FlatPAC Family 50 to 600 Watt AC-DC Switchers Application Notes Functional and Mechanical Layout Installation and Operation Guidelines U-Series Product Description The FlatPAC family of user-definable offline power supplies provides a complete power solution that incorporates one, two, or three standard Vicor DC-DC converters and a front-end subassembly in a modular package. FlatPAC is available with one, two, or three outputs and total output ratings of 50–600 W. These power supplies feature an autoranging input, which automatically senses the input line voltage and sets the power supply’s input range accordingly. FlatPAC’s unique modular design accommodates over 10,000 different configurations. FlatPAC power supplies that contain BatMod current source modules instead of VI-200 converters are indicated by the suffix -BM following the FlatPAC part number. BatMod converters provide a programmable output current, rather than a regulated output voltage. Consequently, the output supervisory terminal functions differ on FlatPACs with BatMod modules. 2 Application Notes AC Mains and Supervisory Connections MOD DIS – MOD DIS + AC OK – AC OK + BUS OK – BUS OK + AC Mains Earth Ground Internal Supervisory Circuits (Optocouplers) L1 2-Up and 3-Up 1-Up L2/N GND Product is internally fused External Supervisory Functions (2-up and 3-up models only) 30mA max. FlatPAC MOD DIS Input. Apply a current of 1–30 mA to disable output. Forward voltage drop of internal opto diode is 1.65 V max. at 30 mA max. V + MOD DIS + AC OK and BUS OK Status Outputs. Outputs low when OK. Vce sat. = < 0.4 V @ 1.5m A. Maximum external pullup is 70 Vdc. AC OK and BUS OK signals are isolated and can have different reference levels. Disable + V 1.5mA max. r + AC OK – 1.5mA max. + V – r + BUS OK – 3 Timing Diagram—Status Signals (2-up and 3-up models only) VLINE > 90 (180)Vac AC Line AC Line Interrupted AC OK BUS OK T0 T1 T2 T3 T4 Conditions: Full Load 90 (180)Vac, AC Line Time Interval T1-T0 T3-T2 T4-T2 T4-T3 Min 0 0 5 5 Typ 0.1 – – – Max 1.0 – – – Units ms ms ms ms Notes Ride-through time Hold-up time AC fail warning time Output Sense and Trim (All models with VI-200s) + VOUT +Out +Sense Trim –Sense R1 10K VOUT RTN –Out R2 +Sense and –Sense must be connected locally or remotely (shown). RESISTOR VALUES FOR TRIMMING STANDARD OUTPUT VOLTAGES Nominal 5V 12 V 15 V 24 V 28 V 48 V Trim Range Output Voltage R1(KΩ) .953 15.8 22.1 41.2 48.7 90.9 +10%, -10% R2(KΩ) 90 90 90 90 90 90 +10%, -10% Typical Applications (Models with BatMods only) Battery Charger Programmable Current or Voltage Source +Out +Out + VTRIM I TRIM I MON External Control Functions 12–48V Battery + VTRIM I TRIM I MON – –Out –Out External Control Functions Load – 4 Functional and Mechanical Layout LU-Series Single output 50-200 W MU-Series Single output 200-400 W NU-Series Single output 300-600 W PU-Series Dual output 100-400 W QU-Series Dual output 150-600 W RU-Series Triple output 150-600 W FlatPAC units are shipped with pins 11-12 and 14-15 connected via jumper plugs (Vicor P/N 02589) for local sense. For remote sense, remove these connections and connect pins 10-12 and 14-16, as shown in the Output Sense and Trim drawing on page 3. 2.540 ±0.030 (64,52 ±0,76) Inputs LU-Series 2.156 ±0.010 (54,76 ±0,25) 1.27 (32,26) 7 8 9 0.192 ±0.010 (4,88 ±0,25) 0.18 (4,57) All FlatPAC models are available with a conduction cooled flat plate instead of the top heat sink. Contact factory for outline drawings. 6.00 (152,4) MU-, PU-Series Inputs 1 2 3 4 5 6 7 8 9 MOD DIS– MOD DIS+ AC OK– AC OK+ BUS OK– BUS OK+ AC in L1 AC in L2/N Chassis Ground 3.83 (97,16) +Power Out +Out** +Sense* Trim* –Sense* –Out** –Power Out *On FlatPACs containing BatMods: 12 VTRIM 13 I TRIM 14 I MON **For local sense connection only— not for load connection 2.281 ±0.010 (57,94 ±0,25) 1.17 (29,72) 7 8 9 0.199 ±0.010 (5,05 ±0,25) 0.18 (4,57) Outputs 10 11 12 13 14 15 16 4.562 ±0.010 (115,87 ±0,25) 4.960 ±0.030 (125,98 ±0,76) 6.00 (152,4) NU-, QU-, and RU-Series 7.380 ±0.030 (187,45 ±0,76) 1 2 3 4 5 6 7.000 ±0.010 (177,8 ±0,25) 4.710 ±0.010 (119,63 ±0,25) 5.48 (139,19) 7 8 9 1.93 (49,02) 2.290 ±0.010 (58,17 ±0,25) 0.190 ±0.010 (4,83 ±0,25) 0.18 (4,57) 6.00 (152,4) 5 All Models Outputs 1.375 ±0.020 (34,91 ±0,51) 1.11 ( 28,19) 0.50 (12,57) LU-Series 9.245 ±0.030 (234,82 ±0,76) OUTPUT 1 MOUNTING HOLE ø 0.15 ±0.01 THRU 4 PLACES #10 NUT* #10 LOCK WASHER* 10 11 12 13 14 15 16 #10 WASHER* USER OUTPUT TERMINAL #10 WASHER* #10 NUT* TORQUED TO 25 in-lbs (2.8 N-m) AT THE FACTORY DO NOT LOOSEN *SUPPLIED WITH FLATPAC OUTPUT STUD CONNECTIONS MU-Series PU-Series Notes: + OUTPUT 2 10 11 12 13 14 15 16 10 11 12 13 14 15 16 OUTPUT 1 MOUNTING HOLE ø 0.15 ±0.01 THRU 5 PLACES 10 11 12 13 14 15 16 + – NU-Series • Connect paralleled outputs as shown (MU-, NU-, and QU-Series) for >40 A out. • All output studs 10-32 UNF. Torque to 20 in-lbs (2.3 N-m). • Input supervisory terminals (1–6): use mating connector Vicor P/N 33100, AMP P/N 644083-6 • Output supervisory terminals (11–15): use mating connector Vicor P/N 16385R, AMP P/N 644083-5 • AMP Termination Tool Pistol Grip Handle P/N 58074-1; with interchangeable head P/N 58246-1 • Do not loosen bottom nut. QU-Series RU-Series MOUNTING HOLE ø 0.15 ±0.01 THRU 6 PLACES 16 16 10 11 12 13 14 15 16 10 11 12 13 14 15 16 – OUTPUT 3 10 + 10 11 12 13 14 15 16 OUTPUT 2 10 OUTPUT 1 OUTPUT 1 16 10 11 12 13 14 15 16 10 11 12 13 14 15 16 OUTPUT 1 + OUTPUT 2 10 10 11 12 13 14 15 16 – + – 6 Installation and Operation Guidelines Fusing. The FlatPAC’s internal fuses are not user-replaceable. Please return the unit to vendor if servicing is necessary. Grounding. To satisfy IEC 950 Class I grounding requirements, connect a ground lead to the terminal marked (GND). For one-up FlatPAC models (max. output 200 W), use 1.5 mm2 / #16 AWG wire; for two-up and three-up models (max. output 400 W and 600 W), use 2.5 mm2 / #14 AWG wire. Input Voltage Connections. Connect the line voltage to L1 (hot) and L2N (neutral). For one-up FlatPAC models (max. output 200 W), use #16 AWG input wire; for twoup and three-up models (max. output 400 W and 600 W), use #14 AWG input wire. Recommended connector screw torque is 5 to 7 in-lbs (0.5 to 0.8 N-m). Recommended strip length is 8 mm. Use your FlatPAC model only with the corresponding input voltages and frequencies shown in the table below. Model 90 –132 Vac 180 – 264 Vac C– Grade VI– ■ U– C ■ 47– 63 Hz 47– 63 Hz I– Grade VI– ■ U– I ■ 47– 440 Hz 47– 440 Hz Output Wire Gauge. Use the output wire gauge that corresponds to the output current of your FlatPAC unit, below: Do not loosen bottom nut. 100 A–160 A : #2 AWG 30 A–50 A : #8 AWG 10 A–15 A : #14 AWG 75 A–100 A : #4 AWG 20 A–30 A : #10 AWG 6 A–10 A : #16 AWG 50 A–75 A : #6 AWG 15 A–20 A : #12 AWG 0 A–6 A : #18 AWG 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 FlatPAC to exceed its maximum operating temperature, which is reached when the heat sink 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 1: 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 torqued screws at all times during operation, whether or not the unit is mounted. If the unit is operated unmounted, insert a #6 or metric panhead screw through each hole from below and secure with a nut on top, torqued to 6 in-lbs (0.7 N-m). Note 2: All FlatPAC models are available with a conduction cooled flat plate instead of the top heat sink. Contact factory for outline drawings. 7 Input/Output Retrofit Connections. A hardware kit available from Vicor allows the input and output supervisory terminals to be connected in the same manner as for the earlier style FlatPAC (two-up model only). The retrofit output terminals are sized to accept AMP Faston® insulated receptacle #2-520184-2. Input Retrofit Kit Part Number: 14136 Output Retrofit Kit Part Number: 14137 For More Information The Vicor Applications Manual and product data sheet contain complete information about FlatPAC AC-DC power supplies. To receive literature or to consult an applications engineer about installation or operation of this product, contact your nearest Vicor office or visit the Vicor Website. (See back panel.) (Bitte lesen Sie die Sicherheits-Vorschriften auf Seite 8.) “AMP” and “Faston” are registered trademarks of AMP, Incorporated, Harrisburg, PA. 8 Sicherheits-Vorschriften Sicherungen. Die internen Sicherungen im FlatPAC können nicht vom Anwender ausgetauscht werden. Für Servicearbeiten schicken Sie das Teil bitte an den Händler zurück. Erdung. Um den IEC 950 Klasse I Erdungsforderungen zu entsprechen, muß ein Erdungskabel an den Anschluß (GND) angeschlossen werden. Für FlatPAC Modelle mit einem Modul (max. Leistung 200 W) benutzen Sie bitte 1.5 mm2 AWG 16- und für Modelle mit 2 und 3 Modulen (max. Leistung 400 W und 600 W) bitte 2.5 mm2 AWG 14-Kabel. Betriebstemperatur. Die maximale Betriebstemperatur des FlatPAC-Gerätes darf nicht überschritten werden. Dies ist gegeben, wenn der Kühlkörper eine Temperatur von 85 Grad Celsius erreicht hat. Die Kühlkörpertemperatur ist eine Größe, die sich aus der Ausgangsleistung und Spannung der Stromversorgung, der Umgebungstemperatur und der Luftzirkulation über dem Kühlkörper ergibt. Bitte bestimmen Sie mit Hilfe des Vicor Applikationshandbuches die maximale Umgebungstemperatur Ihrer Applikation. Weitere Informationen. Das Vicor Applications Manual und Produkt-Datenblätter enthalten ausführliche Informationen über FlatPAC AC-DC Wandler. Fordern Sie bitte Unterlagen bei Vicor oder Ihrer nächsten Vicor Vertretung an. Visit Vicor’s Website at: 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: +39-02-2247-2326 Fax: +39-02-2247-3166 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 Co., Ltd. Tel: +81-3-5487-3880 Fax: +81-3-5487-3885 Printed in U.S.A. Pt. No. 24436 Rev 6.2 03/11