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 800 927.9474 Granite Power 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