MIL-COTS PFC Front End

Not Recommended for New Designs
MIL-COTS PFC Front End
GP-MPFC1H21
AC Input Front End Module
Features
• AC input: 102 – 264 V
• Wide input frequency range:
47 – 440 Hz
• Output power: Up to 1400 W
• Input transient protection
• Power factor corrected
• Rugged construction
Product Highlights
The MIL-COTS PFC Front End from
Granite Power Technologies can accept a
wide 102-264 Vac input range, frequencies
from 47 to 440 Hz and deliver up to 1400 W
of output power. The MIL-COTS PFC Front
End is compliant to select OV transients of
MIL-STD-704F as detailed herein. It also
complies, as noted herein, to the conducted
emissions and susceptibility portions of
MIL-STD-461 when used with the specified
external filter. The MIL-COTS PFC Front
End has a very low profile and robust brick
construction, compliant to many environments
in MIL-STD-810, including shock and vibration.
Absolute Maximum Ratings
Parameter
L to N voltage
Rating
264
+Out to –Out voltage
Mounting torque
Operating temperature
Storage temperature
Pin soldering temperature
Unit
VRMS
385
Vdc
4 – 6 (0.45 – 0.68)
-40 to +100
in-lbs (N-m)
°C
-55 to +125
°C
500 (260)
°F (°C)
Notes
Continuous
8 each 4-40 screw
H-Grade
H-Grade
<5 sec; wave solder
750 (390)
°F (°C)
<7 sec; hand solder
Output current
4.0
Amps
Absolute max.
The MIL-COTS PFC Front End provides
customers with a highly reliable, easily
customizable, and low risk solution suitable
for defense and aerospace environments.
Baseplate temperature
100
°C
MOD Enable to -OUT voltage
30
Vdc
Granite Power Technologies, a division of
the Vicor Corporation, specializes in the design,
development, and manufacture of rapid response
custom switching power supplies and power
systems for the defense industry.
Part Numbering
MIL-COTS PFC Front End
GP - MPFC
Granite
Power
Product
MIL-COTS PFC
1
H
2
1
Output Power
1 = 1,400 W
Product Grade
Operating
Temperature
H = -40 to +100°C
Pin Style
1 = Short
2 = Long
S = Short Modumate
N = Long Modumate
Baseplate
1 = Slotted
2 = Threaded
3 = Through Hole
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 1 of 9
01/2014
800 927.9474
Granite Power
Not Recommended for New Designs
GP-MPFC1H21
ELECTRICAL CHARACTERISTICS
Electrical characteristics apply over the full operating range of input voltage, output power and baseplate temperature, unless otherwise
specified. All temperatures refer to the operating temperature at the center of the baseplate.
INPUT SPECIFICATIONS
Parameter
Min
Operating input voltage
102
Typ
Input undervoltage
AC line frequency
Power factor
47
0.85
0.95
Inrush current
Max
Unit
Notes
264
Vac
Operation to 85 Vac with additional power derating consult Applications Engineering
<65
Vac
Shutdown
440
Hz
0.99
20
102-264 Vac
Amps
Input Power Transients
264 Vac line voltage
As specified below per MIL-HDBK-704,
no other compliance expressed or implied
1 phase 60 Hz 115 V
Table SXF109-II Test Conditions for Normal Voltage Transients for single phase 60 Hz utilization equipment compliant to test conditions A,B,C,D
Table SXF110-II Test Conditions for Normal Frequency Transients for single phase 60 Hz utilization equipment compliant to test conditions A,B,C,D,E
Table SXF302-II Test Conditions for Abnormal Voltage Transients for single phase 60 Hz utilization equipment compliant to test conditions A,B,C,D,E
Table SXF303-II Test Conditions for Abnormal Frequency Transients for single phase 60 Hz utilization equipment compliant to test conditions A,B,C,D,E
1 phase 400 Hz 115 V
Table SAC109-II Test Conditions for MIL-STD-704A Normal Voltage Transients compliant to test conditions A,B,C,D,E,F,G
Table SAC109-III Test Conditions for MIL-STD-704B,C,D,E,F Normal Voltage compliant to test conditions AA,BB,CC,DD,EE,FF,GG
Table SAC110-II Test Conditions for MIL-STD-704A Normal Frequency Transients compliant to test conditions A,B,C,D,E,F,G,H,I
Table SAC110-III Test Conditions for MIL-STD-704B,C,D,E,F Normal Frequency Transients compliant to test conditions AA,BB,CC,DD,EE,FF,GG,HH,II
Table SAC302-II Test Conditions for MIL-STD-704A Abnormal Voltage Transients compliant to test conditions A,B,C,D,E,F,G
Table SAC302-III Test Conditions for MIL-STD-704B,C,D,E,F Abnormal Voltage compliant to test conditions AA,BB,CC,DD,EE,FF,GG,OO
Table SAC303-II Test Conditions for MIL-STD-704A Abnormal Frequency Transients compliant to test conditions A,B,C,D,E
Table SAC303-III Test Conditions for MIL-STD-704B,C,D,E,F Abnormal Frequency Transients compliant to test conditions AA,BB,CC,DD,EE
OUTPUT SPECIFICATIONS
Parameter
Min
Output power
0
Efficiency
@115 Vac
92
@ 230 Vac
Typ
Max
Unit
Notes
1,400
Watts
See Figure 1
95
%
Full load
%
Full load
92
95
Output voltage
375
385
395
Vdc
External hold-up capacitance
1500
2000
3000
μF
Turn-on time
<3
Ripple
10
15
seconds
After application of AC input.
Vp-p
2000uF external capacitance.
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 2 of 9
01/2014
800 927.9474
Granite Power
Not Recommended for New Designs
GP-MPFC1H21
ELECTRICAL CHARACTERISTICS (CONT.)
Electrical characteristics apply over the full operating range of input voltage, output power and baseplate temperature, unless otherwise
specified. All temperatures refer to the operating temperature at the center of the baseplate.
CONTROL SPECIFICATIONS
Parameter
Min
Typ
MOD EN (open drain ouput)
Max
>500
Low State Voltage
0.1
Unit
Notes
mS
After PFC output in regulation.
See Figure 2 for required protection components.
V
Isink = 50mA
EMI
Parameter
Standard
MIL-STD-461F Conducted Emissions
Notes
CE102
Conducted Susceptibility
CS101, CS114, CS115, CS116
Compliant when used with Vicor V375 family DC-DC
converters and external filter supplied by JMK filters, Inc.
(www.jmkfilters.com) Part # FF-2137B-13
SAFETY SPECIFICATIONS (with baseplate earthed and quick acting line fuse.)
Parameter
Min
Typ
Isolation (in to out)
Dielectric withstand
(I/O to baseplate)
Max
Unit
None
Notes
Isolation provided by DC-DC converter(s)
1,500 / 2,121
Vac / Vdc
Leakage current
Baseplate earthed
None (No internal electrical connection to the baseplate,
leakage current will be dependent on external filtering.)
Fuse (External)
15A
Bussman ABC-15 UL-listed
AGENCY APPROVALS
Safety Standards
Agency Markings
EN60950-1, UL60950-1, CSA 60950-1
Notes-1
CE Marked
Low voltage directive
GENERAL SPECIFICATIONS
Parameter
Weight
Size
MTBF
Min
Typ
Max
Unit
9.6 (272)
Ounces (grams)
6.40 x 2.70 x 0.5
Inches
162,2 x 68,6 x 12,7
mm
2,010,528
Hours
Notes
25˚C, Ground Benign MIL HDBK 217F
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 3 of 9
01/2014
800 927.9474
Granite Power
GP-MPFC1H21
Not Recommended for New Designs
Output Power (W)
Power De-Rating
1500
1400
1300
1200
1100
1000
900
800
700
600
500
400
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
Baseplate Temp °C
102-114 VAC
115-196 VAC
197-264 VAC
Figure 1 — Module power de-rating for input voltage at baseplate temperature
F2
•
3A / 5A
•
•
N/C2
N/C3
•
800 V
+In
•
C2
0.1uF
50 V
D2
p 12 V
•
DC/DC
CONVERTER
PC
PR
C3
0.1uF
50 V
–In
D3
p 200mA
1
C1
249R
1/4W
D1
3
PFC
BRICK
R1
p
+Out
MOD EN
R1 = 249 Ohm 0.25 W
C1 = ALEL 1500 µF min 3000 µF max 450 V
C2, C3 = 0.1µF 50V Ceramic
D1 = 800 V Diode
D2 = 12 V 0.5 W Zener
RT1
D3 = 0.2A 40V SCHOTTKY
F2 = 3A or 5A PC-Tron (see DC-DC safety approvals for details)
•
•
•
•
249R 1/4W
•
[a]
R2
R2 = 249 Ohm 0.25 W
RT1*= Cantherm F20BE068505 (85C)
F20BE0610005 (100C)
*Note: RT1 must be placed as close to PFC baseplate as possible
Figure 2 — Mod EN protection circuit and Optional Thermal Safety Ckt
[a] Optional, not required
C
Line
Neutral
>
F2
F1
>
Line
EMI
Filter
PFC
BRICK
JMK
P/N FF-2137B-13
+
+
Neutral
MOD EN
N/C
N/C
–
•
V375x
PC
C1
Protection
Figure 2
PR
–
C
NOTE:
C = 4.7nF
C1 and F2 are the same as those shown in Figure 2
F1 = Bussman ABC-15 UL-listed 250 V Fast Acting
•
Figure 3— Typical Connection diagram
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 4 of 9
01/2014
800 927.9474
Granite Power
Not Recommended for New Designs
GP-MPFC1H21
TEST DATA
VICOR
CE-102-1 117VAC 400Hz Return Line
Equipment ID : MIL-COTS PFC Front End
Serial # - 09121107000024
Mode of Operation - 90% Load
120.0
110.0
Amplitude (dBuV)
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
10.0K
100.0K
1.0M
10.0M
Frequency
Figure 4— 400Hz Return Line
VICOR
CE-102-1 117VAC 400Hz Hot Line
Equipment ID : MIL-COTS PFC Front End
Serial # - 09121107000024
Mode of Operation - 90% Load
120.0
110.0
Amplitude (dBuV)
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
10.0K
100.0K
1.0M
10.0M
Frequency
Figure 5— 400Hz Hot Line
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 5 of 9
01/2014
800 927.9474
Granite Power
Not Recommended for New Designs
GP-MPFC1H21
TEST DATA (CONT.)
VICOR
CE-102-1 117VAC 60Hz Hot Line
Equipment ID : MIL-COTS PFC Front End
Serial # - 09121107000024
Mode of Operation - 90% Load
120.0
110.0
Amplitude (dBuV)
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
10.0K
100.0K
1.0M
10.0M
Frequency
Figure 6— 60Hz Hot Line
VICOR
CE-102-1 117VAC 60Hz Return Line
Equipment ID : MIL-COTS PFC Front End
Serial # - 09121107000024
Mode of Operation - 90% Load
120.0
110.0
Amplitude (dBuV)
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
10.0K
100.0K
1.0M
10.0M
Frequency
Figure 7— 60Hz Return Line
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 6 of 9
01/2014
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Not Recommended for New Designs
GP-MPFC1H21
DESCRIPTION
PFC Brick
Safety Features:
Pin function/description
LINE/NEUTRAL (Pins 1 & 4)
Over Temperature Shut Down:
Connect single phase AC mains from appropriate EMI filter to
these pins via a 15 Amp 250V fuse. Connect the output of the
filter to the LINE and NEUTRAL pins of the PFC Brick. To
meet MIL-STD-461E/F requirements, an EMI filter between the
AC input and PFC Brick similar to that shown in Fig. 4
is required.
The PFC Brick is designed to shut down if the baseplate
temperature (measured in the center of the baseplate) exceeds
100°C. Certain line and load conditions dictate lower maximum
temperatures as indicated in Figure 1.
N/C (Pins 2, 3, 6, 7)
Exceeding the power/temperature limits shown in Figure 1 or
the maximum 100°C limit may result in permanent module
failure. We do not guarantee module survival if the temperature
limits are exceeded.
The addition of the thermal safety components shown in Figure
2 should be used if the application requires operation at input
voltage and output power where a lower baseplate temperature
is required.
No Connect. Do not connect to these pins.
MOD ENABLE (Pin 8)
Connect this pin to the down stream Vicor DC/DC converter(s)
PC pin as shown in Figure 2. The external circuitry between the
MOD ENABLE pin and PC pin shown in the figure must be
used to ensure proper operation. During power up, the MOD
ENABLE pin is held low until the PFC output is up and
regulating. Any fault with the PFC output will cause this pin to
go low and held low until the fault is cleared. If an external load
is connected directly to the output of the PFC Brick, do not
apply the load until the holdup capacitors are fully charged.
Output Over Voltage Protection:
In the event the PFC output exceeds approximately 415VDC, the
boost converter will momentarily shut down to keep the PFC
output below 415VDC. The MOD Enable pin will go low and
stay low until the PFC output returns to its normal
operating range.
Safety Notes:
+/- OUTPUTS (+ Pin 9, - Pin 5)
Connect the +OUT pin to the +IN of the respected Vicor DC/DC
converter. Connect the -OUT pin to the -IN of the respected
Vicor DC/DC converter. In addition, external hold-up capacitor
of 1500uF with a minimum voltage rating of 450VDC is
required across the +OUT and –OUT pins. This capacitor must
be in close proximity of the PFC Brick. Do not exceed 3000uF
of total output capacitance.
The PFC Brick is not isolated from the AC mains. An isolation
transformer must be used when making scope measurements.
The PFC Brick does not provide input to output isolation.
Differential probes should be used to avoid destructive ground
loops.
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 7 of 9
01/2014
800 927.9474
Granite Power
5X
5.93
150.7
4X
2X
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 8 of 9
01/2014
800 927.9474
2X
.40
10.2
.70
17.8
2X 1.00
25.4
2X 1.40
35.6
.550 ±.015
13.97 ±0.38
.266 ±.015
6.76 ±0.38
R .100
2.54
.15 [3.8] X 45
.23
5.9
.100
2.54
CONVERTER PINS
LABEL
FUNCTION
LINE
LINE
N/C
N/C
N/C
N/C
NEUTRAL
NEUTRAL
-OUT
-OUT
N/C
N/C
N/C
N/C
Mod EN
Mod EN
+OUT
+OUT
6.400
162.56
NO.
1
2
3
4
5
6
7
8
9
9
1
8
2
7
6
3
+.02
2.24
- .00
+0.5
56.8
0
4X 2.500
63.5
2.700
68.58
5
4
.500
12.70
7X
2X
.129
3.28
.180 ±.001
4.57 ±0.03
3X R .060
1.52
8X
2X
FULL R
5.400
137.16
DETAIL A
SCALE 2 : 1
.080 ±.001
2.03 ±0.03
2X 3.600
91.44
2X 1.800
45.72
2X
9X R .015 MAX
0.38 MAX
PIN LONG
.62 [15.7]
DIMENSION L
.54 [13.7]
PIN SHORT
9X DIM L
.43
10.9
.50 ±.035
12.7 ±0.9
.20 [5.1]
.018 [0.457]
2X
.38
9.6
THRU HOLE
BASEPLATE
8X #30 DRILL THRU
( .1285)
THREADED
BASEPLATE
8X 4-40UNC-2B THRU
Not Recommended for New Designs
GP-MPFC1H21
MECHANICAL DRAWINGS
Granite Power
Not Recommended for New Designs
GP-MPFC1H21
Vicor’s comprehensive line of power solutions includes high density AC-DC and DC-DC modules and
accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom
power systems.
Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. Vicor makes no
representations or warranties with respect to the accuracy or completeness of the contents of this publication. Vicor reserves the right to make
changes to any products, specifications, and product descriptions at any time without notice. Information published by Vicor has been checked and
is believed to be accurate at the time it was printed; however, Vicor assumes no responsibility for inaccuracies. Testing and other quality controls
are used to the extent Vicor deems necessary to support Vicor’s product warranty. Except where mandated by government requirements, testing of
all parameters of each product is not necessarily performed.
Specifications are subject to change without notice.
Vicor’s Standard Terms and Conditions
All sales are subject to Vicor’s Standard Terms and Conditions of Sale, which are available on Vicor’s webpage or upon request.
Product Warranty
In Vicor’s standard terms and conditions of sale, Vicor warrants that its products are free from non-conformity to its Standard Specifications (the
“Express Limited Warranty”). This warranty is extended only to the original Buyer for the period expiring two (2) years after the date of shipment
and is not transferable.
UNLESS OTHERWISE EXPRESSLY STATED IN A WRITTEN SALES AGREEMENT SIGNED BY A DULY AUTHORIZED VICOR SIGNATORY, VICOR
DISCLAIMS ALL REPRESENTATIONS, LIABILITIES, AND WARRANTIES OF ANY KIND (WHETHER ARISING BY IMPLICATION OR BY OPERATION OF LAW)
WITH RESPECT TO THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, ANY WARRANTIES OR REPRESENTATIONS AS TO MERCHANTABILITY,
FITNESS FOR PARTICULAR PURPOSE, INFRINGEMENT OF ANY PATENT, COPYRIGHT, OR OTHER INTELLECTUAL PROPERTY RIGHT, OR ANY OTHER
MATTER.
This warranty does not extend to products subjected to misuse, accident, or improper application, maintenance, or storage. Vicor shall not be liable
for collateral or consequential damage. Vicor disclaims any and all liability arising out of the application or use of any product or circuit and assumes
no liability for applications assistance or buyer product design. Buyers are responsible for their products and applications using Vicor products and
components. Prior to using or distributing any products that include Vicor components, buyers should provide adequate design, testing and
operating safeguards.
Vicor will repair or replace defective products in accordance with its own best judgment. For service under this warranty, the buyer must contact
Vicor to obtain a Return Material Authorization (RMA) number and shipping instructions. Products returned without prior authorization will be
returned to the buyer. The buyer will pay all charges incurred in returning the product to the factory. Vicor will pay all reshipment charges if the
product was defective within the terms of this warranty.
Life Support Policy
VICOR’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS
PRIOR WRITTEN APPROVAL OF THE CHIEF EXECUTIVE OFFICER AND GENERAL COUNSEL OF VICOR CORPORATION. As used herein, life support
devices or systems are devices which (a) are intended for surgical implant into the body, or (b) support or sustain life and whose failure to perform
when properly used in accordance with instructions for use provided in the labeling can be reasonably expected to result in a significant injury to the
user. A critical component is any component in a life support device or system whose failure to perform can be reasonably expected to cause the
failure of the life support device or system or to affect its safety or effectiveness. Per Vicor Terms and Conditions of Sale, the user of Vicor products
and components in life support applications assumes all risks of such use and indemnifies Vicor against all liability and damages.
Intellectual Property Notice
Vicor and its subsidiaries own Intellectual Property (including issued U.S. and Foreign Patents and pending patent applications) relating to the
products described in this data sheet. No license, whether express, implied, or arising by estoppel or otherwise, to any intellectual property rights is
granted by this document. Interested parties should contact Vicor's Intellectual Property Department.
Vicor Corporation
25 Frontage Road
Andover, MA, USA 01810
Tel: 800-735-6200
Fax: 978-475-6715
email
Customer Service: [email protected]
Technical Support: [email protected]
Vicor Custom
Granite Power
540 North Commercial Street
Manchester, NH 03101 USA
Tel: 603-623-3222
Fax: 603-627-3222
granitepower.com
An ISO9001:2008 Certified Company
MIL-COTS PFC Front End
Rev 1.3
vicorpower.com
Page 9 of 9
01/2014
800 927.9474
Granite Power