USER GUIDE | UG:121
PFC Micro™
Power Factor Corrected AC-DC Switcher
Contents Page
Overview
1
Standard Features
2
Optional Features
2
Part Numbering
3
Mechanical Considerations
3
PFC Micro Dos and Don’ts
3
Technical Description
4
PFC Micro™ Quick
Install Instructions
5
PFC Micro™
Mechanical Drawings
7
Output Connections
for the PFC Micro™
8
Output Connectors
for PFC Micro™
9
Power Connections
9
User Interface Connections 11
Module Power Good
Status Mode
11
Single-Output
Power Supplies (Arrays) 15
Specifications 16
Output Power De-Rating
19
Current Share Boards –
Optional Feature
21
Overview
The PFC Micro is a low-profile switching power supply that combines the advantages of power factor
correction (PFC) and high power density. This guide covers both standard and rugged COTS (MI)
versions of the supply. A PFC Micro provides up to six isolated outputs (from two slots) and each slot
may accommodate the following Vicor DC-DC Converters:
VE-200™/VE-J00™ Series: 1 VE-200 or 2 VE-J00
Maxi/Mini/ Micro Series: 1 Maxi, 2 Minis, or 3 Micros
The use of these converters gives the PFC Micro the inherent power flexibility typical of all Vicor
products. Accepting input voltages of 85 – 264VAC, and 100 – 300VDC, the PFC Micro can provide
up to 800W in a package size of 1.86 x 5.06 x 10.40in [47,3 x 128,5 x 264,1mm]. The PFC Micro is
factory‑configured to meet user output requirements.
UG:121
Page 1
Standard Features
nn
Power Factor Correction: Typically 0.98 (>75% Load)
nn
Universal Input: 85 – 264VAC, 47 – 500Hz, or 120 – 300VDC
nn
Power Output: 800W at 230VAC (200VAC minimum input); 500W at 115VAC (100VAC minimum input)
nn
Up to six isolated outputs (two slots)
nn
Fan cooled
nn
Full power to 45°C; half power at 65°C
nn
Soft start for limiting inrush current
nn
Conducted EMI: FCC Class A; EN55022 Class A (consult factory)
nn
Harmonic Distortion to EN61000-3-2
nn
AC Power OK status signal
nn
RoHS compliant available
nn
Output Sequencing and General Shut Down
nn
Autosense (Refer to pages 6 and 14 for more information on Autosense)
nn
Output overcurrent protection on all outputs
nn
Output overvoltage protection and output overtemperature limiting
(not applicable when using VI-J00)
nn
Ride-through (hold-up) time: >20ms at 500W load
nn
Size: 1.86 x 5.06 x 10.4in [47,3 x 128,5 x 264,1mm]
nn
Safety Agency Approvals: CE Marking, TÜV CUE (certain models may not have all listed approvals)
nn
Uses 300VDC input VI-200™/VI-J00™ modules and/or 375VDC input Maxi/Mini/Micro modules
nn
Power good status signal when Maxi, Mini, or Micro modules used
Optional Features
nn
I/T/H-Grade output converters
nn
Current Share Board for unit to unit power sharing - see pages 22 – 23
nn
Connector kits (# 19-130044)
nnMI Chassis Specific
nnMil-STD 810 for Shock and Vibration
nnMil-STD 704 and 1399 for overvoltage and transients
nn–40°C operation
nnConformal coating - contact factory
UG:121
Page 2
Part Numbering
PFC Micro
PCx1-x2 x3 (-x4)-xxxx-x5
ex: PC6-06-5012-G
x1 = number of outputs
x2 = number of VI-200™/VI-J00™ modules
x3 = number of Maxi/Mini/Micro modules
(-x4 ) = optional Factory assigned
xxxx = sequential number assigned by Vicor
x5 = optional versions
Note: x5 = MI for rugged chassis, = MC for rugged chassis with conformal coating
Mechanical Considerations
The PFC Micro™ can be mounted on one of three surfaces using standard 8-32 or 4mm screws.
Maximum allowable torque is 5in.lbs and the maximum penetration of 0.25in [6mm] on the sides and
0.125in [3mm] on the bottom.
When selecting a mounting location and orientation, the unit should be positioned so air flow is not
restricted. Maintain a 2in [5,1cm] minimum clearance at both ends of the PFC Micro and route all cables
so air flow is not obstructed. The power supply draws air in at the fan side/AC input side and exhausts
air out the load side. If air-flow ducting is used, avoid sharp turns that could create back pressure. The
fan moves approximately 10CFM 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 10in.lbs.
Avoid applications in which the unit is exposed to excessive shock or vibration levels as the unit
is designed primarily for office type equipment. In such applications, a shock-absorbing mount
design is required.
PFC Micro Dos and Don’ts
nn
Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at
the output power terminals. A minimum of two inches in front and behind the supply should be
maintained in order to prevent air obstructions.
nn
Run the output (+/–) power cables next to each other to minimize inductance.
nn
Do not attempt to repair or modify the power supply in any manner. In the event of problems,
contact Customer Service at 1-800-735-6200.
nn
Insert proper fault protection at power supply input terminals (i.e., a fuse).
nn
Use proper size wires to avoid overheating and excessive voltage drop.
nn
Output voltages over 60VDC, whether from individual modules or series arrays, are considered
as hazardous secondary outputs under UL 60950. Appropriate care must be taken in design
implementation of the supply.
UG:121
Page 3
Technical Description
The PFC Micro™ consists of an off-line single-phase, power-factor-corrected front end, EMI filter,
cooling fan, customer interface, power supply control circuit, associated housekeeping circuits and a
selection of Vicor VI-200™/VI-J00™ and/or Maxi DC-DC converters.
Input AC mains voltage is applied to input connector MB1J1. The input current is passed through an
EMI filter designed to meet conducted noise limit "A" specifications of FCC Part 15.
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 EN61000). 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.
Output voltage conversion is achieved by the Vicor 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 Micro 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 converts
the high-voltage DC bus into regulated low voltage to power the internal housekeeping circuits and
DC cooling fan.
The internal housekeeping VCC comes up within 1s 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 the power outputs will come up 250ms later.
An output enable / disable function is provided to control Vicor DC-DC converters. If the Enable/Disable
control pin is pulled low, the modules output is disabled. The nominal delay associated for an output to
come up when measured from release of the Enable/Disable pin is 9 – 12ms. The General Shut Down
function controls all outputs simultaneously and works in a similar manner.
Figure 1
PFC Micro architecture
Input
Line Filter
Bridge
Rectifier
Soft Start
Circuit
Boost Converter
Output Card #1
Output Card #2
Power
Output
Power
Output
PFC Control
Customer
Interface
Power Supply
Control
Enable/Disable -Power Good Read
Fan
Isolated
Housekeeping
Power Supply
UG:121
Page 4
PFC Micro™ Quick Install Instructions
(For Mechanical Drawing, see page 7)
Mounting the PFC Micro
nn
The PFC Micro can be mounted on either of three sides.
nn
Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.25in [6 mm]
on the side and 0.125in [3mm] on the bottom.
nn
Maintain 2in [5,1cm] clearance at both ends of power supply for air flow.
Input Connections
MBJ1-5 PIN
L1
Not Connected
L2/N
GND
MAXI MODULE
(2 ISOLATED OUTPUTS)
S1
Installing bus bars on output studs (when full-size module is used):
10-32 STUDS
-
nn
The right stud is Positive and the left stud is the Return on single output cards.
S2
+
nn
Remove the nut and place ring lug over output stud.
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
S1/S2 J1 (18 Pin)
+ - T + -
+ +
- + - - +
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
S1/S2J1 (16 Pin)
+ T -
- + T
+
nn
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):
nn
S1/S2 J1-7, S1/S2 J1-8 and S1/S2 J1-16 are Positive for output #1, while pins
S1/S2 J1-9, S1/S2 J1-17 and S1/S2 J1-18 are the Returns.
S1/S2 J1-1, S1/S2 J1-10 and S1/S2 J1-11 are Positive for output #2, while pins
S1/S2 J1-2, S1/S2 J1-3 and S1/S2 J1-12 are the Returns.
nn
For this 18-pin housing, use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
nn
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
S1/S2J1
-
Output Connections
Power Connections
+
-
nn
Molex mating receptacle 39-01-4051, terminals 39-00-0090, crimp tool Molex # 11-01-0199.
Note: Outputs with current molex connectors are limited to 9A/pin (27A per output).
A PFC Micro with DIFFERENT Molex connectors capable of 40A is available. Contact factory.
-
- + + T
nn
Apply input AC power connector MBJ1.
nn
Maximum torque is 5in.lbs.
nn
A fuse or circuit breaker in the input line is necessary for safety requirements (10A).
Not Connected
-
Input Power MBJ1
N/C
- +
- + T - +
Installing power connectors with 16-pin Molex connectors (when quarter-size modules used):
nn
S1/S2 J1-7 and S1/S2 J1- 15 are Positive for output #1, while pins
S1/S2 J1-8 and S1/S2 J1- 16 are the Return.
S1/S2 J1-4 and S1/S2 J1-12 are Positive for output #2, while pins
S1/S2 J1-5 and S1/S2 J1- 13 are the Return.
S1/S2 J1-1 and S1/S2 J1-9 are Positive for output # 3, while pins
S1/S2 J1-2, and S1/S2 J1-10 are the Returns.
nn
For this 16-pin housing, use Molex mating receptacle #39-01-2160 with #39-00-0039 terminals.
nn
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
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Page 5
Sense Connections
Sense Connections
Pin
Trim Pin
+REMOTE SENSE
–REMOTE SENSE
1
2
3
S1/S2 J2
Sense connections on output connections with studs:
nn
The PFC Micro™ is shipped with Autosense installed
(For more information on Autosense, refer to page 14)
nn
For remote sense, connect remote-sense wires to remote-sense/trim-pin access connector S1/S2 J2.
nn
Connector pin S1/S2 J2-2 is the +SENSE and
S1/S2 J2-3 is the –SENSE.
nn
Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
nn
Attach terminals to 24 – 30AWG stranded twisted pair wire using Molex tool #11-01-0208.
nn
Attach opposite end of sense lines to their respective outputs to point where regulation is desired.
Verify that sense lines are not cross-connected.
Sense connections on output connections with 18-pin Molex connectors:
S1/S2 J1
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
nn
The PFC Micro is shipped with Autosense installed
(For more information on Autosense, refer to page 14)
nn
If remote sense is desired, connect remote sense wires to sense lines of Connector S1/S2 J1.
S1/S2 J1 (18 Pin)
-
-
+ - T + -
- + + T
+ +
- + - - +
nn
Connector pin S1/S2 J1-13 is the +SENSE and
S1/S2 J1-15 is the –SENSE for output #1.
S1/S2 J1-4 is the +SENSE and
S1/S2 J1-5 is the –SENSE for output #2.
nn
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
nn
Attach 18 – 24AWG stranded twisted pair wire using Molex tool #11-01-0197.
Note: Remote sense is NOT available for triple-output slots.
Trim Connection with Batmod
Pin
Current Trim Access
Voltage Trim
Current Monitor
1
2
3
S1/S2 J2
9 8 7 6 5 4 3 2 1
S1/S2 J1 (18 Pin)
+ - T + -
- + + T
+ +
- + - - +
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
S1/S2J1 (16 Pin)
+ T -
- + T
+
N/C
- +
- + T - +
CBJ3 E/D INTERFACE CONNECTOR
MATING CONNECTOR: (WESTCOR KIT P/N: 19-130044)
HOUSING: MOLEX (50-57-9412)
SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0097)
CRIMP TOOL: MOLEX (11-01-0209)
PIN DESCRIPTION
CBJ3-1
CBJ3-2
CBJ3-3
CBJ3-4
CBJ3-5
CBJ3-6
CBJ3-7
CB3-8
CBJ3-9
CBJ3-10
CBJ3-11
CBJ3-12
SGND
PGR
ACOK
ED6
ED5
ED4
ED3
ED2
ED1
GSD
PGDV
+5 VS
Trim connections on connector with 18-pin molex connectors:
nn
S1/S2 J1-6 provides trim access for output #1, and
S1/S2 J1-14 provides trim access for output #2.
nn
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
nn
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
Trim connections on connectors with 16-pin Molex connectors:
S1/S2J1
-
nn
S1/S2 J2-1 provides trim access.
nn
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0208.
18 17 16 15 14 13 12 11 10
-
Trim connections on output with studs:
nn
Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals.
S1/S2 J1
-
Trim Connections
nn
S1/S2 J1-14 provides trim access for output #1, and
S1/S2 J1-6 provides trim access for output #2, and
S1/S2 J1-3 provides trim access for output #3.
nn
Use Molex mating receptacle #39-01-2180 with #39-00-0039 terminals.
nn
Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197.
Interface Connections
nn
CBJ3-1 is Signal Ground,
CBJ3-2 is Power Good Read and
CBJ3-3 is AC-OK.
nn
CBJ3-4-9 are Enable/Disable,
CBJ3-10 is General Shut Down,
CBJ3-11 is Power Good Data Valid (PGDV) and
CBJ3-12 is +5 VS.
nn
Use Molex mating receptacle #50-57-9412 with #16-02-0097 cinch pins.
nn
Attach terminals to 24 – 30AWG stranded wire.
UG:121
Page 6
REF
SGND
PGR
ACOK
ED6
ED5
ED4
ED3
ED2
ED1
GSD
PGDV
Vcc
PIN
CBJ3-1
CBJ3-2
CBJ3-3
CBJ3-4
CBJ3-5
CBJ3-6
CBJ3-7
CBJ3-8
CBJ3-9
CBJ3-10
CBJ3-11
CBJ3-12
CBJ3 INTERFACE CONNECTOR
SIGNAL GROUND
POWER GOOD/READ
AC POWER OK
ENABLE/DISABLE S2M3
ENABLE/DISABLE S2M2
ENABLE/DISABLE S2M1
ENABLE/DISABLE S1M3
ENABLE/DISABLE S1M2
ENABLE/DISABLE S1M1
GENERAL SHUTDOWN
POWER GOOD/DATA VALID
+5V@40mA
DESCRIPTION
UG:121
A COMPLETE SET OF MATING CONNECTORS
IS AVAILABLE FOR PURCHASE BY SPECIFYING
WESTCOR CONNECTOR KIT P/N: 19-130044.
WITH OPTIONAL BUS BAR
DIMENSIONS SHOWN ARE FROM BOTTOM SURFACE
MOUNTING PEMNUTS EXTEND .010 PAST BOTTOM
SURFACE.
2
3
4
DESIGNATIONS
MOTHER BOARD
CONTROL BOARD
SLOT NUMBER
MODULE NUMBER
REFERENCE
MB
CB
S(x)
M(x)
N/C
N/C
1
NOTES: UNLESS OTHERWISE SPECIFIED
2 MATING CONNECTOR:
HOUSING: MOLEX (50-57-9412)
SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0097)
CRIMP TOOL: MOLEX (11-01-0209)
1
GND
L2/N
L1
MBJ1 (5 PIN)
CBJ3 (12 PIN)
FLOW
1.29 32.69
3
1.22 31.04
.25±.02 6.35±0.51
1 S2
SIX OUTPUT UNIT
PICTURED (THREE
MICRO
MODULES)
4
QUAD OUTPUT
UNIT PICTURED
(FOUR MINI
MODULES)
-
-
+
S1
+
1 S2
1
S1/S2 J2 REMOTE SENSE/TRIM PIN
1 ACCESS CONNECTOR
DUAL OUTPUT UNIT
PICTURED (TWO
MAXI
MODULES)
10-32 STUDS
CSB-01
CSB-02
(SEE PAGE 19 AND 20 FOR MORE INFORMATION ON CURRENT SHARE
BOARDS.
WITH VI-200/VI-J00 MODULES
WITH MAXI/MINI/MICRO MODULES
NOTE: FOR INCREASED OUTPUT POWER, CURRENT SHARE BOARDS ARE
AVAILABLE.
1 S2
1 S1
18 PIN CONNECTOR
SEE PAGE 9 FOR DETAILED OUTPUT
CONNECTION INFORMATION .
16 PIN CONNECTOR
MOUNTING HOLES; 4 PLACES
USE 8-32 X 0.12 or M4 X 3MM MAX LENGTH
FROM OUTSIDE OF UNIT
.71 18.03
3.500 88.90
3
1 S1
5.06 128.52
4 1.86 47.29
1.22 31.04
4
All Westcor power supplies can now be configured online
using VSPOC, the online configurator tool available on vicorpower.com
7.500 190.50
MOUNTING HOLES; 2 PLACES
USE 8-32 X 0.25 or M4 X 6MM MAX LENGTH
FROM OUTSIDE OF UNIT
10.65±.02 270.46±0.51
10.40 264.11
7.500 190.50
AIR
10.24 260.02
.16 4.09
MOUNTING HOLES; 2 PLACES
USE 8-32 X 0.25 or M4 X 6MM MAX LENGTH
FROM OUTSIDE OF UNIT
7.500 190.50
1.29 32.69
MBJ1 A/C INPUT
2
MATING CONNECTOR:
HOUSING: MOLEX (39-01-4051)
TERMINAL: MOLEX (39-00-0090)
CRIMP TOOL: MOLEX (11-01-0199)
PIN-1
1.29 32.69
PFC MICRO
PFC Micro™ Mechanical Drawings
Page 7
Output Connections for the PFC Micro™
A. OUTPUT STUDS - SINGLE OUTPUT (when populated with full size module)
–VOUT
10-32 OUTPUT STUDS
SxJ2 REMOTE SENSE/TRIM
PIN CONNECTOR
+VOUT
3
2
1
–SENSE
+SENSE
TRIM
MATING CONNECTOR:
HOUSING: MOLEX (50-57-9403)
TERMINAL FEM CRIMP 24-30 AWG: MOLEX (16-02-0103)
USE CRIMP TOOL: MOLEX (11-01-0208)
B. 18 PIN MOLEX CONNECTOR - SINGLE OR DUAL OUTPUTS (when populated with half size modules)
9 18
8 17
PIN
7 16
1
2
3
4
5
6
7
8
9
6 15
5 14
4 13
3 12
2 11
1 10
SxJ1 (18 PIN OUTPUT, REMOTE SENSE
AND TRIM PIN CONNECTOR)
DESCRIPTION
PIN DESCRIPTION
+VOUT M2
–VOUT M2
–VOUT M2
+SENSE M2
–SENSE M2
TRIM M1
+VOUT M1
+VOUT M1
–VOUT M1
10
11
12
13
14
15
16
17
18
+VOUT M2
+VOUT M2
–VOUT M2
+SENSE M1
TRIM M2
–SENSE M1
+VOUT M1
–VOUT M1
–VOUT M1
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)
Note: The current molex connectors are limited
to 9A/pin (27A per output). A PFC Micro with
DIFFERENT molex connectors that are capable
of 40A is available. Contact factory!
C. 16 PIN MOLEX CONNECTOR - SINGLE, DUAL, TRIPLE OUTPUTS (when populated with quarter size modules)
8 16
*SxJ1 (16 PIN OUTPUT, REMOTE SENSE
AND TRIM PIN CONNECTOR)
7 15
6 14
5 13
4 12
3 11
2 10
1 9
PIN
1
2
3
4
5
6
7
8
DESCRIPTION
+VOUT M3
–VOUT M3
TRIM M3
+VOUT M2
–VOUT M2
TRIM M2
+VOUT M1
–VOUT M1
PIN
9
10
11
12
13
14
15
16
DESCRIPTION
+VOUT M3
–VOUT M3
N/C
+VOUT M2
–VOUT M2
TRIM M1
+VOUT M1
–VOUT M1
MATING CONNECTOR:
16 PIN HOUSING: MOLEX (39-01-2160)
TERMINAL FEM CRIMP 18-24 AWG: MOLEX (39-00-0039)
USE CRIMP TOOL: MOLEX (11-01-0197)
UG:121
Page 8
Output Connectors for PFC Micro™
(Part #19-130044. Available for purchase from Vicor.)
Item
Qty
1
3
2
8
**
Description
Vendor #1
Part #
HOUSING 3 POS .100 CTR W/LATCH
MOLEX
50-57-9403
TERMINAL FEM CRIMP 22-24AWG SEL GOLD
MOLEX
16-02-0103
CRIMP TOOL FOR ITEM 2
MOLEX
11-01-0208
2
HOUSING 16 POS .165 CTRS W/LATCH
MOLEX
39-01-2160
4
2
HOUSING 18 POS .165 CTRS W/LATCH
MOLEX
39-01-2180
5
40
TERMINAL FEM CRIMP 18-24AWG SEL GOLD
MOLEX
39-00-0039
CRIMP TOOL FOR ITEM 5
MOLEX
11-01-0197
TERMINAL FEM CRIMP 16AWG SEL GOLD
MOLEX
45750-3211
3
**
6
40
CRIMP TOOL FOR ITEM 6
MOLEX
11-01-0199
7
**
1
HOUSING 5 POS .165 CTRS W/LATCH
MOLEX
39-01-4051
8
5
TERMINAL FEM CRIMP 16AWG SEL GOLD
MOLEX
45750-3211
**
9
10
CRIMP TOOL FOR ITEM 8
MOLEX
11-01-0199
1
HOUSING 12 POS .10 CTRS W/LATCH
MOLEX
50-57-9412
14
TERMINAL FEM CRIMP 24-30AWG SEL GOLD
MOLEX
16-02-0097
CRIMP TOOL FOR ITEM 10
MOLEX
11-01-0209
**
** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT)
Power Connections
Chassis Input Power Terminals (MBJ1)
Input AC power is applied through connector MBJ1 using Molex mating connector 39-01-4051.
Use 16AWG wire with Molex Socket Pin 39-00-0090 and Crimp Tool 11-01-0199.
A fault-clearing device, such as a fuse or circuit breaker, with a maximum 10A rating at the power
supply input is required for safety agency compliance. It should be sized to handle the start-up inrush
current of 8.5A peak at 115VAC and 17A peak at 230VAC.
Figure 2
Input power terminal MBJ1
CBJ3-12 PIN
PIN 1
MBJ1 A/C INPUT
MATING CONNECTOR: (WESTCOR KIT P/N: 19-130044)
HOUSING: MOLEX (39-01-4051)
SOCKET CRIMP 16 AWG: MOLEX (39-00-0090)
CRIMP TOOL: MOLEX (11-01-0199)
MBJ1 (5 PIN)
L1
Not Connected
Not Connected
L2/N
GND
UG:121
Page 9
Output Power Connections
There are three types of output power terminals available in the PFC Micro™. Each slot has one of the
following configurations: 10-32 plated steel bolts from outputs using full-size converters, an 18-pin
Molex connector for outputs using half size converters and a 16-pin Molex connector for outputs using
quarter size converters.
Note: The Molex connectors are limited to 9A/pin (27A/output).
The positive polarity of the single-output termination is the right bolt when viewed from the output
end. Each power output is isolated, so outputs of positive or negative polarity can be configured
through proper selection of the output reference terminal.
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. Do not bulk input
AC wires with the output wires because this can couple output noise into the input wires which can
increase EMI. 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 the Vicor
Applications Engineering Department for assistance with applications that use long cable lengths and
excessive load capacitance.
Figure 3
Output power connections
18 17 16 15 14 13 12 11 10
16 15 14 13 12 11 10 9
1.86
8 7 6 5 4 3 2 1
MATING CONNECTORS: (WESTCOR KIT P/N: 19-130044)
16 PIN HOUSING: MOLEX (39-01-2160)
SOCKET CRIMP 18-24 AWG: MOLEX (39-00-0039)
CRIMP TOOL: MOLEX (11-01-0197)
S1/S2 J1 (16 PIN, TRIPLE MICRO MODULES)
PIN DESCRIPTION
PIN DESCRIPTION
S1/S2 J1-1
S1/S2 J12
S1/S2 J1-3
S1/S2 J1- 4
S1/S2 J1-5
S1/S2 J1-6
S1/S2 J1- 7
S1/S2 J1-8
+V OUT M3
-V OUT M3
TRIM M3
+V OUT M2
-V OUT M2
TRIM M2
+V OUT M1
-V OUT M1
S1/S2 J1-9
S1/S2 J1-10
S1/S2 J1-11
S1/S2 J1-12
S1/S2 J1-13
S1/S2 J1-14
S1/S2 J1-15
S1/S2 J1-16
+V OUT M3
-V OUT M3
N/C
+V OUT M2
-V OUT M2
TRIM M1
+V OUT M1
-V OUT M1
MAXI MODULE
(2 ISOLATED OUTPUTS)
DUAL MINI
MODULES (4 OUTPUTS)
TRIPLE MICRO
MODULES (6 OUTPUTS)
S1/S2 J1 REMOTE SENSE/OUTPUT CONNECTORS
S1
5.06
S1
S1
+
128.52
10-32 STUDS
S2
S1
MATING CONNECTORS: (WESTCOR KIT P/N: 19-130044)
18 PIN HOUSING: MOLEX (39-01-2180)
SOCKET CRIMP 18-24 AWG: MOLEX (39-00-0039)
CRIMP TOOL: MOLEX (11-01-0197)
S1/S2 J1 (18 PIN, DUAL MINI & VI-J00 MODULES)
PIN DESCRIPTION
PIN DESCRIPTION
S1/S2 J1- 1 +V OUT M2
S1/S2 J1-2 -V OUT M2
S1/S2 J1-3 -V OUT M2
S1/S2 J14 + SENSE M2
S1/S2 J15 - SENSE M2
S1/S2 J16 TRIM M1
S1/S2 J17 +V OUT M1
S1/S2 J1 8 +V OUT M1
S1/S2 J19 -V OUT M1
S1/S2 J110
S1/S2 J111
S1/S2 J1 12
S1/S2 J113
S1/S2 J114
S1/S2 J115
S1/S2 J116
S1/S2 J117
S1/S2 J118
+V OUT M2
+V OUT M2
-V OUT M2
+ SENSE M1
TRIM M2
- SENSE M1
+V OUT M1
- OUT M1
- OUT M1
S2
+
S1/S2 J2-3 PIN (VI-200/MAXI MODULE)
Note: The molex connectors are limited
to 9A/pin (27A per output)
S1/S2 J1 REMOTE SENSE/OUTPUT CONNECTORS
9 8 7 6 5 4 3 2 1
47.29
UG:121
3
2
1
- REMOTE SENSE
+ REMOTE SENSE
Trim Pin
S1/S2 J2 REMOTE SENSE/TRIM PIN ACCESS CONNECTOR
MATING CONNECTOR: (WESTCOR KIT P/N: 19-130044)
HOUSING: MOLEX (50-57-9403)
SOCKET CRIMP 24-30 AWG: MOLEX (16-02-0103)
CRIMP TOOL: MOLEX (11-01-0208)
Page 10
User Interface Connections
Signal Ground (CBJ3-1)
Signal Ground on CBJ3-1 is an isolated secondary ground reference for all CBJ3 interfacing signals. This
is not the same as Earth Ground on input power connector MBJ1.
Bidirectional I/O lines (CBJ3-4 to CBJ3-9)
(Enable/Disable or Module Power Good Status)
Enable/Disable Mode
Enable/Disable mode is the default condition for these I/O lines. In this mode, the control pins allow
the outputs to be sequenced either ON or OFF. To disable a module, the E/D pin should be pulled low
to less than 0.7V with respect to signal ground. The E/D lines will typically source 250mA (1mA max.)
under this condition. To enable a module, a E/D pin should be open circuited or driven high to a
logic‑high voltage of 3.5V (40mA typical) or greater not to exceed 5V. (When one has a two module
array, use GSD to disable the output instead of using E/D.)
The correspondence between a module and its E/D line as seen from the output end of the power
supply goes from left to right. The PFC Micro™ power supply is a two-slot box. Slot 1 is the left slot and
Slot 2 is the right slot. See Table 1. E/D1, E/D2, E/D3 correspond with VOUT M1, VOUT M2 and VOUT
M3 on slot 1. E/D4, E/D5, E/D6 correspond with VOUT M1, VOUT M2 and VOUT M3 on slot 2.
Table 1
Enable/Disable mode
Module
Slot 1
E/D1
E/D2
Maxi
X
Mini
X
X
X
Micro
X
VI-200™
X
VI-J00™
X
Slot 2
E/D3
E/D4
E/D5
E/D6
X
X
X
X
X
X
X
X
X
X
X
Module Power Good Status Mode
The power supply will enter the Power Good status mode when logic high (50mA typical) is applied to
Power Good Read (PGR) pin (CBJ3-2). After transitioning to PGR mode the I/O lines (CBJ3-4 to CBJ3-9)
will be outputs and will give a onetime readout of the associated module status. These outputs give an
indication of the status of the modules of the power supply at the time of transition to PGR. A TTL "1"
(>3.5V) on a line indicates the module is ON and functioning properly and a TTL "0" (0.98
Transient Burst Immunity
EN61000-4-4 (consult factory)
Surge Immunity
Compliant with IEC 61000-4-5, Level 3, Performance Criteria B
(Common Mode & Normal Mode) (Temporary loss of output power may occur which is self recoverable.)
Dielectric Withstand
Primary to Chassis GND = 2,121VDC
Secondary to Chassis GND = 750VDC
MI Chassis Overvoltage
and Transients
Compliant to Mil-STD 704 and 1399
[a]
[b]
Do Not to exceed an input current of 7.5A.
See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal
output voltage.
UG:121
Page 16
Specifications (Cont.)
Typical at 25°C, nominal line and 75% load, unless otherwise specified.
Output (VI-200™/VI-J00™ Modules)
Parameter
Typ
Max
Units
Accuracy [c]
0.5
1
%
of VNOM
Load/Line Regulation
0.05
0.5
%
LL to HL,
10% to Full Load
Load/Line Regulation
0.2
0.5
%
LL to HL,
No Load to 10%
Temperature Regulation
0.01
0.02
%/°C
Long-Term Drift
0.02
%/K hours
Output Ripple & Noise:
≤10VOUT
>10VOUT
100
1.0
mV
% VOUT
50 – 110
% VOUT
Set-Point
Min
Voltage Trim Range:
VI-200/VI-J00 Slots
Notes
Over rated temperature
20MHz bandwidth
±10% on
10 – 15VOUT
Total Remote-Sense
Compensation
0.5
OVP Set Point [d]
115
125
135
%VOUT
Recycle Power
Current Limit
105
115
125
% of IMAX
Auto Recovery
130
%
Short Circuit Current
Volts
120 (105 [e])
Overtemperature Limiting
Autosense.
See pages 6 & 14
Not available on VI-J00
Maxi, Mini and Micro Series Modules
Parameter
Typ
Max
Units
Accuracy [f]
±0.5
±1
% of VNOM
Load/Line Regulation
±0.08
±0.45 (±7)
% of VNOM
Temperature Regulation
0.002
0.005
Long-Term Drift
0.02
%/K hours
Output Ripple and Noise:
≤10VOUT
>10VOUT
100
1.0
mV
%VOUT
20MHz
bandwidth
10 – 110
% VOUT
Preload may be
required
Set-Point
Min
Voltage Trim Range:
Maxi/Mini/Micro Slots
Total Remote-Sense
Compensation
0.5
OVP Set Point
112
Current Limit
102
%/°C
Volts
115
Overtemperature Limiting
Notes
0 – 100%
–40 to 100°C
Autosense.
See pages 6 & 14 [g]
135
% of VOUT
Recycle power
135
% of IMAX
Auto Recovery
Not available
[a]
Do Not to exceed an input current of 7.5A.
See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal
output voltage.
[c] For special and adjustable voltages, maximum set-point accuracy is 2% of V
NOM.
[d] 131% nominal for booster modules. No OVP for VI-J00.
[e] VI-J00 modules only.
[f] For special, adjustable voltages and 48V
DC outputs, maximum set-point accuracy is 2% of VNOM.
Note: See individual module data sheets for specific module specifications.
[g] Micro modules do not support remote sense.
[b]
UG:121
Page 17
Specifications (Cont.)
Typical at 25°C, nominal line and 75% load, unless otherwise specified.
Environmental
Storage Temperature
–40 to +85°C
Operating Temperature
Full Power
Half Power
–20 to +45°C (–40 to +45°C option w/MI chassis)
–20 to +65°C (–40 to +60°C option w/MI chassis)
Altitude
Derate 2.6% total output power for each 1,000ft to a maximum operating
altitude of 15,000ft. Non-operating storage maximum altitude is 40K.
Shock and Vibration
Mil-STD 810 (MI rugged chassis only)
Humidity
0 – 95% non condensing
Product Weight
5.2lbs [2,4kg]
Dimensions
1.86 x 5.06 x 10.40in [47,3 x 128,5 x 264,1mm]
Warranty [h]
2 years limited warranty.
See vicorpower.com for complete warranty statement.
[a]
Do Not to exceed an input current of 7.5A
See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal
output voltage.
[c] For special and adjustable voltages, maximum setpoint accuracy is 2% of V
NOM.
[d] 131% nominal for booster modules. No OVP for VI-J00.
[e] VI-J00 modules only.
[f] For special, adjustable voltages and 48V
DC outputs, maximum set-point accuracy is 2% of VNOM.
Note: See individual module data sheets for specific module specifications.
[g] Micro modules do not support remote sense.
[h] 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.
[b]
UG:121
Page 18
Output Power De-Rating
Figure 9
PFC Micro™ output power vs.
AC input voltage
PFC Micro Output Power vs. AC Input Voltage
Output Power (Watts)
800
750
700
650
600
Power Limit Exceeded
550
500
450
Safe Operating Area
8.33 Watts/Volt
400
350
85 95 105 115 125 135 145 155 165 175 185 195 205 215 225 235 245 255 265
Input Voltage (VAC)
Figure 10
PFC Micro output power vs.
DC input voltage
PFC Micro Output Power vs. DC Input Voltage
Output Power (Watts)
800
720
640
Power Limit Exceeded
560
480
Safe Operating Area
400
320
240
160
80
100
120
140
160
180
200
220
240
260
280
300
Input Voltage (VDC)
Power (W)
UG:121
Page 19
Figure 11
PFC Micro™ output power
temperature de-rating
PFC Micro: Output Power Temperature De-Rating
800
Output (Watts)
700
600
500
400
300
200
100
0
0
45
65
Temperature (degrees)
1. For all module configurations. The PFC Micro or an individual output may be limited by module
power limitations e.g. 5V Maxi module is 400W maximum. One cannot exceed the output power
rating of the PFC Micro regardless of the module capability.
2. Also see output power vs. input voltage charts on page 19.
3. Please note that a PFC Micro configuration that uses a Molex connector is limited to 9A/pin
(27A per output). This is a Molex connector limitation, NOT a module power limitation. Please
consult Applications Engineering for assistance on requirements that exceed the 27A limitation.
UG:121
Page 20
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
>100A. 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 five-wire connection method to achieve
a ±1mV accuracy between the negative output power rails. This accuracy translates to a 1% current
sharing if there is a total of 100mV 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 example
D*
+OUT
Supply # 1
5V @ 120A
+V OUT
+S
TRIM
Yellow
–S
–OUT
T1
–V1
T2
–V2
Brown
D*
+OUT
Supply # 2
5V @ 120A
CSB02
+S
TRIM
–S
Power
Red
–V OUT
White
Black
–OUT
UG:121
Page 21
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 12. Each leg of the "Y" must have a minimum of a few millivolts of drop in
order for proper operation. 50 – 100mV of drop will provide from 5 – 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 above.
6. Terminate sense leads either locally or remotely as shown in Figure 12.
7. For paralleling more than two supplies, consult factory for assistance.
UG:121
Page 22
Current Share Boards – Optional Feature (Cont.)
0.13in [3.3mm] Dia Non
Plated thru hole 4
places
1.74"
[44.2mm]
Pin
1
2
3
4
5
6
2
1
4
3
6
5
Molex CT43045F surface mountable
connector. .390" height above board.
1.500"
[38.1mm]
J1 Pinout
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 – 50VDC at 5mA maximum.
2. Accuracy: ±1mV between –VOUT connections.
3. Output current when not trimming up: ±1µA (VI-200/J00), ±5µA (Maxi).
4. Use four non-plated through holes with standoffs for mounting.
5. CSB01 MUST be used for current sharing VI-200™/VI-J00™ converters.
6. CSB02 MUST be used for current sharing Maxi/Mini/Micro converters.
PLEASE NOTE: THE CSB IS NOT INTENDED FOR HOT-SWAP APPLICATIONS.
Contact your Regional Applications Engineer at 1-800-927-9474 for additional information.
UG:121
Page 23
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 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 high-density DC-DC converters and accessory components.
This product line includes:
LoPAC™ FAMILY:
nn
PFC MicroS™
nn
PFC Micro™
nn
PFC Mini™
MegaPAC™ FAMILY:
nn
PFC MegaPAC™
nn
4kW MegaPAC™
nn
PFC MegaPAC™ (High Power)
nn
PFC MegaPAC-EL™
nn
Mini MegaPAC™
nn
ConverterPACs™
Others:
nn
FlatPAC-EN™
Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini, PFC MegaPAC.
UG:121
Page 24
Limitation of Warranties
Information in this document is believed to be accurate and reliable. HOWEVER, THIS INFORMATION
IS PROVIDED “AS IS” AND WITHOUT ANY WARRANTIES, EXPRESSED OR IMPLIED, AS TO THE
ACCURACY OR COMPLETENESS OF SUCH INFORMATION. VICOR SHALL HAVE NO LIABILITY FOR THE
CONSEQUENCES OF USE OF SUCH INFORMATION. IN NO EVENT SHALL VICOR BE LIABLE FOR ANY
INDIRECT, INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, WITHOUT
LIMITATION, LOST PROFITS OR SAVINGS, BUSINESS INTERRUPTION, COSTS RELATED TO THE REMOVAL
OR REPLACEMENT OF ANY PRODUCTS OR REWORK CHARGES).
Vicor reserves the right to make changes to information published in this document, at any time
and without notice. You should verify that this document and information is current. This document
supersedes and replaces all prior versions of this publication.
All guidance and content herein are for illustrative purposes only. Vicor makes no representation or
warranty that the products and/or services described herein will be suitable for the specified use without
further testing or modification. You are responsible for the design and operation of your applications
and products using Vicor products, and Vicor accepts no liability for any assistance with applications or
customer product design. It is your sole responsibility to determine whether the Vicor product is suitable
and fit for your applications and products, and to implement adequate design, testing and operating
safeguards for your planned application(s) and use(s).
VICOR PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR WARRANTED FOR USE IN LIFE SUPPORT,
LIFE-CRITICAL OR SAFETY-CRITICAL SYSTEMS OR EQUIPMENT. VICOR PRODUCTS ARE NOT CERTIFIED
TO MEET ISO 13485 FOR USE IN MEDICAL EQUIPMENT NOR ISO/TS16949 FOR USE IN AUTOMOTIVE
APPLICATIONS OR OTHER SIMILAR MEDICAL AND AUTOMOTIVE STANDARDS. VICOR DISCLAIMS
ANY AND ALL LIABILITY FOR INCLUSION AND/OR USE OF VICOR PRODUCTS IN SUCH EQUIPMENT OR
APPLICATIONS AND THEREFORE SUCH INCLUSION AND/OR USE IS AT YOUR OWN RISK.
Terms of Sale
The purchase and sale of Vicor products is subject to the Vicor Corporation Terms and Conditions of
Sale which are available at: (http://www.vicorpower.com/termsconditionswarranty)
Export Control
This document as well as the item(s) described herein may be subject to export control regulations.
Export may require a prior authorization from U.S. export authorities.
Contact Us: http://www.vicorpower.com/contact-us
Vicor Corporation
25 Frontage Road
Andover, MA, USA 01810
Tel: 800-735-6200
Fax: 978-475-6715
www.vicorpower.com
email
Customer Service: custserv@vicorpower.com
Technical Support: apps@vicorpower.com
©2019 Vicor Corporation. All rights reserved. The Vicor name is a registered trademark of Vicor Corporation.
All other trademarks, product names, logos and brands are property of their respective owners.
01/19
P/N 03-00048
Rev 1.2
Page 25
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