICATION TIPS Selecting Heat Sinks VIPAC Power System Dissipation VIPAC Power Systems are rated for operation in ambient Pout (n) - Pout (n) Pdiss = η(n) 1–n 0 .95 Σ temperatures up to 65˚C with a maximum chassis temperature of 95˚C. Operation within these limits is essential for long life and users should select an appropriate thermal management system. The thermal performance of a particular VIPAC chassis Remote Sense A remote sense feature is provided on outputs configured configuration can be approximated from the thermal resistance with Mini or Maxi sized DC-DC converters. The output of the chassis, ambient operating temperature and total power sense connections must be terminated either locally or dissipation, using a few simple formulas shown below. remotely and may not be left open. The sense lines for VIPACs configured with a single paralleled output must Thermal Resistance: Refer to pg 20 be terminated to the same point. VIPACs provided with the optional LugMate connectors are configured for local Ambient Temperature: User specified, not to exceed 65˚C sensing via removable jumpers installed at the factory. Power Dissipation: Calculated as: (Pout/Efficiency) –Pout The jumpers will need to be removed if access to the secondary control function is made via mating connector Example: Verify a 400 W, 28 Vdc output VIPAC does not exceed P/N 16385 and connections will need to be established 95˚C chassis temperature (Tc). for local or remote sensing. • MVP-B chassis configuration with 1” transverse heat sink is selected and 200 LFM airflow is provided. Wire Routing Avoid routing wires over VIPAC Power System. • Thermal resistance (θ) of 0.47˚C/W is obtained from Do not bundle Input and Output leads together. the chart on pg 20. • Ambient operating temperature (TA) specified by the user is 40˚C. Parallel Outputs • VIPAC Power System efficiency (η) is 80% overall. The VIPAC can be configured with parallel modules for increased power or redundancy. When used for increased power, short the SC pin to –Sense on one module. This configures the module as a Booster. The user must properly connect the output and sense terminals (See Formula: Tc = (( Pout – Pout ) x θ) + TA η 400 = (( – 400) x 0.47) + 40 0.8 above). At no time operate a paralleled output with a load = 87˚C Conclusion: This VIPAC will operate in the conditions specified and applied only to one module! (See Output Connection Options, pages 10 – 12) not exceed maximum chassis temperature. Comment: v Efficiency of a particular VIPAC will depend on the specific output voltages and operating load conditions. In general the efficiency of VIPACs with outputs of 5 Vdc or less is approximately 70% and those with outputs greater than 5 Vdc is 80%. A more accurate calculation can be derived by summing dissipation of each DC-DC converter module used in the VIPAC and the front-end section of the VIPAC (using 95% efficiency for the front end). i c o r p o w e r . c o m 19 Contact Us: For Vicor Global Office Locations and Technical Support, please go to: www.vicorpower.com/contact-us or call 800-735-6200. 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. No user serviceable components, contact Vicor to arrange for repair or replacement. Specifications are subject to change without notice. vicorpower.com Rev. 1.7 02/16