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