VIPAC TM Family of Power Systems 50 to 900 Watt Description & Installation Guide Product Description Vicor’s VIPAC is a new type of integrated power system leveraging the latest advances in DC-DC converter technology and modular front-ends. VIPAC combines application specific power processing units (PPU), a choice of chassis styles and remotely located hold-up capacitors 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 may be specified for 115/230 Vac operation. The PPU incorporates Vicor’s autoranging FARM modular front-end to provide transient protection, EMI filtering and inrush current limiting. The web-based PowerBench™ enables designers to configure the PPU with up to three independently regulated outputs having power levels from 50 to 500 W and with as much as 900 W total output power. (continued) 2 Product Description cont. Vicor’s Maxi, Mini, Micro Family DC-DC converters, in industry standard quarter, half and full brick packages, are used to deliver output voltages from 2 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: • AC input modular front-end • Vicor’s Maxi, Mini, Micro Family, high density DC-DC converters • Coldplate or finned chassis • User interface • 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. VIPACs use remotely located capacitors to facilitate packaging and placement options not previously available. The low profile PPU can be placed closer to the load or attached to cabinet walls while the capacitors may be integrated into the host system away from heat sources for improved reliability. System hold-up / ride-thru requirements can also be tailored for specific applications via different value capacitors. The hold-up capacitors may be obtained from Vicor as a prepackaged hold-up box (HUB). VIPAC is a new class of flexible, high density power solutions. PPU HUB 3 A D B E F C G A Input 115/230 Vac Autoranging D I/O Interface Output Sequencing BUS-OK B Pre-assembled and Tested Front-ends FARM – Filter Autoranging Rectifier Module E Protective Features Auto Restart Inrush Current Limiting EMI Filtering Input Transient Protection C Platform Options Low Profile Coldplate 0.5" and 1" Optional Finned Configurations F Vicor’s Maxi, Mini, Micro DC-DC Converters Output Voltages 0.5 – 48 Vdc 50 – 500 W / Output (1/4 Brick Modules Shown) G Choice of Output Termination LugMate (shown) PlugMate 4 Overview The front-end section utilizes Vicor’s FARM input module to provide EMI filtering, transient protection, inrush current limiting and rectification. The front-end also contains input connectors, fusing and control circuitry to which the user can interface with discrete circuitry. Up to three individually fused Vicor Maxi, Mini, Micro DC-DC converter modules are combined with the front-end in an integrated mechanical assembly providing a high efficiency power supply delivering up to 900 W of output power. 6 Pin 115/230 Vac Connector Input + V BUS Strap - V BUS L2/N GND L1 HUB VIPAC BLOCK DIAGRAM - AC INPUT AC-DC Power Rectification Input Autoranging Inrush Current Limiting Line Filter J2 ST + ST _ FARM Hold-up Box + _ Terminals on Input Connector J2 + PC PR – + PC I/O Interface J3 Control Circuit Local Control – Output Sequencing – BUS-OK Control 1 Control 2 Control 3 PR – + PC PR – + DC-DC Converter Output #1 SC DC-DC Converter Output #2 SC DC-DC Converter Output #3 SC – + – + – Output 5 Application Tips Remote Sense A remote sense feature is provided on outputs configured with Mini or Maxi sized DC-DC converters. The output sense connections must be terminated either locally or remotely and may not be left open. VIPACs provided with the optional LugMate connectors are configured for local sensing via removable jumpers installed at the factory. The jumpers will need to be removed if access to the secondary control function is made via mating connector 16385 and connections will need to be established for local or remote sensing. Hold-up Capacitors Hold-up capacitors can be located remotely with up to 3' of cable. Vicor applications engineering should be consulted for projects requiring greater separation. Wire Routing Avoid routing wires over the VIPAC Power System. Do not bundle Input and Output leads together. Crimping Tool Amp Hand Tool P/N Die Set # 91508-1 20-18 AWG 91506-1 69710-1 Wire Size 16-14 AWG 58380-1 12 AWG 58380-2 10 AWG Parallel Outputs The VIPAC can be configured with parallel modules for increased power or redundancy. When output terminations other than the LugMate are specified the user must properly connect the output and sense terminals. At no time operate a paralleled output with a load applied to only one module! (See Output Connection Options) 6 Input Connections V Bus+ Strap V BusP/N 21394* 115 / 230 Vac Autoranging I/O Interface Removable Jumper IN= Local Control OUT= Remote Control P/N 33542 10 J3 1 HUB 2200-s 2700-s 3300-s J2 1 2 3 4 5 6 L2/N L1 GND HUB 820-s 1200-s 1800-s P/N 21393* P/N 22499 Maximum cable length between the HUB and VIPAC ≤ 3' *In the event of interference when connecting to the HUB, please remove the unused strain relief tab on the connector. J3 J2 AC Input/V Bus Funct. Mating Conn. Conn. Pin# 1 V Bus+ P/N 22499 Conn. 2 Strap 3 V Bus– 4 L2/N 5 L1 6 GND Conn. Pin# J2 I/O Interface J3 Funct. Mating 1 Module 1 E/D Return P/N 33542 2 Module 1 E/D Supply 3 Module 2 E/D Return 4 Module 2 E/D Supply 5 Module 3 E/D Return 6 Module 3 E/D Supply 7 BUS-OK Status Return 8 BUS-OK Status Supply 9 N/C 10 BUS-OK Drive Input Output Connection Options 7 Discrete Output Configurations LugMate (Factory Installed Option) Ring Lugs LugMate Pin Out Micro LugMate Pin # Solder Pad Function 1 1 Rd SC Ru 3 3 – Vout Trim Down Secondary Control Trim Up + Vout 1 Micro LugMate - with Rd/Ru trim 3 resistor solder pads. (Design calculator for trim resistors located at vicorpower.com) 1 3 #4-40 Torque 4 in. lbs. 1 Rd SC Ru 3 Mini/Maxi LugMate Pin # Conn. Function 1 1 J4 1 P/N 16385 5 – Vout J4-1 – Vout J4-2 – Sense *Removable Jumper 5 J4-3 Secondary Control J4-4 + Sense 1 J4-5 + Vout J4 1 5 Mating Conn. P/N 16385 *Removable Jumper + Vout 5 5 *Removable jumper is factory installed for local sensing. See Pg 5 for details #10-32 Torque 16 in. lbs. Output Connection Options 8 Parallel Output Configurations Shown with the output of two modules connected in parallel using BUS BARS. LugMate (Factory Installed Option) Ring Lugs Micro LugMate LugMate Pin Out Pin # Solder Pad Function 1 Rd SC Ru 1 3 3 – Vout Trim Down Secondary Control Trim Up + Vout Micro LugMate - with Rd/Ru trim 1 resistor solder pads. (Design calculator for trim resistors located at vicorpower.com) 3 1 3 1 Rd #4-40 Torque 4 in. lbs. Ru SC 3 Mini/Maxi LugMate Pin # Conn. Function 1 1 J4 1 – Vout J4-1 – Vout J4-2 – Sense P/N 16385 5 *Removable Jumper 5 J4-3 Secondary Control J4-4 + Sense 1 J4-5 + Vout J4 1 5 Mating Conn. P/N 16385 *Removable Jumper + Vout 5 5 #10-32 Torque 16 in. lbs. *Removable jumper is factory installed for local sensing. See Pg 5 for details Output Connection Options 9 Please 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. PlugMate Mating Connector Kits PlugMate Pin Out (Factory Installed Option) Micro PlugMate (Looking into PlugMate) 1 5 Vicor P/N 25073 4 8 Pin # Function Pin # Function 1 2 3 4 +Vout +Vout –Vout –Vout 5 6 7 8 +Vout N/C SC –Vout Mating Conn. Amp. P/N Vicor P/N Housing Pin Kit TYC-794657-8 1-106529-2 1 10 Mini PlugMate Vicor P/N 25067 9 18 Pin # Function Pin # Function 1 2 3 4 5 6 7 8 9 +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 Mating Conn. Housing Pin Kit Amp. P/N Vicor P/N TYC1-794657-8 25050 1-106529-2 24796 25067 12 24 1 13 Maxi PlugMate Vicor P/N 25061 25056 24796 25073 Pin # Function Pin # Function 1 2 3 4 5 6 7 8 9 10 11 12 +Vout +Vout +Vout +Vout +Vout N/C SC –Vout –Vout –Vout –Vout –Vout 13 14 15 16 17 18 19 20 21 22 23 24 +Vout +Vout +Vout +Vout +Vout +S –S –Vout –Vout –Vout –Vout –Vout Mating Conn. Housing Pin Kit Amp. P/N Vicor P/N TYC2-794657-4 25044 1-106529-2 24796 25061 10 General Information Input Mating Connector Kits Part Number Description 23485R For use with: 115/230 Vac Autoranging Input VIPAC using HUB 820-S, 1200-S or 1800-S Kit Contains: One 3 pin HUB mating connector, Vicor P/N 21393 One 6 pin AC Input mating connector, Vicor P/N 22499 One 7 pin I/O Interface mating connector, Vicor P/N 22988 One 10 pin I/O Interface mating connector, Vicor P/N 33542 23486R For use with: 115/230 Vac Autoranging Input VIPAC using HUB 2200-S, 2700-S or 3300-S Kit Contains: One 3 pin HUB mating connector, Vicor P/N 21394 One 6 pin AC Input mating connector, Vicor P/N 22499 One 7 pin I/O Interface mating connector, Vicor P/N 22988 One 10 pin I/O Interface mating connector, Vicor P/N 33542 Output Mating Connector Kits Part Number Description 23488R For use with: Mini or Maxi LugMate Kit Contains: One control connector, Vicor P/N 16385; Two ring lugs 23489 For use with: Micro LugMate Kit Contains: Two ring lugs 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 General Information 11 Mating Connector Cross Reference Designator Description Vicor P/N Manufacturer Pin & Housing P/N Pin 350551-1 P/N Housing J2 VIPAC Input - 6 Pin 22499 AMP J3 VIPAC I/O Interface - 10 Pin 33542 JST 10ZR-3H or 10ZR-8M J4 VIPAC Output Control - 5 Pin 16385 AMP MTA100-IDC644083-5 HUB 820-S, 1200-S, 1800-S 3 Pin 21393 AMP 770248-1 770018-1 HUB 2200-S, 2700-S, 3300-S 3 Pin 21394 AMP 193842-1 770018-1 Micro PlugMate mating conn. – 8 Pin 25073 AMP 1-106529-2 TYC-794657-8 Mini PlugMate mating conn. – 18 Pin 25067 AMP 1-106529-2 TYC1-794657-8 Maxi PlugMate mating conn. – 24 Pin 25061 AMP 1-106529-2 TYC2-794657-4 Suggested Wire Gauge Function Wire Gauge Application AC Input Leads #14 All AC and earth GND leads (VIPAC power systems) DC Output Leads #20 #18 #16 #14 #12 #10 #8 #6 #4 0A–3A 4A–6A 7 A – 10 A 11 A – 15 A 16 A – 25 A 26 A – 40 A 41 A – 65 A 66 A – 104 A 105 A – 160 A 640585-1 12 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. Visit the Vicor website at: vicorpower.com Printed in U.S.A. P/N 24663 Rev.2.5 4/14