DESIGN GUIDE VIPAC ™ CONTENTS 2–3 PRODUCT OVERVIEW 4 FEATURES 5 INPUT / OUTPUT OPTIONS 6 SPECIFICATIONS 7–8 9 TECHNICAL OVERVIEW INPUT CONNECTIONS 10 – 12 OUTPUT CONNECTION OPTIONS 13 – 14 CHASSIS CONFIGURATIONS 15 – 16 MOUNTING OPTIONS 17 – 20 MECHANICAL DRAWINGS 21 MECHANICAL INFORMATION 22 THERMAL MANAGEMENT 23 GENERAL INFORMATION 24 APPLICATION TIPS PRODUCT OVERVIEW Vicor’s VIPAC™ is an integrated power system leveraging the latest advances in DC-DC converter technology and modular front-ends. VIPAC combines application specific power solutions. PPU 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. 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 • 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. The use of standard chassis footprints allows different input voltage configurations of the VIPAC to be used interchangeably depending on system and market requirements. 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 2 HUB Input 115/230 Vac Autoranging I/O Interface Output Sequencing BUS-OK Output Enable / Disable Pre-assembled and Tested Front End FARM – Filter Autoranging Rectifier Module Protective Features Auto Restart Inrush Current Limiting EMI Filtering Input Transient Protection Vicor’s Maxi, Mini, Micro Family DC-DC Converters Output Voltages 0.5 – 48 Vdc 50 – 500 W / Output (1/4 Brick Modules Shown) Platform Options Low Profile Coldplate 0.5" and 1" Optional Finned Configurations Choice of Output Termination (LugMate Shown) AC Input Autoranging • 115/230 Vac • 50/60 Hz (400 Hz optional) v i c o r p o w e r . c o m / v c a d 3 FEATURES • Analog User Interface Power Up / Down control BUS-OK • Partitioned Power Architecture Maximizes packaging flexibility Top view, HUB + Remote hold-up capacitors (AC input) + – + User-definable hold-up characteristics (AC input) ST ST – + – Enhanced reliability – Wide operating temperature range –20˚ to +95˚C chassis C – Grade – 40˚ to +95˚C chassis T – Grade Micro 1.23 V 1 kΩ Error Amp 0.033 μF –Out RD Trim Down SC Load +Out • Secondary Control Output voltage trimming Mini and Maxi 10 – 110% Vout 1.23 V 1k Ω Error Amp 0.033 μF –Out –S SC +S +Out 4 RD Trim Down Load OUTPUT OPTIONS Output Voltage Selection VIPAC Configuration 2V 3.3 V 5V Micro 12 V 15 V 24 V 28 V 36 V 48 V Total Maximum Output Power (W)* # Outputs Single 50 75 100 150 150 150 150 150 150 150 100 150 200 300 300 300 300 300 300 300 50 50 75 75 100 100 150 150 150 150 150 150 150 150 150 150 150 150 300 100 50 150 75 200 100 300 150 300 150 300 150 300 150 300 150 300 150 450 50 50 50 75 75 75 100 100 100 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 450 VP-G Single ll Dual VP-D Dual ll Triple VP-A # Outputs Mini Maximum Output Power (W)* Single 100 150 200 250 250 250 250 250 250 250 Single ll 200 300 400 500 500 500 500 500 500 500 Dual 100 100 150 150 200 200 250 250 250 250 250 250 250 250 250 250 250 250 500 VP-E VP-B # Outputs Maxi Maximum Output Power (W)* Single 160 264 400 500 500 500 500 500 500 500 Single ll 320 528 800 900 900 900 900 900 900 900 Dual 160 160 264 264 400 400 500 500 500 500 500 500 500 500 500 500 500 500 900 VP-F VP-C *Model numbers and total output power capability are application specific. Component tolerances may effect total output power (±5%) in parallel (//) configurations. See VIPAC configuration tool at: vicorpower.com/vcad v i c o r p o w e r . c o m / v c a d 5 SPECIFICATIONS 115/230 Vac Autoranging Input Parameter Operating input voltage Min 90 180 Input undervoltage shut down AC line frequency Power factor Inrush current Input surge withstand Performance Criteria B Hold-up capacitance Leakage current EMI Typ Max 132 264 90 63 440 Unit Vac Vac Vac Hz Hz 30 Amps 1,800 3,300 3.2 μF mA Typ Max Unit Vdc Vrms Vrms 95 95 °C °C g g % 47 47 0.60 EN61000-4-5 Notes Autoranging doubler mode Autoranging bridge mode No damage C-Grade T-Grade Nominal Line 264 Vac peak line, cold start 2 kV – 50 μs common mode 1 kV – 50 μs differential mode Refer to VCAD calculator at 264 Vac input Additional filter components are required for compliance to EN55022 and FCC conducted emissions requirements. Environmental Parameter Dielectric withstand Input to chassis Input to output Min 2,121 1,500 3,000 Operating temperature – chassis C-Grade T-Grade Shock Vibration Humidity Safety approvals cTÜVus EN 60950-1, UL 60950-1, CE Marked (LVD) -20 -40 50 1 5 95 Notes Vdc test recommended due to Y-caps Class 1 product. Isolation components tested prior to assembly. Do not test finished product at this value. GR 6063, NEBS, Zone 4 (designed to meet) GR 6063, NEBS, Zone 4 (designed to meet) Non-condensing Output Specifications – General at 25°C, nominal line and nominal load, per module unless otherwise specified Parameter Output voltage set point Line regulation Temperature regulation Over temperature shut down Power sharing accuracy Programming range Min Typ ±0.02 ±0.002 115 ±2 10 Current limit Short circuit current Max ±1 ±0.2 ±0.005 ±5 110 115 115 Unit % % %/˚C ˚C % % % Iout max. % Iout max. See 300 V Maxi, Mini, Micro Family data sheets for detailed module specifications. Interface Control Functions ( See technical description) 6 Type Output Enable /Disable Output Sequencing Bus OK Remote 4 4 4 Notes Vout nom Low line to high line; full load Over operating temp. range 10% to 100% of full load Of nominal output voltage. (For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required) Output voltage 95% of nominal Output voltage <250 mV TECHNICAL OVERVIEW Overview At initial power up, the front end is configured Vicor’s VIPAC offers a 115 / 230 Vac autoranging input. for 230 Vac operation and the PTC inrush The front-end section utilizes Vicor’s FARM input module to limiter permits the main storage capacitors to provide EMI filtering, transient protection, inrush current charge up at a controlled rate toward full operating DC bus limiting and rectification. The VIPAC has provisions to allow potential. If the bus voltage settles below the operating controlling the operation of the individual outputs and threshold, the unit will auto-strap for 115 Vac operation. The providing a BUS OK status indication. Reference the figure strapping function is performed by an SCR that configures the below for circuit operation. front end as either a full wave bridge or a voltage doubler. If the unit is operating in the 115 Vac mode and a long Up to three individually fused Maxi, Mini, Micro Family duration transient is applied to the VIPAC (>150 Vac for 50 DC-DC converters are combined with the front end in an ms), the unit will auto-strap for 230 Vac operation. Input integrated mechanical – assembly providing a high efficiency power must be removed for approximately one minute to power supply delivering up to 900 W of output power. restore normal operation from 115 Vac. A control circuit holds the DC-DC converter PC pins low, DC outputs off, the Circuit Operation The AC autoranging input VIPAC utilizes the FARM module which provides inrush current limiting, transient protection, EMI filtering and rectification. The AC line voltage is applied via an agency approved 6 pin connector. A fuse in the “L1” lead protects the VIPAC from damage due to internal shorts. At start-up, AC inrush current is limited by a PTC thermistor. The PTC thermistor serves as both an inrush current limiter on power up and a current limiting shut-down device in the event of an input over voltage condition. The PTC is shunted out shortly after initial power up by a DC bus voltage sense circuit. The main energy storage capacitors are located remotely in the HUB (Hold-up Box) or as customer supplied hold-up capacitors. The main rectifiers and filter capacitors act as either a full wave bridge or voltage doubler (depending on the applied AC voltage) delivering a nominal 300 Vdc to one or more Vicor Maxi, Mini, Micro Family DC-DC converters. The DC-DC converters deliver the 6 Pin 115/230 Vac Connector selected output voltage and current Input levels, provide output over voltage + V BUS Strap protection, output current limiting, - V BUS J2 L2/N voltage regulation, trim capability L1 and input to output isolation. GND PTC shunt inactive and the BUS-OK output in FAIL status until the DC bus potential reaches a minimum threshold. The PC terminals of all converter modules internal to the VIPAC are FET controlled by a logical replica of the BUS-OK status line, and therefore inhibit converter operation at power up until the DC bus potential has settled to a proper operating level. At this point, the converters are enabled and the PTC shunt activated. A voltage sensing circuit connected across the DC bus performs input over voltage sensing and protection. In the event of an over voltage condition, an SCR/PTC combination will simultaneously disable the DC-DC converters and hold down the DC bus. Normal operation will resume when the input voltage returns within steady-state limits. HUB Hold-up Box VIPAC BLOCK DIAGRAM - AC INPUT ST + _ Terminals on Input Connector J2 + AC-DC Power Rectification Input Autoranging Inrush Current Limiting Line Filter + + PC ST PR DC-DC Converter Output #1 – SC – _ FARM + + PC PR DC-DC Converter Output #2 SC Output – – Control 1 Control Circuit Control 2 I/O Interface – Output Sequencing – BUS-OK J3 i c o r p o w e r . c o m / v c a + PC PR Local Control v Control 3 – d + DC-DC Converter Output #3 SC – 7 BUS-OK Electrical Connections An internal replica of BUS-OK is wired to the PC pin of all J3 status output pair BUS-OK+ (PIN 8), BUS-OK– (PIN 7) are internal driver modules. The modules will be disabled (no the collector (+) and emitter (–) of NPN optocoupler output DC output) during initial power up of the VIPAC until the transistor. The collector terminal BUS-OK+ of the optocoupler, internal DC input bus voltage to the DC-DC converters is in a typical application, and the drive pin (PIN 10) can be sufficient to support fully-loaded operation. The BUS-OK connected via current limiting resistors to an external source status output reflects the status of this inhibit function. This no greater than 18 Vdc. These resistors should limit the same logic circuit will shut down the converters when the maximum current to the optocoupler output transistors to 2 mA. internal DC bus voltage is insufficient to support proper The emitter terminal BUS-OK– is connected to the return of loaded operation. This shut down will occur during normal the external source. power down, line dropouts of duration exceeding the hold up time, or internal faults causing the internal DC bus voltage The status FAULT condition will set the BUS OK at the input of the converters to collapse. The BUS-OK output optocoupler output transistors in saturation and are capable provide the user with an optically isolated status indication of sinking up to 1.5 mA with a Vce saturation voltage of 0.4 of the internal DC bus. This output, in system applications, V. Users should be cautioned that although the output of the can provide power supply status, switch in (standby) backup VIPAC can be used as the pull up source, shortly after BUS- sources or initiate “power down” sequences to save volatile OK changes from OK (High Z) to NOT OK (Saturated), the memory contents in the event of a power loss. pull up voltage will be shut down. It is thus advisable to provide a capacitive reservoir, if the pull up source is one of Individual Module Control Driving the appropriate optocoupler can independently the VIPAC’s outputs, in order to maintain the pull up control each DC-DC module within the VIPAC. The minimum potential after loss of DC current output. Use edge sensing optocoupler input current for disabling the supplies is 3 mA. logic to detect assertion of logic outputs, or a separate The maximum allowable current is 20 mA. J3 connector pins source of bias supply voltage (i.e., backup batteries) to 1 and 2 always control module 1, pins 3 and 4 always control provide a safe pull up voltage source regardless of the line module 2 (if present) and pins 5 and 6 control module 3 status. (if present). TP11 TP12 TP13 TP14 U1 1 8 2 7 3 6 4 5 To FARM BOK Pin 10 9 BUS-OK 8 TP15 TP16 6 To Module 3 PC Pin 4 1 5 3 To Module 2 PC Pin U2 4 4 2 3 1 2 TP17 TP18 3 To Module 1 PC Pin U3 4 3 1 2 1 U4 2 TP19 GND 8 7 TP20 J3 ENABLE INPUT CONNECTIONS AC Input/V Bus I/O Interface* Conn. Pin# Funct. Mating Conn. Conn. Pin# J2 J3 1 2 3 4 5 6 V Bus+ P/N 22499 Strap V Bus– L2/N L1 GND V Bus+ Strap V Bus- Funct. Mating Conn. 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 115/230 Vac Autoranging I/O Interface Removable Jumper IN= Local Control OUT= Remote Control P/N 21394 P/N 33542 10 J3 HUB 2200-s 2700-s 3300-s 1 J2 HUB 820-s 1200-s 1800-s 1 2 3 4 5 6 P/N 21393 P/N 22499 L2/N L1 GND Maximum cable length between the HUB and VIPAC 3' v i c o r p o w e r . c o m / v c a d 9 OUTPUT CONNECTION OPTIONS Discrete Output Configurations LugMate (Factory Installed Option) Ring Lugs LugMate Pin Out Micro LugMate Pin # 1 Solder Pad 1 3 Function – Vout Rd Trim-Down SC Secondary Control Ru Trim-Up 3 + Vout 1 Micro LugMate - with Rd/Ru trim resistor solder pads. (Design calculator for trim resistors located at vicorpower.com) 3 1 1 3 Rd #4-40 Torque 4 in. lbs. SC Ru 3 Mini/Maxi LugMate Pin # Conn. Function 1 1 J4 1 5 5 5 – Vout J4-1 – Vout J4-2 – Sense J4-3 Secondary Control J4-4 + Sense J4-5 + Vout *Removable Jumper P/N 16385 *Removabl e Jumper + Vout *Removable jumper is factory installed for local sensing. See Pg 24 for details 1 J4 1 5 5 #10-32 Torque 16 in. lbs. 10 P/N 16385 Mating Conn. OUTPUT CONNECTION OPTIONS Parallel Output Configurations Shown with the output of two modules connected in parallel using BUS BARS. LugMate Ring Lugs (Factory Installed Option) LugMate Pin Out Micro LugMate Pin # 1 Solder Pad 1 3 Function – Vout Rd Trim-Down SC Secondary Control Ru 3 Trim-Up + Vout 1 Micro LugMate - with Rd/Ru trim resistor solder pads. (Design calculator for trim resistors located at vicorpower.com) 3 1 1 3 #4-40 Torque 4 in. lbs. Rd SC Ru 3 Mini/Maxi LugMate Pin # Conn. Function 1 1 P/N 16385 1 J4 5 5 5 – Vout J4-1 – Vout J4-2 – Sense J4-3 Secondary Control J4-4 + Sense J4-5 + Vout *Removable Jumper P/N 16385 *Removable Jumper + Vout *Removable jumper is factory installed for local sensing. In using 2 modules configured as a single output as illustrated, one module must be dedicated as a master, or the sense lines must be terminated to the same point physically to their respective output. 1 1 J4 Mating Conn. 5 5 #10-32 Torque 16 in. lbs. v i c o r p o w e r . c o m / v c a d 11 OUTPUT CONNECTION OPTIONS PlugMate Mating Connector Kits PlugMate Pin Out (Looking into PlugMate) (Factory Installed Option) Micro PlugMate 1 5 4 8 Vicor P/N 25073 Pin # Function Pin # Function 1 2 3 4 +Vout +Vout –Vout –Vout 5 6 7 8 +Vout N/C SC –Vout Mating Connector Housing Pin Kit Mini PlugMate Vicor P/N 25056 24796 25073 1 10 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 Connector Housing Pin Kit Maxi PlugMate Amp. P/N 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. 25050 24796 25067 12 24 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 Connector Note: Vicor P/N TYC1-794657-8 1-106529-2 1 13 Vicor P/N 25061 12 Amp. P/N TYC-794657-8 1-106529-2 Housing Pin Kit Amp. P/N TYC2-794657-4 1-106529-2 Vicor P/N 25044 24796 25061 CHASSIS CONFIGURATIONS VP-A VP-C 3 MICRO l l l l 2 MAXI 4.96" x 6.8" (126,0 x 172,7 mm) Dual or Triple Output Up to 450 W Up to 75 A l l l l VP-D VP-B 2 MICRO 2 MINI l l l l v 4.96" x 6.8" (126,0 x 172,7 mm) Single or Dual Output Up to 500 W Up to 100 A i 4.96" x 9.15" (126,0 x 232,4 mm) Single or Dual Output Up to 900 W Up to 160 A c o r p o w e r l l l l . c o m / v c a d 3.15" x 6.8" (80,0 x 172,7 mm) Single or Dual Output Up to 300 W Up to 50 A 13 CHASSIS CONFIGURATIONS Finned Chassis Configurations Coldplate VP-E 1 MINI l l l 3.15" x 6.8" (80,0 x 172,7 mm) Single Output Up to 250 W Optional 0.5" Fin Optional 1" Fin VP-F 1 MAXI l l l l 3.15" x 9.15" (80,0 x 232,4 mm) Single Output Up to 500 W Up to 80 A Longitudinal VP-G 1 MICRO l l l l 3.15" x 6.8" (80,0 x 172,7 mm) Single Output Up to 150 W Up to 25 A Transverse 14 MOUNTING OPTIONS Surface Mounting Thru Hole Mounting Thermal compound both sides VIPAC with integral finned heat sink thru hole mounted External user supplied heat sink VIPAC with external user supplied heat sink VIPAC with integral finned heat sink thru hole mounted v i c o r p o w e r . c o m / v c a d 15 MOUNTING OPTIONS Coldplate VIPAC Coldplate VIPAC mounted to custom thermal interface Thermal compound VIPAC with integral finned heat sink (down) For proper clearance use: Long standoff (P/N 23709R) for mounting 1" heat sink fins down. Short standoff (P/N 23710R) for mounting 0.5" heat sink fins down or either heat sink fins up. 16 VIPAC with integral finned heat sink (up) MECHANICAL DRAWINGS Configuration VP-A LugMates LugMates/Bus Bars PlugMates 0.75 19,1 4.96 126 0.200 5,08 4.560 115,82 0.63 16 2.680 68,07 6.80 172,7 6.000 152,40 7.26 184,5 0.33 8,3 0.15 3,8 0.58 14,7 1.520 38,61 3.040 77,22 0.70 17,8 0.70 17,8 2.13 54,1 0.70 17,8 3.68 93,5 Configuration VP-B LugMates LugMates/Bus Bars PlugMates 0.77 19,6 4.96 126 0.200 5,08 4.560 115,82 0.63 16 2.680 68,07 6.80 172,7 6.000 152,40 7.39 187,7 0.22 5,5 0.17 4,3 0.28 7,1 INSULATED BUS BAR (2 PL.) 2.280 57,91 Torque in. / lbs. Feature Locations indicated by i c o r p 2.94 74,8 Type MOUNTING Quantity of holes provided for VIPAC Model Configuration Max. Chassis Temp. (Thermal interface material required) Clearance holes for 8-32 90 CS to .30 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 12 Finned heat sink threaded thru hole for 8-32 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 4 16 Micro Lugmate Mini/Maxi Lugmates Coldplate v 0.66 16,9 1.35 34,3 1.35 34,3 o w e r . All dimensions are c o m / v c a d in mm 17 MECHANICAL DRAWINGS Configuration VP-C LugMates LugMates/Bus Bars PlugMates 0.81 20,46 4.96 126 4.560 115,82 0.200 5,08 0.63 16 MOUNT (7) PL USING #8 FLAT HEAD SCREW 2.680 68,07 (M4 FLAT HEAD SCREW) TORQUE TO 12 IN. lbs. 9.15 232,4 8.350 212,09 0.32 8,01 4.15 105,41 0.40 10,28 Configuration VP-D LugMates LugMates/Bus Bars PlugMates 0.75 19 3.15 80 0.161 4,09 2.828 71,83 0.63 16 MOUNT (7) PL USING #8 FLAT HEAD SCREW (M4 FLAT HEAD SCREW) TORQUE TO 12 IN. lbs. 2.680 68,07 6.80 172,7 7.26 184,3 #4-40 STUD FITS 1 LUGS MIN (VICOR P/N 23519) TORQUE TO 4 IN. lbs. 4 PLACES 6.000 152,40 0.33 8,5 0.14 3,6 INSULATED BUS BAR (2 PL) 1.414 35,92 0.70 17,8 Torque in. / lbs. Feature 2.00 50,8 Type MOUNTING Quantity of holes provided for VIPAC Model Configuration Max. Chassis Temp. (Thermal interface material required) Clearance holes for 8-32 90 CS to .30 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 12 Finned heat sink threaded thru hole for 8-32 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 4 16 Micro Lugmate Mini/Maxi Lugmates Coldplate 18 Locations indicated by 0.45 11,4 0.70 17,8 All dimensions are in mm MECHANICAL DRAWINGS Configuration VP-E LugMates PlugMates Configuration VP-F LugMates Torque in. / lbs. PlugMates Feature Locations indicated by Type i c o r p Max. Chassis Temp. (Thermal interface material required) Clearance holes for 8-32 90 CS to .30 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 12 Finned heat sink threaded thru hole for 8-32 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 4 16 Micro Lugmate Mini/Maxi Lugmates Coldplate v MOUNTING Quantity of holes provided for VIPAC Model Configuration o w e r . All dimensions are c o m / v c a d in mm 19 MECHANICAL DRAWINGS Configuration VP-G LugMates Torque in. / lbs. PlugMates Feature Locations indicated by Type MOUNTING Quantity of holes provided for VIPAC Model Configuration Max. Chassis Temp. (Thermal interface material required) Clearance holes for 8-32 90 CS to .30 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 12 Finned heat sink threaded thru hole for 8-32 VP - 6 6 6 5 6 6 6 A B C D E F G 95°C 4 16 Micro Lugmate Mini/Maxi Lugmates Coldplate All dimensions are in mm Heat Sink Options 0.56 0.75 (14,2) (19,1) 1.37 (34,8) 0.81 (20,6) 0.50 (12,7) 1.31 (33,3) 0.22 (5,6) Coldplate 0.5" Fin Option 0.08 (2,0) 0.32 (8,1) 1.87 (47,5) 1.00 (25,4) 1" Fin Option Fin spacing and relief are the same for both Fin options. 20 MECHANICAL INFORMATION VIPAC Product Weight Chassis Configuration VIPAC Model Prefix Chassis Configuration Coldplate 0.5" Fins 1" Fins Pounds Grams Pounds Grams Pounds Grams VP-G 1 Micro 0.9 411 1.4 640 1.6 731 VP-D 2 Micro 1.0 457 1.5 686 1.7 777 VP-A 3 Micro 1.4 640 2.2 1006 2.5 1143 VP-E 1 Mini 1.0 457 1.4 640 1.6 731 VP-B 2 Mini 1.4 640 2.2 1006 2.6 1189 VP-F 1 Maxi 1.3 594 2.0 914 2.3 1051 VP-C 2 Maxi 2.2 1006 3.0 1371 3.5 1600 VIPAC Standoff Mounting Kits Vicor Kit P/N Kit Description For use with: 23709R Qty. 6 – #23655 long standoff 1” finned heat sinks 23710R Qty. 6 – #23656 short standoff 1/2” finned heat sinks or coldplate Hold-up Box (HUB) Description* Top view, HUB 3.45 87,63 1.55 39,37 * Height (Inches ±.06") (mm) Weight Ounces Grams Part Number 820 μF 1.55 39,4 3.95 112 HUB820-S 1200 μF 1.75 44,5 4.85 137 HUB1200-S 1800 μF 2.14 54,4 6.11 173 HUB1800-S 2200 μF 2.85 72,4 7.44 211 HUB2200-S 2700 μF 3.52 89,4 8.70 247 HUB2700-S 3300 μF 3.52 89,4 9.38 266 HUB3300-S Each HUB contains two (2) capacitors of the value shown. Maximum cable length between the HUB and VIPAC ≤ 3' v i c o r p o w e r . c o m / v c a d 21 THERMAL MANAGEMENT Thermal Impedance Specifications (˚C/W) Airflow VIPAC Model Prefix Chassis Config. Heat Sink Natural Convection 200 (LFM) 400 (LFM) 600 (LFM) 800 (LFM) 1000 (LFM) 1200 (LFM) VP-A 3 Micro 0.5" L 1.98 0.77 0.53 0.45 0.39 0.36 0.33 0.5" T 1.71 0.68 0.48 0.40 0.36 0.33 0.30 1.0" L 1.68 0.58 0.42 0.36 0.32 0.30 0.28 1.0" T 1.27 0.46 0.33 0.28 0.25 0.23 0.21 0.5" L 1.90 0.77 0.53 0.44 0.39 0.36 0.33 0.5" T 1.67 0.69 0.48 0.41 0.37 0.33 0.31 1.0" L 1.49 0.54 0.39 0.34 0.31 0.28 0.27 1.0" T 1.22 0.47 0.33 0.28 0.25 0.23 0.21 0.5" L 1.50 0.62 0.42 0.35 0.31 0.28 0.25 0.5" T 1.19 0.52 0.36 0.31 0.27 0.25 0.23 1.0" L 1.17 0.43 0.31 0.27 0.24 0.22 0.20 1.0" T 0.86 0.35 0.25 0.21 0.19 0.17 0.16 0.5" L 3.13 1.28 0.89 0.74 0.66 0.59 0.54 0.5" T 2.40 1.02 0.73 0.63 0.56 0.51 0.47 VP-B VP-C VP-D VP-E VP-F VP-G 22 2 Mini 2 Maxi 2 Micro 1 Mini 1 Maxi 1 Micro 1.0" L 2.81 0.97 0.70 0.60 0.54 0.50 0.46 1.0" T 1.87 0.75 0.55 0.47 0.42 0.39 0.35 0.5" L 3.11 1.26 0.88 0.74 0.65 0.59 0.54 0.5" T 2.39 1.01 0.73 0.62 0.56 0.51 0.47 1.0" L 2.51 0.87 0.64 0.56 0.51 0.48 0.45 1.0" T 1.76 0.70 0.52 0.44 0.40 0.37 0.33 0.5" L 2.42 1.02 0.69 0.57 0.50 0.45 0.41 0.5" T 1.72 0.77 0.55 0.47 0.42 0.38 0.37 1.0" L 2.01 0.72 0.52 0.45 0.41 0.38 0.36 1.0" T 1.26 0.53 0.38 0.33 0.29 0.27 0.25 0.5" L 3.13 1.28 0.89 0.74 0.66 0.59 0.54 0.5" T 2.40 1.02 0.73 0.63 0.56 0.51 0.47 1.0" L 2.81 0.97 0.70 0.60 0.54 0.50 0.46 1.0" T 1.87 0.75 0.55 0.47 0.42 0.39 0.35 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 Suggested Wire Gauge Part Number Description Function 23488R For use with: Mini or Maxi LugMate Kit Contains: One control connector, Vicor P/N AC Input Leads Wire Gauge #14 16385 Application All AC and earth GND leads (VIPAC power systems) Two ring lugs 23489 DC Output Leads 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 #20 0A–3A #18 4A–6A #16 7 A – 10 A #14 11 A – 15 A #12 16 A – 25 A #10 26 A – 40 A #8 41 A – 65 A #6 66 A – 104 A #4 105 A – 160 A Mating Connector Cross Reference Designator Description J2 J3 J4 v i c o Vicor P/N Pin & Housing Manufacturer VIPAC AC Input - 6 Pin VIPAC I/O Interface - 10 Pin VIPAC Output Control - 5 Pin HUB 820-S, 1200-S, 1800-S 3 Pin HUB 2200-S, 2700-S, 3300-S 3 Pin 22499 33542 16385 21393 21394 AMP JST AMP AMP AMP 350551-1 640585-1 10ZR-3H or 10ZR-8M MTA100-IDC644083-5 770248-1 770018-1 193842-1 770018-1 Micro PlugMate mating connector - 8 pin Mini PlugMate mating connector - 18 pin Maxi PlugMate mating connector - 24 pin 25073 25067 25061 AMP AMP AMP 1-106529-2 1-106529-2 1-106529-2 r p o w e r . c o m / v c a d Part Number Pin Housing TYC-794657-8 TYC1-794657-8 TYC2-794657-4 23 APPLICATION TIPS Selecting Heat Sinks VIPAC Power System Dissipation VIPAC Power Systems are rated for a maximum chassis temperature of 95˚C. Operation within these limits is essential for long life and users should select an appropriate thermal Σ Pdiss = 1- n management system. The thermal performance of a particular VIPAC chassis configuration can be approximated from the thermal resistance of the chassis, ambient operating temperature and total power dissipation, using a few simple formulas shown below. Thermal Resistance: Refer to pg 22 Power Dissipation: Calculated as: (Pout / Efficiency) –Pout Example: Verify a 500 W, 28 Vdc output VIPAC does not exceed 95˚C chassis temperature (Tc). Pout (n) η(n) 0.95 – Pout (n) 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. The sense lines for VIPACs configured with a single paralleled output must be terminated to the same point. 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 P/N 16385 and connections will need to be established for local or remote sensing. • VP-C chassis configuration with 1" transverse heat sink is selected and 200 lfm airflow is provided. • Thermal resistance (θ) of 0.35˚C/W is obtained from the chart on pg 22. • Ambient operating temperature (TA) specified by the 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. user is 40˚C. • VIPAC Power System efficiency (η) is 80% overall. Wire Routing Avoid routing wires over VIPAC Power System. Formula: Tc = (( Pout - Pout ) x θ) + TA η 500 = (( - 500) x 0.35) + 40 0.8 = 83.75˚C Conclusion: This VIPAC will operate in the conditions specified and not Do not bundle Input and Output leads together. Crimping Tool Amp Hand Tool P/N Die Set # 91508-1 91506-1 69710-1 exceed maximum chassis temperature. Wire Size 20-18 AWG 16-14 AWG 58380-1 12 AWG 58380-2 10 AWG Comment: Parallel Outputs Efficiency of a particular VIPAC will depend on the specific The VIPAC can be configured with parallel modules for output voltages and operating load conditions. increased power or redundancy. When used for increased In general the efficiency of VIPACs with outputs of 5 Vdc or power, short the SC pin to –Sense on one module. less is approximately 70% and those with outputs greater This configures the module as a Booster. The user than 5 Vdc is 80%. A more accurate calculation can be must properly connect the output and sense terminals (See derived by summing dissipation of each DC-DC converter above). module used in the VIPAC and the front-end section of the At no time operate a paralleled output with a load applied only VIPAC (using 95% efficiency for the front-end). to one module! (See Output Connection Options) 24 TECHNICAL SUPPORT CONTACTS For a complete and updated list of contacts visit Vicor at: http://www.vicorpower.com/contact-us?selectedTab=%23contact_tab2 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. v i c o rp o w e r. c o m P/N 27288 Rev. 3.4 4/15