USER GUIDE | UG:115 PFC MiniTM Power Factor Corrected AC-DC Switcher March 2010 Contents Page Overview of Product 1 Mechanical Considerations 2 PFC Mini Do’s and Don’ts 3 Technical Description 3 PFC Mini Configuration Layout 5 Part Numbering 6 Quick Install Instructions 7 Overview Mechanical Drawings 10 Output Connectors 11 Interface Connections 12 Output Power De-rating 20 Specifications 21 Current Share Boards 24 Low Leakage Version 27 Low Output Ripple 27 The PFC Mini is an extremely low profile, 1 RU, switching power supply that combines the advantages of power factor correction and high power density. This design guide covers both standard and rugged chassis COTS (MI) versions of the product. The PFC Mini can provide up to six isolated outputs (three slots) and each slot accommodates the following Vicor DC-DC Converters. VI/E-200 and VI/E-J00 series: One VI/E-200 or Two VI/E-J00 converters Maxi, Mini Micro series: One Maxi, Two Mini converters (Micros cannot be used) The use of these converters give the PFC Mini the inherent power flexibility typical of all Vicor products. Using the VSPOC configurator tool available on vicorpower. com, anybody can now configure a PFC Mini (and other Vicor power supplies) online. Accepting input voltages of 85 Vac to 264 Vac, and 100 Vdc to 380 Vdc, the PFC Mini can provide up to 1,500 Watts in a package size of 1.72" H (43,6 mm) x 6" W (152,4 mm) x 12.2" L (309,9 mm). The PFC Mini is factory configured to meet user requirements. Note: If you have a PFC Mini that shipped from October 2005 onwards, please see Page 19 for more details. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 1 Standard Features n Power Factor Correction: 0.99 at 115 Vac; 0.95 at 230 Vac n Universal Input: 85 – 264 Vac, 47 – 500 Hz, or 100 – 380 Vdc n Power Output: 1,500 W at 230 Vac; 800 W at 115 Vac n Up to 6 isolated outputs (3 slots) n Fan cooled n Full power to 45°C; half power at 65°C nConducted EMI: VI-200/VI-J00 series: Maxi, Mini, Micro series: FCC Class B EN55022 Class B FCC Class A EN55022 Class A (certain configurations meet EN55022 Class B) n Harmonic Distortion complies with EN61000-3-2 n AC Power OK status signal n Autosense (for more information, see Page 8 and Page 14) n Output overcurrent protection on all outputs n Output overvoltage protection (not applicable when using VI-J00) n Output overtemperature limiting (not applicable when using VI-J00) n Ride-through (hold-up) time: >20 ms at 1,200 W load (nominal line) n Size: 1.72" H (43,6 mm) x 6" W (152,4 mm) x 12.2" L (309,9 mm) n Safety Agency Approvals: CE Mark, cTÜVus, UL (Note: Certain MI chassis may not carry all safety certs) Optional Features n Extended temperature range output converters n Current share board - see Page 24 n RAM modules for low noise applications - see Page 27 n Connector kit available (#19-130047) n Low leakage available - see Page 27 n Office environment fan - see Page 27 n MI chassis specific options - Mil-STD 810 for Shock and Vibration - Mil-STD 704 and 1399 for overvoltage and transients - -40°C Operation - Conformal coating - contact factory Mechanical Considerations The PFC Mini can be mounted on either of two surfaces using standard 8-32 (4 mm) size screws. Maximum allowable torque is 4.4 in. lbs., and the maximum penetration is 0.16 in. (4 mm). UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 2 When selecting a mounting location and orientation, the unit should be positioned so airflow is not restricted. Maintain a 2" (5,1 cm) minimum clearance at both ends of the PFC Mini, and route all cables so airflow is not obstructed. The power supply draws air in at the fan side/AC input side and exhausts air out the load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fans move approximately 20 CFM of air. Avoid excessive bending of output power cables after they are connected to the output terminals. For high-current outputs, use cable ties to support heavy cables and minimize mechanical stress on connectors. Be careful not to short-out to neighboring outputs. The maximum torque recommended on output nuts is 10 in. lbs. Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such applications, a shock-absorbing mount design is required. PFC Mini Do’s and Don’ts n If Sense jumpers are removed, do not leave Sense lines open (especially if unit does not have Autosense). Sense lines must be terminated to their respective outputs. Use twisted pair 20-22 AWG wire when installing Remote Sense. n NEVER disconnect the +Out and -Out load wires while the supply is operating as disconnecting WILL cause damage to the power supply. Ensure load wires connected before remote sense connected. n To prevent damage to supply, verify polarity of remote sense connection before turning supply on. n Always turn the power supply off before disconnecting input or output wires. n Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the output terminals. n Run the output (+/–) power cables next to each other to minimize inductance. n Do not repair or modify the power supply in any manner. Doing so will void the warranty. Contact Factory. n Insert proper fault protection at power supply input terminals (i.e., a fuse). n Use proper size wires to avoid overheating and excessive voltage drop. n Output voltages over 60 Vdc, whether from individual modules or series arrays, are considered as hazardous secondary outputs under UL60950. Appropriate care must be taken in design implementation of the supply. Technical Description The PFC Mini consists of an offline single phase, power-factor-corrected front end, EMI filter, cooling fan, customer interface, associated housekeeping circuits, and a selection of Vicor’s DC-DC converters. Input AC mains voltage is applied to a terminal block. The input current is passed through an EMI filter designed to meet conducted noise limit “B” specifications in FCC Part 15 and EN55022, Class B (with VI-200/VI-J00 series modules. If Maxi, Mini, Micro series modules are used, it meets FCC Class A and EN55022 Class A. (Certain configurations meet Class B). At start-up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after initial power-up by a DC bus voltage sense circuit driving a relay. After rectification, the input voltage is put through a boost converter that keeps the AC input current sinusoidal and synchronized with the input AC voltage (in compliance with UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 3 EN61000-3-2). The boost converter delivers a regulated input to the hold-up capacitors and a high-voltage backplane. The backplane supplies power to the DC-DC converters that provide the desired low voltage regulated outputs. Voltage conversion is achieved by Vicor’s family of zero-current switching (ZCS) DC-DC converters. These are forward converters in which the main switching element switches at zero current. This patented topology has a number of unique attributes: low switching losses; high frequency operation, resulting in reduced size for magnetics and capacitors; excellent line and load regulation; wide adjustment range for output; low EMI/RFI emission and high efficiencies. At initial power-up, the PFC Mini outputs are disabled to limit the inrush current and to allow the DC bus potential to settle out to the correct operating level. A low-power flyback converter operating with PWM current-mode control converts the high voltage DC bus into regulated low voltage to power the internal housekeeping circuits and DC cooling fans. The internal housekeeping VCC comes up within two seconds after the application of input power. Once the high voltage bus is within operating limits, the AC Power OK signal asserts to a TTL "1," indicating the input power is OK, and enables the power outputs. An auxiliary VCC output of 5 Vdc sourcing up to 0.3 A is provided for peripheral use. An output Enable/Disable function is provided by using an optocoupler to control Vicor’s DC-DC converters. If the Enable/Disable control pin is pulled low, the optocoupler turns on and disables the output. The nominal delay associated for an output to come up when measured from release of the Enable/Disable pin is 5-10 ms. The General Shutdown function controls all outputs simultaneously and works in a similar manner. Figure 1. Input Line Filter Rectifier Soft Start Circuit Boost Converter High Voltage Bus Waveform Sample Output Card #1 Output Card #2 Current Sample E/D Control Fan UG:115 Power Output PFC Control Output Card #3 Customer Interface Power Output vicorpower.com Power Output Enable/Disable Control Isolated Housekeeping Power Applications Engineering: 800 927.9474 Page 4 PFC Mini Configuration Layout AC input Fan Fan AC input Fan Fan S 3 -M 2 S1-M1 S2-M1 S3-M1 S1-M1 S2-M1 S 3-M1 Slot 1 Slot 2 Slot 3 Slot 1 Slot 2 Slot 3 Shown above, are two sample PFC Mini configuration layouts. Due to the configurability nature of the PFC Mini, various output combinations are possible. See Page 12 for more information about your output connections. The PFC Mini has three slots and each slot accommodates either full or half-brick modules. Please note that the maximum output power of the PFC Mini is 1,500 W at 230 Vac, 800 W at 115 Vac, irrespective of the maximum output power of the modules e.g. if a PFC Mini is configured with three Maxi modules, on the configuration sheet, the maximum output power of the module (600 W) is listed. However, irrespective of the maximum output power of the three Maxi modules (1,800 W), the maximum output power of the PFC Mini is still 1,500 W at 230 Vac and 800 W at 115 Vac. When populated with 12 V modules, the maximum output power per slot is 500 W (with other modules it is 600 W). Hence, when a 12 V Maxi module is used, the maximum output power is limited to 500 W. If a 12 V Mini module is used, the maximum output power is limited to 250 W. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 5 SLO T#3 V375A5C400BN4 E/D#2 SLO T#2 Output #1 VI-J60-CY -S E/D#3 V375A5C400BN4 E/D#1 SLOT #1 Output #2 VI-J63-CW-S E/D#3 Configuration Example: SLOT# 1 VOLTS AMPS WATTS 5.0 80 800 2 Modules V375A5C400BN4* V375 V375A5C400BN4* V375A5C40 3 (M1) 5.0 10 50 VI-J60-CY-S* VI- 3 (M2) 24.0 4.2 100 VI-J63-CW -S* VI- * Actual module part numbers may vary depending on customer configuration E/D = Enable/Disable Part Numbering PFC Mini PMx1-x2 x (x4)-xxxx(-x5)(-x6) eg. PM4-22-2988 PM1-03B-48 PM3-03-2643-2 PM6-60-2888-2-QF PM = PM x1 = number of outputs x2 = number of VI-200/VI-J00 x3 = number of Maxi, Mini x4 = optional - standard product designator xxxx = configuration/customer specific # assigned by Vicor x5 = optional factory assigned note - MI =rugged chassis + MC for conformal coated rugged x6 = additional option codes revised to orginal configuration - QF = quiet fan/office enviornment LL = low leakage UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 6 PFC MegaPAC “Quick Install” Instructions (For Mechanical Drawing, see Page 10) Mounting the PFC Mini n Mount the PFC Mini on either of two sides. n Use #8-32 or 4 mm mounting screws. Maximum penetration should not exceed 0.16" (4 mm). n Maintain 2" (5,1 cm) clearance at both ends of power supply for airflow. Input Connections Input Power MBJ1 n Apply input AC power to terminal block MBJ1 using a pressure screw terminal. NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS. 115-230 VAC 10A 47 TO 500 Hz 300VDC --- L1 DO NOT OPERATE WITHOUT EARTH GND L2/N INPUT CONNECTIONS MBJ1-1 EARTH GROUND MSJ1-2 L2-NEUTRAL MBJ1-3 L1 n Strip length of AC power conductors to be 0.35 inches. n Maximum torque is 4.4 in. lbs. n Place a fuse or circuit breaker in the input line for safety requirements. n The connector manufacturer recommends the wires not be tinned. A ferrule can be used to prevent fraying. Output Connections (See Page 7 for more details on output connectors) Power Connections Installing bus bars on output studs (when full-size module is used): Output n The right stud is Positive and the left stud is the Return. Output Return n Remove the top nut and place ring lug over output stud. n Do not remove the lower nut next to the PCB. SxJ2 n Replace and tighten the nut to a torque of 10 inch pounds. Do Not over-tighten nuts. Installing power connectors with 18-pin molex connectors* (when half size module used): n SxJ1-1, SxJ1-10, SxJ1-11 are Positive for output #1, while pins SxJ1-2, SxJ1-3, SxJ1-12 are the Return. SxJ1-7, S3J1-8 and SxJ1-16 are Positive for output #2, while pins SxJ1-9, SxJ1-17 and SxJ1-18 are the Return. [a] Locking Key 18 9 17 16 15 14 13 - + -S T +S + + T -S +S 8 7 6 5 4 12 11 10 - + + - - + 3 2 1 SxJ1 Dual Output connector M1 Output M2 Output Pin 1 Identifier n Use Molex mating receptacle #39-01-2180 with #44476-3112 terminals. n Attach 18-24 AWG stranded wire using Molex tool #11-01-0199. n Current PFC Minis have 18-pin SxJ1 connectors. * Outputs with current molex connectors are limited to 9 A/pin (27 A per output). [a] Where x refers to the slot number. Note: Effective January 2001, all PFC Mini units have 18-pin connectors (Molex PN#39-01-2180) vs. the 14-pin (Molex PN# 39-01-2140). If you already have a 14-pin design in, remove the harness assembly from the 14-pin connector housing and insert the harness connector pins into the 18-pin connector housing. For further information, contact an Applications Engineer. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 7 Sense Connections Note: PFC Mini units built after 12/2000 have been equipped with a feature called Autosense. If no Sense connections are made, the PFC Mini will automatically operate in Local Sense mode. If Remote Sense connections are made, the PFC Mini will operate in a Remote Sense mode. For units built before 12/2000 (units without Autosense), Sense connections must ALWAYS be made. Not connecting Sense Lines to their respective outputs can cause failure to the unit. Sense connections on output connections with studs n PFC Minis are currently shipped with Autosense installed. Those without the Autosense were shipped with Local Sense installed. (See note on Page 14) Remove jumpers for Remote Sense n If Remote Sense is desired, remove jumpers MBJ1 and J3, located behind the Sense connector. n Connector pin SxJ2-2 is the +Sense and SxJ2-3 is the -Sense. n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals. n Attach terminals to 20-22 AWG stranded twisted pair wire using Molex tool #11-01-0208. n Attach opposite end of sense lines to point where regulation is desired. n Verify that sense lines are not cross-connected. Sense connections on output connection with Molex connectors n PFC Minis are currently shipped with Autosense installed. Those without the Autosense were shipped with Local Sense installed. (See note on Page 14) n If Remote Sense is desired, remove jumpers on MBJ1 and J3, located on either side of the output connector. Remove jumpers for Remote Sense on Output # 2 n Connector pin SxJ1-4 is the +Sense and SxJ1-5 is the -Sense for output #1. SxJ1-13 is the +Sense and SxJ1-15 is the -Sense for output #2. Connector J2 n Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals. Remove jumpers for Remote Sense on Output # 1 n Attach 18-24 AWG stranded twisted pair wire using Molex tool #11-01-0197. Trim Connections Trim connections on outputs with studs: Trim Connector 1 2 3 SxJ2 Pin Trim Pin Access +Sense -Sense n Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals. n Attach 20-22 AWG stranded wire using Molex tool #11-01-0208. Trim connections on outputs with Molex connectors: Locking Key 18 17 16 15 14 13 - - + -S T +S - + + T -S +S 9 8 7 6 5 4 n SxJ2-1 provides Trim access. 12 11 10 - + + - - + 3 2 1 SxJ1 Dual Output connector M1 Output M2 Output Pin 1 Identifier n SxJ1-14 provides Trim access for output #1, and SxJ1-6 provides Trim access for output #2. n Use Molex mating receptacle #39-01-21 with #39-00-0039 terminals. n Attach 18-24 AWG stranded wire using Molex tool #11-01-0197. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 8 J3 INTERFACE CONNECTION MATING HDWR: HOUSING: AMP P/N 205204-4 TERMINALS: AMP P/N 66506-9 SCREW LOCK: AMP P/N 205980-4 CRIMP TOOL: AMP 58448-3 J3 INTERFACE PIN OUT J3-1 J3-2 J3-3 J3-4 E/D-1 E/D-2 E/D-3 SIGNAL GROUND Interface Connections n J3-1 to 3 are Enable/Disable for cards 1-3, respectively. n J3-4 is Signal Ground, J3-5 is +5V, J3-6 is AC Power OK, and J3-7 is General Shutdown. n Use mating receptacle AMP P/N 205204-4 with terminals AMP P/N 66506-9. n Attach terminals to 18-24 AWG stranded wire. J3-5 VCC +5V 300mA J3-6 ACOK AC POWER OK J3-7 GSD GENERAL SHUTDOWN J3-8 SPARE J3-9 SPARE UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 9 .487 12.36 .920 23.37 43.69 ±0.51 UG:115 L1 L2/N 2.210 1.600 vicorpower.com 133.81 AIR FLOW 56.13 40.64 5.268 3 4 A COMPLETE SET OF MATING CONNECTORS CAN BE PURCHASED FROMWESTCOR BY SPECIFYING CONNECTOR KIT P/N: 19-130047 REF DESIGNATION LEGEND MB = MOTHER BOARD S1 = (SLOT 1) DAUGHTERBOARD MODULES E/D 1. S2 = (SLOT 2) DAUGHTERBOARD MODULES E/D 2. S3 = (SLOT 3) DAUGHTERBOARD MODULES E/D 3. WITH OPTIONAL BUSBAR. 2 1. INTERPRET DRAWING PER ANSI Y14.5-1994. NOTES: UNLESS OTHERWISE SPECIFIED MBJ1 INPUT CONNECTIONS MBJ1-1 EARTH GROUND MBJ1-2 L2 / NEUTRAL MBJ1-3 L1 DO NOT OPERATE WITHOUT EARTH GND NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS. 115-230 VAC 10A 47 TO 500 Hz 300VDC --- CLAMPING SCREWS 14 AWG WIRE J3 INTERFACE CONNECTION MATING HDWR: (AMP P/N: OR EQUIVALENT) HOUSING: AMP P/N: 205204-4 TERMINALS: AMP P/N: 66506-9 SCREW LOCK: AMP P/N: 205980-4 CRIMP TOOL: AMP 58448-3 J3 INTERFACE PIN OUT 5 1 J3-1 E/D-1 9 6 J3-2 E/D-2 J3-3 E/D-3 J3-4 SIGNAL GROUND J3-5 VCC +5V 300mA J3-6 ACOK AC POWER OK J3-7 GSD GENERAL SHUTDOWN J3-8 SPARE J3-9 SPARE 1.72 ±.02 1.00 4.00 25.40 101.60 8.00 203.20 12.03 305.56 317.29 ±0.51 308.86 12.49 ±.02 12.16 2 203.20 SCALE: 1:2 BOTTOM VIEW 8.00 .47 50.80 11.94 152.40 2 S1JX CSB-01 CSB-02 3 SEE PAGE 21 AND 22 FOR MORE INFORMATION ON CURRENT SHARE BOARDS. WITH VI-200/VI-J00 MODULES WITH MAXI/MINI MODULES 3 S2JX NOTE: FOR INCREASED OUTPUT POWER, CURRENT SHARE BOARDS ARE AVAILABLE. CUSTOMER MOUNTING HOLES: 4X #8-32 X .156 or M4 X 4mm MAX LG. FROM OUTSIDE OF POWER SUPPLY 50.80 8.64 ±0.51 All Westcor power supplies can now be configured online using VSPOC, the online configurator tool available on vicorpower.com 2.00 CUSTOMER MOUNTING HOLES: 2X #8-32 X .156 or M4 X 4mm MAX LG. FROM OUTSIDE OF POWER SUPPLY 2.00 6.00 .34 ±.02 S3JX 4 4 SEE PAGE 11 FOR DETAILED OUTPUT CONNECTION INFORMATION 3 4 PFC Mini Mechanical Drawing Applications Engineering: 800 927.9474 Page 10 Output Connectors for PFC Mini A. OUTPUT STUDS - SINGLE OUTPUT (when populated with full-size modules) -V OUT 10-32 OUTPUT STUDS SxJ2 REMOTE SENSE/TRIM PIN CONNECTOR +V OUT 3 2 1 - SENSE + SENSE TRIM MATING CONNECTOR: HOUSING: MOLEX P/N 50-57-9403 TERMINALS: MOLEX P/N 16-02-0103 USE CRIMP TOOL: MOLEX P/N 11-01-0208 B. MOLEX CONNECTOR - SINGLE OR DUAL OUTPUT - (when populated with half-size modules) 18-pin Housing 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1 10 PIN 1 2 3 4 5 6 7 8 9 SxJ1 (18 PIN OUTPUT, REMOTE SENSE AND TRIM PIN CONNECTOR) DESCRIPTION PIN DESCRIPTION +V OUT M1 10 +V OUT M1 -V OUT M1 11 +V OUT M1 -V OUT M1 12 -V OUT M1 + SENSE M1 13 + SENSE M2 - SENSE M1 14 TRIM M1 TRIM M2 15 - SENSE M2 +V OUT M2 16 +V OUT M2 +V OUT M2 17 - V OUT M2 -V OUT M2 18 - V OUT M2 MATING CONNECTOR: 18 PIN HOUSING: MOLEX (39-01-2180) TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039) USE CRIMP TOOL: MOLEX (11-01-0197) The Molex connectors are limited to 9A/pin (27A per output.) M1 Output M2 Output C. MOLEX CONNECTOR - SINGLE OR DUAL OUTPUT SLOT (14-pin Housing - PFC Minis built prior to 1/2001) 7 14 6 13 5 12 4 11 3 10 2 1 9 8 PIN 1 2 3 4 5 6 7 SxJ1 (14 PIN OUTPUT, REMOTE SENSE AND TRIM PIN CONNECTOR) DESCRIPTION PIN DESCRIPTION + SENSE M1 8 - SENSE M1 + OUTPUT M1 9 +OUTPUT M1 - OUTPUT M1 10 - OUTPUT M1 TRIM M1 11 TRIM M2 + OUTPUT M2 12 + OUTPUT M2 - OUTPUT M2 13 - OUTPUT M2 + SENSE M2 14 - SENSE M2 UG:115 MATING CONNECTOR: 14 PIN HOUSING: MOLEX (39-01-2140) TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039) USE CRIMP TOOL: MOLEX (11-01-0197) vicorpower.com Applications Engineering: 800 927.9474 Page 11 PFC Mini Connector Kit (19-130047) Listing (Avaialble for purchase) Item Qty 1 3 10 2 ** Description Vendor #1 Part # HOUSING 3 POS .100 CTR W/LATCH MOLEX 50-57-9403 TERM FEM CRIMP 22-24AWG SEL GOLD MOLEX 16-02-0103 CRIMP TOOL FOR ITEM 2 MOLEX 11-01-0208 205204-4 3 1 HOUSING FEMALE D-SUB 09 PIN AMP 3 10 TERM MALE CRIMP 22-24 AWG TIN AMP 66506-9 3 1 SCREW LOCK MALE (1 PAIR) AMP 205980-4 CRIMP TOOL FOR ITEM 3 AMP 58448-3 ** 4 3 HOUSING 18 POS .165 CTR W/LATCH MOLEX 39-01-2180 5 60 TERM FEM CRIMP 18-24 AWG SEL GOLD MOLEX 39-00-0039 CRIMP TOOL FOR ITEM 5 MOLEX 11-01-0197 TERM FEM CRIMP 16 AWG SEL GOLD MOLEX 45750-3211 CRIMP TOOL FOR ITEM 6 MOLEX 11-01-0199 ** 6 60 ** ** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT) Interface Connections Chassis Input Power Terminals (MBJ1) Input AC power is applied to terminal block MBJ1 using a pressure screw terminal that accepts a maximum wire size of 14 AWG. The insulation should be stripped 0.35 inches and the maximum torque applied to the screws should not exceed 4.4 in. lbs. The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N 32-00-58-0, provided in optional connector kit) can be used to prevent fraying. MBJ1-1 (GND) is Earth Ground for safety; MBJ1-2 (L2) and MBJ1-3 (L1) are the other "hot" connections. A fault clearing device, such as a fuse or circuit breaker, with a maximum 15 A rating at the power supply input is required for safety agency compliance. It should be sized to handle the start-up inrush current of 8.5 A pk at 115 Vac and 17 A pk at 230 Vac. Figure 2. Input Power Terminal MBJ1 NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS. 115-230 VAC 10A 47 TO 500 Hz 300VDC --- L1 L2/N DO NOT OPERATE WITHOUT EARTH GND INPUT CONNECTIONS MBJ1-1 EARTH GROUND MSJ1-2 L2-NEUTRAL MBJ1-3 L1 Output Power Connections There are two types of output power terminals available in the PFC Mini. Outputs from full-sized converters are terminated in two 10-32 plated steel bolts. The positive polarity of the output is the right bolt when viewed from the output end. Outputs from halfsized converters terminate in a Molex connector. Note: The Molex connectors are limited to 9 A/pin (27 A/output). Each power output is isolated, so outputs of positive or negative polarity can be configured through proper selection of the output reference terminal. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 12 In order to minimize parasitic cable inductance and reduce EMI, the output power cables should be routed in close proximity to one another, and large current loops should be avoided. To avoid excessive voltage drop, do not undersize power cables, especially for high-current outputs. Excessive cable inductance coupled with large capacitive loading can introduce instability in switching power supplies. This problem can be avoided with proper system design. Consult Vicor’s Applications Engineering Department for assistance with applications that use long cable lengths and excessive load capacitance. Note: Effective January 2001, PFC Minis using VI-J00 modules on a dualboard (dual output) now require an 18-pin connector (Molex PN# 39-01-2180) vs. a 14-pin (Molex PN# 39-01-2140), making them the same as dualboards with Mini converters. If you already have a 14-pin design in, the change to the 18-pin should not affect your design in. Remove the harness assembly from the 14-pin connector housing and insert the harness connector pins into the 18-pin connector housing. Contact Field Applications for further information. Figure 3. Power Connections for Single Output Output Output Return SxJ2 Figure 4. Power Connections for Dual Output 14 13 12 11 10 7 6 5 3 9 8 2 1 18 17 16 15 9 8 7 6 14 13 12 11 10 5 4 3 2 1 14 PIN DUAL MODULE OUTPUT CONNECTIONS 18 Pin DUAL MINI AND JR. MODULE OUTPUT CONNECTIONS PIN DESCRIPTION PIN DESCRIPTION PIN DESCRIPTION SxJ1-1 +SENSE M1 SxJ1-2. +OUTPUT M1 SxJ1-3. -OUTPUT M1 SxJ1-4. TRIM M1 SxJ1-5. +OUTPUT M2 SxJ1-6. -OUTPUT M2 SxJ1-7. +SENSE M2 4 UG:115 SxJ1-8. -SENSE M1 SxJ1-9. +OUTPUT M1 SxJ1-10. -OUTPUT M1 SxJ1-11. TRIM M2 SxJ1-12. +OUTPUT M2 SxJ1-13. -OUTPUT M2 SxJ1-14. -SENSE M2 vicorpower.com SxJ1-1. +OUTPUT M1 SxJ1-2. -OUTPUT M1 SxJ1-3. -OUTPUT M1 SxJ1-4.+SENSE M1 SxJ1-5.-SENSE M1 SxJ1-6. TRIM M2 SxJ1-7. +OUTPUT M2 SxJ1-8. +OUTPUT M2 SxJ1-9. -OUTPUT M2 PIN DESCRIPTION SxJ1-10. +OUTPUT M1 SxJ1-11. +OUTPUT M1 SxJ1-12. -OUTPUT M1 SxJ1-13. +SENSE M2 SxJ1-14. TRIM M1 SxJ1-15. -SENSE M2 SxJ1-16. +OUTPUT M2 SxJ1-17. -OUTPUT M2 SxJ1-18. -OUTPUT M2 Applications Engineering: 800 927.9474 Page 13 +Sense/ –Sense (SxJ2/SxJ1) Current PFC Mini units are shipped with Autosense installed. If the unit does not have Autosense, sense selection is very important. In units without Autosense, the Sense lines for the outputs are shipped from the factory with Local Sense installed. If Remote Sense is desired the Local Sense jumpers can be removed for individual outputs. If the Local Sense jumpers are removed, the Sense lines must be connected for Remote Sense. Leaving the Sense lines open will prevent proper output regulation and can result in damage to the unit. When Local Sense is used, the power supply will regulate the output at the output terminals. The voltage appearing at the load may drop slightly due to voltage drop in the power cables. If it is necessary to compensate for voltage drop along the output power cables, the output can be trimmed up or configured for Remote Sense. Use stranded twisted pair 20-22 AWG wire for the Remote Sense lines. Remote Sense can compensate for a voltage drop of up to 0.5 V, or 0.25 V on each leg. Installing Remote Sense requires the Local Sense jumpers to be removed. On single output cards, the Local Sense jumpers are located behind the Sense connector on MBJ1 and J3. To remove the jumpers, make certain the power to the supply is off, and pull them off the connectors MBJ1 and J3. On dual output cards, the local Sense jumpers are on either side of the output connector at MBJ1 and J3. The jumpers at MBJ1 are for output #1, and the jumpers at J3 are for output #2. The Sense connector for a single output board is a 3-pin connector providing the +Sense connection on SxJ2-2 and the -Sense connection on SxJ2-3. The Sense connector for a dual output board is an 18-pin connector that also provides the output and trim connections. +Sense and -Sense for the first output are located on SxJ1-4 and SxJ1-5, respectively. +Sense and -Sense for the second output are located on SxJ1-13 and SxJ1-15, respectively. Figure 5. Removing Local Sense Jumpers TOP VIEW Dual Output Sense Connections Single Output Sense Connections Remove jumpers for Remove jumpers for Remote Sense on Remote Sense on Output # 1 Output # 2 Connector SxJ1 Local Sense jumpers located behind the Sense Connector. END VIEW 14 Pin Dual Output Sense Connectors Local Sense jumpers are to the left of the output connector for Output # 2. 14 13 12 11 10 7 6 5 4 3 9 8 2 1 18 Pin Dual Output Connectors Local Sense jumpers are to the left of the output connector for Output # 2 Local Sense jumpers are to the left of the output connector for Output # 1 Local Sense jumpers are to the left of the output connector for Output # 1 18 17 16 15 9 8 7 6 14 13 12 11 10 5 4 3 2 1 Single Output Sense Connections Local Sense jumpers located behind the Sense Connector. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 14 Figure 6. Remote Sense +Out +Sense Load -Sense -Out Use 20-22 AWG Twisted Pair Wires Figure 7. External Trim +P +Out Use 20-22 AWG Twisted Pair Wires (Remote Sense) R1 SxJ2-2 +Sense To Error Amplifier + RTH R5 R8 R2 SxJ2-1 R6 R3 SxJ2-3 -Sense V1 V Ref - R7 Load + V2 - R4 -P -Out Use 20-22 AWG Twisted Pair Wires Table 1. Module Internal Reference Voltages and Thevenin Resistances Output Module Vref RTH VI-200/VI-J00 ≥3.3 V 2.5 V 10.0 kΩ VI-200/VI-J00 <3.3 V 0.97 V 3.88 kΩ Maxi, Mini Micro series (Predefined) 1.23 V 1 kΩ Maxi, Mini Micro series (User Defined) 1.23 V Consult Factory External Trim (SxJ2/SxJ1) The Trim pin at SxJ2 is referenced to the -Sense pin and can be used for external control of the output voltage. For dual output cards, the Trim pins are available at SxJ1-14 and SxJ1-6 for outputs 1 and 2, respectively. A 10% increase to the trim pin voltage will result in a 10% increase in output voltage. Reducing the trim pin voltage by 10% will result in a 10% decrease in output voltage. Note: Converters are sometimes pre-trimmed at the factory if a nonstandard output voltage is requested. If a nonstandard voltage is requested, the resistor calculations will differ from those that follow. Consult Vicor Applications Engineering for assistance. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 15 Example: ±10% Trim adjust on a 12 V nominal output. Figure 7 shows a typical variable trim circuit. Using a 10 k trimpot (R7), the resistor values for R6 and R8 can be calculated as follows: V1 = Vref + 10% = 2.75 V IR5 = (2.75 V - Vref)/RTH = (2.75 V - 2.5 V)/10 kΩ = 25 µA Given: RTH = 10 kΩ (see Table 1) Given: Vref = 2.5 V (see Table 1) Setting the bottom limit: VR6 = 2.5 V - 10% = 2.25 V And since IR5 = IR6 = 25 µA, R6 = VR6/IR6= 2.25 V/25 µA = 90 kΩ V2 = V1 + VR6 = 2.75 V + 2.25 V = 5 V IR7 = V2/R7 = 5 V/10 kΩ = 500 µA IR8 = IR7 + IR6 = 525 µA VR8 = (Vnom +10%) - V2 = 13.2 V - 5 V = 8.2 V R8 = VR8/IR8 = 8.2 V/525 µA = 15.62 kΩ Given: Vnom = 12 V CONSULT APPLICATIONS ENGINEERING WHEN TRIMMING OUTPUTS BELOW 5 V. Signal Ground (J3-4) Signal Ground on J3-4 is an isolated secondary ground reference for all J3 interfacing signals. This is not the same as Earth Ground on input power connector MBJ1. Enable/Disable (J3-1 to J3-3) The Enable/Disable control pins allow outputs to be sequenced either on or off. J3-1 through J3-3 are the control pins for output cards 1 through 3, respectively. For 2-output cards, both outputs are enabled or disabled with a single control. The Enable/Disable pins should be pulled low to less than 0.7 V with respect to Signal Ground to disable the outputs. They will source 4 mA maximum. These pins should be open circuited or allowed to exceed 4.5 V when enabled. Do not apply more than 5 V to these inputs. Figure 8. Enable/Disable and General Shutdown J3 PFC Mini A TTL "1" applied to the base of the transistor turns output OFF. Pin 1 (or Pin 7 for GSD) is pulled Low with respect to Signal Ground. 5 Vcc Enable/Disable Output 1 1 Enable/Disable Control General Shutdown TTL "1" (OFF) TTL "0" (ON) 7 1 0 Signal Ground 4 UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 16 Enable/Disable Control of Maxi, Mini, Micro Series Module Arrays When using the Enable/Disable function on an output that consists of two or more Maxi/Mini series modules, it is necessary to connect the Enable/Disable pins of the corresponding module locations together such that both modules are commanded to turn ON or OFF simultaneously. Example: S1 and S2 has been configured as a single output parallel array (see Figure 9) In order to disable the 48 V output, Enable/Disable 1 and 2 should be shorted together as shown in Figure 9. With Enable/Disable 1 and 2 connected together, a single switch can then be used to remotely enable and disable the output. Note: For single output Maxi/Mini series power supply configurations, the simplest method of remotely enabling and disabling the output is to use the General Shutdown (GSD) function. Figure 9. Enable/Disable Control of Maxi, Mini, Micro Series Module Arrays J3 1 2 3 4 5 6 7 8 9 V375A5C400A 1 2 3 S3 V375A48C600A 1 2 3 S2 J1 V373A48C600A 1 2 3 Load S1 General Shutdown/GSD (J3-7) The GSD control pin on J3-7 allows simultaneous shutdown of all outputs. This pin must be pulled down to less than 0.7 V, and will source 4 mA maximum to shut down all outputs. The GSD pin should be open circuited or allowed to exceed 4.5 V when not in use, or when the outputs are to be enabled. Do not apply more than 5 V to this input at any time. Normal open circuit voltage is 1.5 to 3 V with respect to Signal Ground. AC OK (J3-6) AC OK is an active high TTL compatible signal and provides a status indication of the AC input power. It is on pin J3-6 and is capable of sinking 16 mA maximum. This signal switches to a TTL "1" when the high voltage bus exceeds low-line condition during turnon. Upon loss of input power, the bus voltage will drop, causing the AC OK signal to go low. A minimum of 3 ms hold-up time is provided for a 1,200 W load following the loss of the AC OK signal. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 17 Figure 10. AC OK J3 +5V 10K 2.49K Pin 6 Bus Monitor PN2222 AC Power OK Pin 4 Signal Ground Auxiliary VCC +5 V/0.3 A (J3-5) The VCC on J3-5 is an auxiliary 5 V regulated power source. It is +5 Vdc +/–5% with respect to Signal Ground and can supply 300 mA maximum. It is short-circuit-proof, but if shorted, all outputs will shut down through the Enable/Disable circuitry. Figure 11. Auxiliary Vcc 78M05 +5V/300 mA J3 J3-5 Auxiliary Vcc 0.1 µF J3-4 Signal Ground Single Output Power Supplies (Arrays) Vicor’s standard configuration for single output power supplies is to set the left module (as seen from looking at the power supply output) as the controlling module of the array. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 18 Minor Changes for PFC Mini Shipped October 2005 Onwards As part of our philosophy of continuous improvement for the PFC Mini, Vicor made a number of changes to the unit. Usually such actions have no impact on form, fit, or function of the supplies. In this instance, the improvements required minor changes in the external appearance of the supply. The fans have been moved 0.62" and are now centered. The D-Sub logic connector has also been rotated 90 degrees. Please see the following photos for a visual comparison. No other external dimensions, mounting locations, or performance characteristics have been changed. PFC Mini - Without Change PFC Mini - With Change 5.268 1.600 1.72 ±.02 .920 .487 133.81 40.64 2.210 56.13 43.69 ±0.51 23.37 12.36 How to Identify When Your Unit was Manufactured Serial numbers for Vicor products are determined as follows: XXXXXXXMMYY XXXXXXX = Factory assigned MM = Month of manufacture Y = Last digit of year of manufacture UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 19 PFC Mini Output Power vs. Input Voltage PFC Mini Output Power vs. AC Input Voltage 1600 1400 Output Power 1200 1000 800 638 600 400 200 0 85 105 125 145 165 185 200 205 225 245 265 AC Input Voltage PFC Mini Output Power vs. DC Input Voltage 1600 1400 Output Power 1200 1000 800 750 600 400 200 0 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 DC Input Voltage UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 20 Specifications General Number of Outputs 1–6 Efficiency >80% cURus – UL 60950-1, CSA 60950-1; cTÜVus – EN 60950-1, UL 60950-1, CSA 60950-1 Safety Approvals CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC Note: certain MI chassis may not carry all safety approvals Maximum Output Power+ >800 W at 115 Vac; (+Not to exceed an input 1,500 W at 230 Vac current of 10 A) Note: Only PFC Minis populated with 12 V Maxi modules are limited to 500 W max. per slot. With 12 V Mini modules, it is limited to 250 W. Input Input 85 – 264 Vac, 47 – 500Hz; 100 – 380 Vdc VI-200/VI-J00:± 0.2% max.10% to full load; ± 0.5% max. Line/Load Regulation 0 to 10% load Line Regulation Maxi/Mini:± 0.20% max. to 0.3% max LL to HL, Full Load Inrush Current 8.5A pk at 115 Vac; 17A pk at 230 Vac Ride Through Time 20 ms at 1,200 W load VI-200/VI-J00 Ss: Maxi, Mini (some configs. may meet Class B): Conducted EMI EN55022 Class B EN55022 Class A Mil-STD 461 will require external filter Power Factor 0.99 at 115 Vac: 0.95 at 230 Vac Voltage Fluctuations and Flicker EN61000-3-3 ESD Susceptibility EN61000-4-2, Level 3, Performance Criteria A RF Radiated Immunity, 10v/m EN61000-4-3, Performance Criteria A Transient Burst Immunity EN 61000-4-4, Level 3, Performance Criteria B Surge Immunity EN 61000-4-5 Installation Class 3, Performance Criteria B RF Conducted Immunity EN61000-4-6, Limit Class 3 Performance Criteria A Voltage Dips and Interrupts EN61000-4-11 Primary to Chassis GND = 2,121 Vdc Dielectric Withstand Primary to Secondary = 4,242 Vdc Secondary to Chassis GND = 750 Vdc MI Chassis Overvoltage and Transients Compliant to Mil-STD 704 and 1399 Note: See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal output voltage. Environmental Storage Temperature -40°C to +85°C Operating Temperature Full Power -20°C to +45°C [b] (-40°C to +45°C optional with MI chassis) Half Power -20°C to +65°C (-40°C to +65°C optional with MI chassis) Specific temperature data on all module configurations can be obtained by contacting Applications Engineering. [b] 45°C is the maximum operating temperature. If one is using a Maxi/Mini module less than 24 V output and more than 500 Watts, the maximum operating temperature is 40°C. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 21 Environmental (Cont.) Mil-STD 810 Shock and Vibration Derate 2.6% total output power for each 1,000 ft to a maximum (MI Chassis) Altitude operating altitude of 15,000 ft. Non-operating storage maximum altitude is 40 K. 75% maximum load Humidity 0 to 95% non condensing Product Weight 5.5 lbs. (2,5 kg) Dimensions 1.72" H (43,6 mm) x 6.0" W (152,4 mm) x 12.2" L (309,9 mm) 2 years limited warranty. Warranty [c] See vicorpower.com for complete warranty statement. [b] 45°C is the maximum operating temperature. If one is using a Maxi/Mini module less than 24 V output and more than 500 Watts, the maximum operating temperature is 40°C. [c] Opening, repairing or modifying the unit will void the warranty. If you have any problem with the power supply, please contact Customer Service at 1-800-735-6200. If the unit needs to be returned for inspection/analysis, an RMA number will be issued. All units must have a RMA number prior to return. Ouput VI-200/VI-J00 Modules Parameter Setpoint MIN Accuracy [d] TYP MAX UNITS Notes 1 % of Vnom Load/line Regulation ± 0.2 % 10% to full load Load/line Regulation ± 0.5 % 0.02 %/°C 0.5 Temperature Regulation 0.01 No load to 10% load Over rated temp. Long Term Drift Output Ripple & Noise: ≤10 Vout 100 mV 20 MHz bandwidth >10 Vout 1.0 % Vout 20 MHz bandwidth 50-110 % Vout ± 10% on 10 – 15 Vout Voltage Trim Range VI-200/VI-J00 series Slots Total Remote Sense Compensation OVP Set Point [e] Current Limit Short Circuit Current 0.5 Volts 115 125 105 115 20 (105 [f]) Overtemperature Limiting Autosense. See Pages 8 & 14 135 % Vout Recycle Power 125 % of I max Auto Recovery 130 % Not available on VI-J00 [d] For special, adjustable voltages and 48 Vdc outputs, maximum setpoint accuracy is 2% of Vnom. Note: See individual module data sheets for specific module specifications. [e] 131% Nominal for Booster Modules. No OVP for VI-J00 [f] VI-J00 modules only UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 22 Maxi, Mini, Micro Series Modules (Maxi and Mini Modules Only) Parameter MIN Setpoint Accuracy [d] Load Regulation TYP MAX UNITS ±0.5 ±1 % of Vnom See module design guide % of Vnom for exact specifications ±0.1 Temperature Regulation 0.002 0.005 %/°C Notes -20°C to 100°C Long Term Drift Output Ripple & Noise: ≤10 V out 100 mV 20 MHz bandwidth >10 V out 1.0 % Vout 20 MHz bandwidth 10-110 % Vout Preload may be required Voltage Trim Range Maxi/Mini Slots Total Remote Sense Compensation OVP Set Point 0.5 112 Current Limit Overtemperature Limiting Volts 115 100 115 Autosense. See Pages 8 & 14 135 % Vout Recycle Power 135 % of I max Auto Recovery MMM OTL is non-latching [d] For special, adjustable voltages and 48 Vdc outputs, maximum setpoint accuracy is 2% of Vnom. Note: See individual module data sheets for specific module specifications. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 23 Current Share Boards - Optional Feature "Current Sharing" also known as Load Sharing, is the ability to divide the output current evenly across all active power supplies. This greatly reduces stresses on each power supply and allows them to run cooler, resulting in higher reliability. Standard "Current Sharing" techniques typically utilize shunt resistors or Hall-Effect devices to measure the current from each power supply. Power shunt resistors continually dissipate power and require cooling especially when dealing with high output currents of >100 Amps. Hall-Effect devices measure magnetic fields generated by current flowing through a conductor and, although they dissipate no power, they tend to be large and expensive. First developed by Vicor engineering for paralleling MegaPAC supplies, the Box-to-Box Current Share Board or CSB allows two or more Vicor power supplies to current share by utilizing the inherent voltage drop produced in the negative output return cable. This eliminates the need for additional shunt resistors or expensive Hall-Effect devices and provides a simple 5 wire connection method to achieve a +/-1 mV accuracy between the negative output power rails. This accuracy translates to a 1% current sharing if there is a total of 100 mV conductional voltage drop in the negative return path. Constructed as a current source to drive the Trim pin of a Vicor module, the design uses an accurate comparator circuit to monitor the power returns. In addition, the circuit is unidirectional and can only trim an output voltage up. The benefit is that only the supply that is supporting less current is adjusted up. This action balances the currents to the load by matching the output voltages of the supplies. In the case of one supply failing, the circuit will attempt to trim the failed supply only. This will leave the remaining functional supply alone to provide power to the load at its nominal voltage. Thus the circuit also offers simple redundancy. In addition, because CSB functions as a current source, the Trim outputs (T1 and T2) of the CSB can be placed in parallel to create a summing node. This allows current sharing between more than two supplies by paralleling the T2 output of one CSB circuit with the T1 output of the next CSB. Please note: The CSB is not intended for use in Hot-Swap applications. Figure 12. CSB Interconnect Expample D* +OUT Power Supply 1 24V@1kW +VOUT +S TRIM Yellow -S -OUT Brown D* +OUT Power Supply 2 24V@1kW +S TRIM -S T1 -V1 T2 -V2 Power Red CSB02 -VOUT White Black -OUT UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 24 Current Share Boards - Optional Feature (Cont.) Requirements: 1.For proper operation, the power supplies being paralleled should be enabled at the same time. 2.-Out conductors must be of equal length and wire gauge. Separate -Out conductors must be used from each supply to the load, or the use of a "Y" connection to a common point must be used as shown in Figure 1. Each leg of the "Y" must have a minimum of a few millivolts of drop in order for proper operation. 50 mV to 100 mV of drop will provide from 5% to 1% accuracy. 3.-V1 and -V2 for all box-to-box circuits must be connected directly at the negative output power studs or terminals to achieve accurate current sharing. 4.D* can be added if redundancy is needed. If redundancy is not required, D* can be replaced with direct wire connections. 5.When using D*, the Power input should be connected on the cathode side of the paralleling diodes as shown in Figure 12. 6.Terminate Sense Leads either locally or remotely as shown in Figure 1. 7.For paralleling more than two supplies consult Applications engineering for assistance. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 25 Current Share Boards - Optional Feature (Cont.) 0.13" (3.3mm) Dia Non Plated thru hole 4 places 1.74" (44.2mm) 2 1 4 3 6 5 Molex CT43045F surface mountable connector. .390" height above board. 1.500" (38.1mm) J1 Pinout Pin 1 2 3 4 5 6 Description P ow e r T1 -V1 T2 -V2 No Connection 0.12" (3.0mm) 0.12" (3.0mm) 0.900" (22.9mm) 1.14" (29.0mm) Figure 13. Mechanical Drawing 24.0" +/- 1.0" Red, 22 AWG P1 Po w e r Yellow, 22 AWG T1 Brown, 22 AWG -V1 White, 22 AWG T2 Black, 22 AWG -V2 Figure 14. Cable Drawing Specifications: 1.Power: 2 – 50 Vdc at 5 mA maximum. 2.Accuracy: +/-1 mV between -Vout connections. 3.Output current when not trimming up: +/-1 uA (VI-200/J00), +/-5 µA (Maxi, Mini, Micro series). 4.Use four non-plated through holes with standoffs for mounting. 5.CSB01 MUST be used for current sharing VI-200/VI-J00 series converters (VI-200/J00). 6.CSB02 MUST be used for current sharing Maxi, Mini, Micro series converters (Maxi, Mini and Micros). PLEASE NOTE: THE CSB IS NOT INTENDED FOR HOT-SWAP APPLICATIONS. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 26 Low Leakage Version (Available upon request) If Low Leakage is required, Vicor has a PFC Mini model variant (must be requested). This model enables the user to meet various additional specifications. The advantage of the Low Leakage PFC Mini power supply is in multiple power supply systems that have one AC input. This option will lower the input leakage current for these products to 500 μA or less (may vary if Maxi, Mini, Micro series modules are used. Contact Applications Engineering for more details.) An additional external EMI filter is typically required. How Low Leakage is Obtained Low Leakage is obtained with the removal of the "Y" capacitors from within the EMI filter of the PFC Mini [a]. This reduces the leakage current from the AC input to AC ground (chassis) to below 500 μA. At the same time, since the "Y" capacitors are a vital component of the EMI filter, without them, the EMI will go up. When this happens, the unit may no longer meet Vicor’s published specifications for conducted EMI. In order to reduce the EMI to within an acceptable limit, an additional external EMI filter may be required. All safety agency certifications for the PFC Mini remains intact[g]. Contact Applications Engineering for more information. [g] Please note that the PFC Mini (including Low Leakage version) is NOT UL2601 compliant. Low Output Ripple If output ripple of 10 mV p-p or 0.15% (whichever is greater) is required, a PFC Mini with RAM modules can be configured if the maximum output power per output does not exceed 100 W. If this configuration is required, please contact: [email protected] to have it configured since this option is currently not available using the online configuration tool (VSPOC). If there are space restrictions, an external RAM/µRAM can also be used. Office Environment Fan A PFC Mini using an office environment fan is available. Please note that the maximum output power for this version is 1,200 W. The maximum output power per slot is limited to 500 W. Molex Connector Limitation Please note that those PFC Mini configurations that use Molex connectors are limited to 9 A/pin (27 A per output). This is a Molex connector limitation, NOT a module power limitation. Vicor’s online configuration tool (VSPOC) will not provide a PFC Mini solution for requirements that exceed the 27 A limitation. UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 27 NOTES: UG:115 vicorpower.com Applications Engineering: 800 927.9474 Page 28 For Vicor Global Office Locations, please go to: www.vicorpower.com/contact-us or call 800-735-6200. For more information about this or other Vicor products, or for assistance with component-based power system design, contact the Vicor office nearest you. Vicor's comprehensive line of power solutions includes modular, high-density DC-DC converters and accessory components, configurable power supplies, and custom power systems. Vicor designs and builds configurable power supplies incorporating Vicor’s high density DC-DC converters and accessory components. This product line includes: LoPAC FAMILY: • PFC MicroS • PFC Micro • PFC Mini MegaPAC FAMILY: • PFC MegaPAC • 4kW MegaPAC • 4kW MegaPAC-EL (Low Noise) • PFC MegaPAC (High Power) • PFC MegaPAC (Low Noise/High Power) • PFC MegaPAC-EL (Low Noise) • Mini MegaPAC • Autoranging MegaPAC • ConverterPACs OTHERS: • FlatPAC-EN • PFC FrontEnd • MicroPAC • Conduction Cooled MicroPAC Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini, PFC MegaPAC, Standard MicroPAC and Conduction Cooled MicroPAC. 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. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. THE LATEST DATA IS AVAILABLE ON THE VICOR WEBSITE AT VICORPOWER.COM The Power Behind Performance Rev 1.2 03/2015 P/N 07-130245-01A vicorpower.com Applications Engineering: 800 927.9474 Page 29