ComPAC Family Installation and Operation Guide

ComPAC Family
50 to 600 Watt
DC-DC Switchers
Application Notes
Functional and Mechanical Layout
Installation and Operation Guidelines
Product Description
The ComPAC family of user-definable power supplies provides a complete
power solution optimized to meet the voltage, noise, and transient
protection input requirements of commercial, industrial, military, and
telecommunications applications. These switchers are available with one,
two, or three outputs and total output ratings up to 600 Watts. Each unit
incorporates one, two, or three component-level Vicor DC-DC converters in
a chassis-mount housing. ComPAC’s unique modular design accommodates
thousands of different configurations.
2
Application Notes
Input Connections
Disable +
Master Disable
Disable –
VIN +
DC Input
VIN –
Earth Ground
GND
See fuse chart on page 6
Master Disable Drive Circuit
20 mA Max.
Disable
+
V
DIS+
DIS–
The Master Disable input is optically isolated and incorporates a reverse polarity
protection diode. Apply a current of up to 20 mA to disable output(s). See ComPAC
data sheet for minimum levels.
Input Operating Voltage
24V Inputs
Standard
100V
48V Input
Wide Range
R.E.
100V
R.E.
160V
I.S.W.
Full Load
S.D.
100V
36V
32V
1
10ms
Normal Operating Area
42V
0.1
18V
1000
100
1
48V Wide Range Input
276V
125V
500V
100V
S.D.
I.S.W.
Full Load
400V
Normal Operating Area
1
10ms
100
100
1000
R.E.
800V
76V
36V
0.1
10ms
300V Input
R.E.
I.S.W.
Full Load
S.D.
60V
Normal Operating Area
21V
0.1
I.S.W.
Full Load
S.D.
1000
500ms
S.D.
Normal Operating Area
200V
0.1
1
10ms
100
1000
500ms
Long Term Safe Operating Curves. I.S.W. = Input Surge Withstand (no
disruption of performance, 1% duty cycle max.).
R.E. = Ratings Exceeded. S.D. = Shutdown. For short duration transient
capability, refer to product specifications.
3
Thermal Impedance
Note: Not applicable for conduction cooled (–CC) models.
Below are the chassis-to-air thermal impedance values, as a function of airflow,
for ComPAC package configurations that incorporate one, two, and three internal
component DC-DC converters.
Thermal Impedance—Case-to-Air (°C/Watt)
Standard Units
With Optional H1 Heatsink
1-Up 2-Up 3-Up
1-Up
Free Air (Horiz.)
3.6
1.7
1.4
2.1
Forced Convection Through Heat sink Fins
50 LFM
2.7
1.4
1.3
1.5
100 LFM
2.3
1.3
1.1
1.2
250 LFM
1.6
1.0
0.8
0.7
500 LFM
1.2
0.7
0.6
0.4
750 LFM
0.9
0.5
0.5
0.3
1000 LFM
0.8
0.5
0.4
0.2
2-Up
1.3
3-Up
1.0
1.1
0.9
0.5
0.3
0.2
0.2
0.9
0.7
0.4
0.3
0.2
0.2
To calculate case temperature: total power dissipated times
thermal impedance plus ambient temperature.
To calculate Watts dissipated per output: output power
divided by efficiency minus output power.
Output Trimming
Trim resistors not required for operation at rated output voltage.
+ VOUT
+ OUT
+ SENSE
TRIM
R2
R1
10K
To Load
— SENSE
— OUT
— VOUT
+Sense and –Sense must be connected locally or remotely (shown).
Resistor Values for Trimming Standard Output Voltages
Nominal Output Voltage 5 V 12 V 15 V 24 V 28 V 48 V
R1(KΩ)
.953 15.8 22.1 41.2 48.7 90.9
R2(KΩ)
90
90
90
90
90
90
Trim Range
+10%, -10%
Refer to Applications Manual, Chapter 5, for other trimming methods.
4
Functional and Mechanical Layout
LC-Series
Single output
50-200 Watts
Inputs
0.99
(25,15)
All Models
0.5
(12,57)
8.63 ±.025
MC-Series
Single output
100-400 Watts
(219,2±,64)
1.37
(34,80)
NC-Series
Single output
300-600 Watts
0.5
(12,57)
9.25 ±.120
(235,0 ±3,05)
PC-Series
Dual output
100-400 Watts
LC-Series
0.18
(4,6)
QC-Series
Dual output
150-600 Watts
5
0.91
(23,1)
2.54
(64,5)
RC-Series
Triple output
150-600 Watts
6.00
(152,4)
4
3
0.20
(5,1)
2
0.19
2.156 (4,8)
(54,76)
1
ø.150 ± .005 THRU 4 PLACES
(ø3,81 ± 0,13)
0.20
(5,1)
MC-, PC-Series
6.00
(152,4)
0.18
(4,6)
0.19
2.281 (4,8)
(57,94)
3.04
3.58 (77,2)
(90,9)
4.96
(126,0)
5
4.562
(115,87)
4
3
2
0.20
(5,1)
1
ø.150 ± .005 THRU 5 PLACES
(ø3,81 ± 0,13)
NC-, QC-, and RC-Series
0.18
(4,6)
6.00
(152,4)
0.19
2.288 (4,8)
(58,12)
4.42
4.96 (112,3)
(126,0)
7.380
(187,45)
5
7.00
(177,8)
2.420
(61,47)
4
3
2
0.20
(5,1)
Drawing: P.N. 11926
1
ø.150 ± .005 THRU 6 PLAC
(ø3,81 ± 0,13)
5
Outputs
±.025
Measure case temperature on this surface.
Inputs
1
2
3
4
5
STANDARD UNITS
2±,64)
0.41
(10,4)
1.12
(28,4)
±.120
Outputs
OPTIONAL HEATSINK (H1)
±3,05)
A
B
C
D
E
LC-Series
2.76
(70,1)
0
.41 (10,41)
.75 (19,05)
1.14 (28,96)
1.53 (38,86)
OUTPUT 1
A
B
C
D
.25 TYP
#8-32 STUD
2 PLACES
MC-Series
+Out
+Sense
Trim
–Sense
–Out
Consult factory for outline
drawings of models with
conduction cooled (–CC) option.
2.11 (53,59)
E
PLACES
Ground
–VIN
+VIN
–Disable
+Disable
PC-Series
2.76
(70,1)
OUTPUT 2
B
C
D
OUTPUT 1
OUTPUT 1
B
C
D
2.11 (53,59)
A
2.83 (71,88)
3.17 (80,52)
3.56 (90,42)
3.95 (100,33)
4.53 (115,06)
E
.25 TYP
#8-32 STUD
4 PLACES
#10-32 STUD
2 PLACES
NC-Series
QC-Series
2.76
(70,1)
RC-Series
E
B
C
D
A
OUTPUT 3
A
B
C
D
0
.41 (10,41)
.75 (19,05)
1.14 (28,96)
1.53 (38,86)
E
2.11 (53,59)
A
2.83 (53,59)
3.17 (80,52)
3.56 (90,42)
3.95 (100.33)
B
C
D
E
OUTPUT 2
E
A
OUTPUT 1
OUTPUT 1
OUTPUT 1
B
C
D
OUTPUT 2
#8-32 STUD
2 PLACES
A
6 PLACES
E
B
C
D
E
PLACES
0
.41 (10,41)
.75 (19,05)
1.14 (28,96)
1.53 (38,86)
A
A
B
C
D
E
4.53 (115,06)
A
5.25 (133,35)
5.59 (141,99)
5.98 (151,89)
6.37 (161,80)
B
C
D
E
6.95 (176,53)
.25 TYP
#10-32 STUD
2 PLACES
#10-32 STUD
2 PLACES
#8-32 STUD
6 PLACES
6
Installation and Operation Guidelines
Input Line Fusing. The ComPAC must be fused externally. The table below lists the fuse
ratings for one-, two-, and three-up units (max. output 200, 400, and 600 Watts).
VI Series
24 V Input
24 V Wide Input
48 V Input
48 V Wide Input
300 V Input
MI Series
200 W
10 A/32 V (AGC-10)
12 A/32 V (3AB-12)
8 A/60 V (3AB-8)
6 A/100 V (3AB-6)
2 A/250 V (3AB-2)
200 W
400 W
20 A/32 V (AGC-20)
20 A/32 V (AGC-20)
15 A/60 V (3AB-15)
15 A/100 V (3AB-15)
4 A/250 V (3AB-4)
400 W
600 W
35 A/32 V (AGC-35)
35 A/32 V (AGC-35)
25 A/60 V (3AB-25)
25 A/100 V (3AB-25)
6 A/250 V (3AB-6)
600 W
Use MIL-F-15160 or MIL-F-23419 equivalents of the commercial fuses listed below.
28 V Input
270 V Input
10 A/250 V (3AB-10) 20 A/250 V (3AB-20) 30 A/125 V (3AB-30)
2 A/250 V (3AB-2) 4 A/250 V (3AB-4) 6 A/250 V (3AB-6)
Grounding. For safe operation, the ComPAC unit must be grounded. Connect a ground lead to
the terminal marked
(GND). Use the same wire gauge as that specified for your ComPAC
unit’s input voltage connections, below.
Input Voltage Connections. Connect the line voltage to VIN + (positive) and VIN – (negative).
For one-up ComPAC models (max. output 200 W), use #16 input wire; for two-up and threeup models (max. output 400 W and 600 W), use #14 input wire. Be sure to tighten the lead
connections securely—recommended connector screw torque is 3.5 in-lbs (0.4 N-m).
Recommended strip length is 9 mm.
Output Wire Gauge. Use the output wire gauge that corresponds to the output current of
your ComPAC unit, below:
105 A–160 A : #4
66 A–104 A : #6
41 A–65 A : #8
26 A–40 A : #10
16 A–25 A : #12
11 A–15 A : #14
7 A–10 A : #16
4 A–6 A : #18
0 A–3 A : #20
Output Voltage Trimming. Do not trim the outputs higher than 110% of their nominal
output voltage. When an output is trimmed up, do not exceed its maximum rated output power.
Operating Temperature. Do not allow the ComPAC to exceed its maximum operating
temperature, which is reached when the heat sink/– CC plate is 85°C. (Full power can be
delivered up to this temperature.) Heat sink temperature is a function of the output power
and voltage of the supply, ambient temperature, and airflow across the heat sink. Refer to the
Vicor Applications Manual to determine the maximum ambient temperature for your
application. Always use worst-case conditions when calculating operating temperature.
Note: To ensure proper heat transfer from the internal module(s) to the heat sink, the
mounting holes through the heat sink (2, 3, and 4 holes on one-, two-, and three-up models,
respectively) must contain properly torqued screws at all times during operation, whether or
not the unit is mounted.
7
If the unit is operated unmounted, insert a #6 or metric flathead screw
through each hole from below and secure with a nut on top, torqued to 6 inlbs (0.7 N-m). A thermal interface material is recommended for –CC models
– consult factory.
Output Terminal Connections. A hardware kit with parts for output terminal
connections is provided with each ComPAC unit. The following drawing
shows the assembly of those parts for the proper connection of metal power
terminals. Assembly for PCB power terminals is the same except that they do
not require an external tooth lockwasher. Consult the table below for the
recommended torque level for each stud size.
Metal Terminal
#10 TERMINAL
RETAINING NUT
EXTERNAL TOOTH
LOCKWASHER
USER OUTPUT
TERMINALS
TERMINAL COVER
NEGATIVE
#10 NUT PLATE
HELICAL
LOCKWASHER
(FITS WITHIN
OPENING PROVIDED)
#10 BRASS STUD
Terminal and
Product Model
–Output, +Output
LC-, PC-, &
RC-Series
MC- & NC-Series
QC-Series
Supervisory
All models
Drawing: P.N. 10894 #1
Terminal
Style
Stud Size
Recommended
Torque
PCB
8-32 UNC
10 in-lbs (1.1 N-m)
Metal
10-32 UNC 15 in-lbs (1.7 N-m)
PCB
8-32 UNC
10 in-lbs (1.1 N-m)
Metal
10-32 UNC 15 in-lbs (1.7 N-m)
Sized to accept AMP Faston® insulated
receptacle #2-520184-2
For More Information
The Vicor Applications Manual and product data sheet contain complete
information about ComPAC DC-DC Switchers. To receive literature or to
consult an applications engineer about installation or operation of this product,
contact your nearest Vicor office. (See page 8.)
(Bitte lesen Sie die Sicherheits-Vorschriften auf Seite 8.)
“AMP” and “Faston” are registered trademarks of AMP, Incorporated, Harrisburg, PA.
8
Sicherheits-Vorschriften
Absicherung am Eingang. Das ComPAC muß mit einer externen
Sicherung am Eingang versehen werden. Die entsprechenden
Sicherungswerte entnehmen Sie bitte der Tabelle auf Seite 6 unter der
Rubrik “Input Line Fusing”.
Erdung. Um den IEC 950 Klasse I Erdungsforderungen zu
entsprechen, muß ein Erdungskabel an den Anschluß
(GND)
angeschlossen werden. Für ComPAC Modelle mit einem Modul (max.
Leistung 200 W) benutzen Sie bitte AWG 16- und für Modelle mit 2
und 3 Modulen (max. Leistung 400 W und 600 W) AWG 14-Kabel.
Anschlüsse Eingangsspannung. Vergewissern Sie sich, daß die Kabel
für die Eingangsspannung fest angeschlossen sind und achten Sie auf
die Polarität.
Betriebstemperatur. Die maximale Betriebstemperatur des ComPACGerätes darf nicht überschritten werden. Dies ist gegeben, wenn der
Kühlkörper eine Temperatur von 85 Grad Celsius erreicht hat.
Weitere Informationen. Das Vicor Applications Manual und
Produkt-Datenblätter enthalten ausführliche Informationen über
ComPAC DC-DC Wandler. Fordern Sie bitte Unterlagen bei Vicor
oder Ihrer nächsten Vicor Vertretung an.
Visit the Vicor website at:
www.vicorpower.com
Vicor Corporation
Andover, MA, U.S.A
Tel: 800-735-6200
Fax: 978-475-6715
Chicago, IL
Tel: 630-769-8780
Fax: 630-769-8782
Sunnyvale, CA
Tel: 408-522-5280
Fax: 408-774-5555
Vicor France
Tel: +33-1-3452-1830
Fax: +33-1-3452-2830
Vicor Italy
Tel: +39-2-2247-2326
Fax: +39-2-2247-3166
Vicor Hong Kong
Tel: +852-2956-1782
Fax: +852-2956-0782
Vicor Germany
Tel: +49-89-962-439-0
Fax: +49-89-962-439-39
Vicor U.K.
Tel: +44-1276-678-222
Fax: +44-1276-681-269
Vicor Japan
Tel: +81-3-5487-3880
Fax: +81-3-5487-3885
Printed in U.S.A.
Pt. No. 23935
Rev 4.1
11/09