PM1-03B-15-G

USER GUIDE | UG:115 PFC Mini™ Power Factor Corrected AC-DC Switcher Contents Page Overview 1 Standard Features 2 Optional Features 2 Mechanical Considerations 2 PFC Mini Dos and Don’ts 3 Technical Description 3 PFC Mini™ Configuration Layout 5 Part Numbering 6 PFC MegaPAC Quick Install Instructions 7 PFC Mini™ Mechanical Drawing 9 Output Connectors for PFC Mini™ 10 PFC Mini™ Connector Kit (19-130047) Listing 11 Interface Connections 11 Enable / Disable Control of Maxi, Mini, Micro Series Module Arrays 16 Minor Changes for PFC Mini™ Shipped October 2005 Onwards 18 PFC Mini™ Output Power vs. Input Voltage 19 Specifications 20 Current Share Boards – Optional Feature 23 Low-Leakage Version 26 Low Output Ripple 26 Office Environment Fan 26 Overview The PFC Mini is an extremely low-profile 1RU switching power supply that combines the advantages of power-factor correction and high power density. This guide covers both standard- and rugged‑chassis COTS (MI) versions of the product. The PFC Mini can provide up to six isolated outputs (three slots) and each slot accommodates the following Vicor DC-DC Converters. VI/E-200™ and VI/E-J00™ series: one VI/E-200 or two VI/E-J00 converters Maxi, Mini Micro series: one Maxi, two Mini converters (Micros cannot be used) The use of these converters give the PFC Mini the inherent power flexibility typical of all Vicor products. Accepting input voltages of 85 – 264VAC, and 100 – 380VDC, the PFC Mini can provide up to 1,500 Watts in a package size of 1.72 x 6 x 12.2in [43,6 x 152,4 x 309,9mm]. The PFC Mini is factory‑configured to meet user requirements. Note: If you have a PFC Mini that shipped from October 2005 onwards, please see Page 18 for more details. Molex Connector Limitation 26 UG:115 Page 1 Standard Features nn Power factor correction: 0.99 at 115VAC; 0.95 at 230VAC nn Universal input: 85 – 264VAC, 47 – 500Hz, or 100 – 380VDC nn Power output: 1,500W at 230VAC; 800W at 115VAC nn Up to six isolated outputs (three slots) nn Fan cooled nn Full power to 45°C; half power at 65°C nn Conducted EMI: VI-200™/VI-J00™ series: FCC Class B EN55022 Class B Maxi, Mini, Micro series: FCC Class A EN55022 Class A (certain configurations meet EN55022 Class B) nn Harmonic distortion complies with EN61000-3-2 nn AC Power OK status signal nn Autosense (for more information, see Page 8 and Page 13) nn Output overcurrent protection on all outputs nn Output overvoltage protection (not applicable when using VI-J00) nn Output overtemperature limiting (not applicable when using VI-J00) nn Ride-through (hold-up) time: >20ms at 1,200W load (nominal line) nn Size: 1.72 x 6 x 12.2in [43,6 x 152,4 x 309,9mm] nn Safety agency approvals: CE Mark, cTÜVus, UL (Note: certain MI chassis may not carry all safety certs.) Optional Features nn Extended temperature range output converters nn Current share board - see Page 23 nn RAM™ modules for low noise applications - see Page 26 nn Connector kit available (#19-130047) nn Low leakage available – see Page 26 nn Office environment fan – see Page 26 nn MI-chassis-specific options: 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:115 Page 2 Mechanical Considerations The PFC Mini™ can be mounted on either of two surfaces using standard 8-32 (4 mm) size screws. Maximum allowable torque is 4.4in.lbs and the maximum penetration is 0.16in [4mm]. When selecting a mounting location and orientation, the unit should be positioned so airflow is not restricted. Maintain a 2in [5,1cm] minimum clearance at both ends of the PFC Mini and route all cables so airflow is not obstructed. The power supply draws air in at the fan-side/AC-input side and exhausts air out the load side. If airflow ducting is used, avoid sharp turns that could create back pressure. The fans move approximately 20CFM 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. In such applications, a shock-absorbing mount design is required. PFC Mini Dos and Don’ts nn If sense jumpers are removed, do not leave sense lines open (especially if unit does not have Autosense). Sense lines must be terminated to their respective outputs. Use twisted pair 20 – 22AWG wire when installing remote sense nn NEVER disconnect the +OUT and –OUT load wires while the supply is operating as disconnecting WILL cause damage to the power supply. Ensure load wires connected before remote sense connected. nn To prevent damage to supply, verify polarity of remote-sense connection before turning supply on. nn Always turn the power supply off before disconnecting input or output wires. nn Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the output terminals. nn Run the output (+/–) power cables next to each other to minimize inductance. nn Do not repair or modify the power supply in any manner. Doing so will void the warranty. Contact Factory. 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 UL60950. Appropriate care must be taken in design implementation of the supply. UG:115 Page 3 Technical Description The PFC Mini consists of an offline single-phase, power-factor-corrected front end, EMI filter, cooling fan, customer interface, associated housekeeping circuits and a selection of Vicor DC-DC converters. Input AC mains voltage is applied to a terminal block. The input current is passed through an EMI filter designed to meet conducted noise limit “B” specifications in FCC Part 15 and EN55022, Class B (with VI-200™/VI-J00™ series modules. If Maxi, Mini, Micro series modules are used, it meets FCC Class A and EN55022 Class A. (Certain configurations meet Class B). At start up, inrush current is limited by a PTC thermistor. The PTC is shunted out shortly after initial power up by a DC bus voltage sense circuit driving a relay. After rectification, the input voltage is put through a boost converter that keeps the AC input current sinusoidal and synchronized with the input AC voltage (in compliance with EN61000-3-2). The boost converter delivers a regulated input to the hold-up capacitors and a high-voltage backplane. The backplane supplies power to the DC-DC converters that provide the desired low-voltage regulated outputs. Voltage conversion is achieved by 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 Mini™ outputs are disabled to limit the inrush current and to allow the DC bus potential to settle out to the correct operating level. A low-power flyback converter operating with PWM current-mode control converts the high-voltage DC bus into regulated low voltage to power the internal housekeeping circuits and DC cooling fans. The internal housekeeping VCC comes up within two seconds after the application of input power. Once the high-voltage bus is within operating limits, the AC Power OK signal asserts to a TTL "1," indicating the input power is OK and enables the power outputs. An auxiliary VCC output of 5VDC sourcing up to 0.3A is provided for peripheral use. An output enable / disable function is provided by using an optocoupler to control Vicor DC-DC converters. If the enable / disable control pin is pulled low, the optocoupler turns on and disables the output. The nominal delay associated for an output to come up when measured from release of the enable / disable pin is 5 – 10ms. The General Shut Down function controls all outputs simultaneously and works in a similar manner. Figure 1 Input Line Filter Rectifier Soft-Start Circuit Boost Converter High-Voltage Bus Waveform Sample Current Sample Customer Interface Power Output Output Card #2 Power Output Output Card #3 Power Output PFC Control E/D Control Fan Output Card #1 Enable/Disable Control Isolated Housekeeping Power UG:115 Page 4 PFC Mini™ Configuration Layout AC input Fan Fan AC input Fan Fan S 3-M2 S1-M1 S2-M1 S3-M1 S1-M1 S2-M1 S3-M1 Slot 1 Slot 2 Slot 3 Slot 1 Slot 2 Slot 3 Shown above are two sample PFC Mini configuration layouts. Due to the configurability nature of the PFC Mini, various output combinations are possible. See Page 11 for more information about your output connections. The PFC Mini has three slots, and each slot accommodates either full- or half-brick modules. Please note that the maximum output power of the PFC Mini is 1,500W at 230VAC, 800W at 115VAC, irrespective of the maximum output power of the modules; e.g., if a PFC Mini is configured with three Maxi modules on the configuration sheet, the maximum output power of the module (600W) is listed. However, irrespective of the maximum output power of the three Maxi modules (1,800W), the maximum output power of the PFC Mini is still 1,500W at 230VAC and 800W at 115VAC. When populated with 12V modules, the maximum output power per slot is 500W (with other modules it is 600W). Hence, when a 12V Maxi module is used, the maximum output power is limited to 500W. If a 12V Mini module is used, the maximum output power is limited to 250W. UG:115 Page 5 SLO T#3 V375A5C400BN4 E/D#2 SLO T#2 Output #1 VI-J60-CY -S E/D#3 V375A5C400BN4 E/D#1 SLOT #1 Output #2 VI-J63-CW-S E/D#3 Configuration Example: SLOT# 1 VOLTS AMPS WATTS 5.0 80 800 2 Modules V375A5C400BN4* V375 V375A5C400BN4* V375A5C40 3 (M1) 5.0 10 50 VI-J60-CY-S* VI- 3 (M2) 24.0 4.2 100 VI-J63-CW -S* VI- * Actual module part numbers may vary depending on customer configuration E/D = Enable/Disable Part Numbering PFC Mini™ PMx1-x2 x (x4)-xxxx(-x5)(-x6) e.g.: PM4-22-2988 PM1-03B-48 PM3-03-2643-2 PM6-60-2888-2-QF PM = PM x1 = number of outputs x2 = number of VI-200™/VI-J00™ x3 = number of Maxi, Mini x4 = optional - standard product designator xxxx = configuration/customer specific # assigned by Vicor x5 = optional factory assigned note MI = rugged chassis + MC for conformal coated rugged x6 = additional option codes revised to orginal configuration QF = quiet fan/office enviornment LL = low leakage UG:115 Page 6 PFC MegaPAC™ Quick Install Instructions (For mechanical drawing, see Page 9) Mounting the PFC Mini™ nn Mount the PFC Mini on either of two sides. nn Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.16in [4mm]. nn Maintain 2in [5,1cm] clearance at both ends of power supply for airflow. Input Connections Input Power MBJ1 nn Apply input AC power to terminal block MBJ1 using a pressure screw terminal. NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS. 115-230 VAC 10A 47 TO 500 Hz 300VDC --- L1 DO NOT OPERATE WITHOUT EARTH GND L2/N INPUT CONNECTIONS MBJ1-1 EARTH GROUND MSJ1-2 L2-NEUTRAL MBJ1-3 L1 nn Strip length of AC power conductors to be 0.35 inches. nn Maximum torque is 4.4in.lbs. nn Place a fuse or circuit breaker in the input line for safety requirements. nn The connector manufacturer recommends the wires not be tinned. A ferrule can be used to prevent fraying. Output Connections (see Page 10 for more details on output connectors) Power Connections Installing bus bars on output studs (when full-size module is used): Output nn The right stud is Positive and the left stud is the Return. Output Return nn Remove the top nut and place ring lug over output stud. nn Do not remove the lower nut next to the PCB. nn Replace and tighten the nut to a torque of 10 inch pounds. Do Not over-tighten nuts. SxJ2 Installing power connectors with 18-pin molex connectors [a] (when half size module used): Locking Key 18 9 17 16 15 14 13 - + -S T +S + + T -S +S 8 7 6 5 4 12 11 10 - + + - - + 3 2 1 SxJ1 Dual Output connector M1 Output M2 Output Pin 1 Identifier nn SxJ1-1, SxJ1-10, SxJ1-11 are Positive for output #1, while pins SxJ1-2, SxJ1-3, SxJ1-12 are the Return. SxJ1-7, S3J1-8 and SxJ1-16 are Positive for output #2, while pins SxJ1-9, SxJ1-17 and SxJ1-18 are the Return. [b] nn Use Molex mating receptacle #39-01-2180 with #44476-3112 terminals. nn Attach 18 – 24AWG stranded wire using Molex tool #11-01-0199. nn Current PFC Minis have 18-pin SxJ1 connectors. Note: Effective January 2001, all PFC Mini units have 18-pin connectors (Molex PN#39-01-2180) vs. the 14-pin (Molex PN# 39-01-2140). If you already have a 14-pin design in, remove the harness assembly from the 14-pin connector housing and insert the harness connector pins into the 18-pin connector housing. For further information, contact an Applications Engineer. [a] [b] Outputs with current molex connectors are limited to 9A/pin (27A per output). Where x refers to the slot number. UG:115 Page 7 Sense Connections Note: PFC Mini™ units built after 12/2000 have been equipped with a feature called Autosense. If no sense connections are made, the PFC Mini will automatically operate in local-sense mode. If remote-sense connections are made, the PFC Mini will operate in a remote-sense mode. For units built before 12/2000 (units without Autosense), Sense connections must ALWAYS be made. Not connecting Sense Lines to their respective outputs can cause failure to the unit. Sense connections on output connections with studs Remove jumpers for Remote Sense nn PFC Minis are currently shipped with Autosense installed. Those without the Autosense were shipped with local sense installed. (See note on Page 13) nn If remote sense is desired, remove jumpers MBJ1 and J3, located behind the sense connector. nn Connector pin SxJ2-2 is the +SENSE and SxJ2-3 is the –SENSE. nn Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals. nn Attach terminals to 20 – 22AWG stranded twisted pair wire using Molex tool #11-01-0208. nn Attach opposite end of sense lines to point where regulation is desired. nn Verify that sense lines are not cross-connected. Sense connections on output connection with Molex connectors nn PFC Minis are currently shipped with Autosense installed. Those without the Autosense were shipped with local sense installed. (See note on Page 13) Remove jumpers for Remote Sense on Output # 2 nn If remote sense is desired, remove jumpers on MBJ1 and J3, located on either side of the output connector. Connector J2 nn Connector pin SxJ1-4 is the +SENSE and SxJ1-5 is the –SENSE for output #1. SxJ1-13 is the +SENSE and SxJ1-15 is the –SENSE for output #2. Remove jumpers for Remote Sense on Output # 1 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. Trim Connector 1 2 3 SxJ2 Pin Trim Pin Access +SENSE –SENSE Trim Connections Trim connections on outputs with studs: nn SxJ2-1 provides trim access. nn Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals. nn Attach 20 – 22AWG stranded wire using Molex tool #11-01-0208. Trim connections on outputs with Molex connectors: Locking Key 18 9 17 16 15 14 13 - + -S T +S + + T -S +S 8 7 6 5 4 12 11 10 - + + - - + 3 2 1 SxJ1 Dual Output connector M1 Output M2 Output Pin 1 Identifier nn SxJ1-14 provides trim access for output #1, and SxJ1-6 provides trim access for output #2. nn Use Molex mating receptacle #39-01-21 with #39-00-0039 terminals. nn Attach 18 – 24AWG stranded wire using Molex tool #11-01-0197. Interface Connections nn J3-1 to 3 are Enable/Disable for cards 1-3, respectively. nn J3-4 is Signal Ground, J3-5 is +5V, J3-6 is AC Power OK, and J3-7 is General Shutdown. nn Use mating receptacle AMP P/N 205204-4 with terminals AMP P/N 66506-9. J3 INTERFACE CONNECTION MATING HDWR: HOUSING: AMP P/N 205204-4 TERMINALS: AMP P/N 66506-9 SCREW LOCK: AMP P/N 205980-4 CRIMP TOOL: AMP 58448-3 nn Attach terminals to 18 – 24AWG stranded wire. J3 INTERFACE PIN OUT J3-1 J3-2 J3-3 J3-4 E/D-1 E/D-2 E/D-3 SIGNAL GROUND J3-5 VCC +5V 300mA J3-6 ACOK AC POWER OK J3-7 GSD GENERAL SHUTDOWN J3-8 SPARE J3-9 SPARE UG:115 Page 8 .487 12.36 .920 23.37 43.69 ±0.51 L1 L2/N 2.210 1.600 133.81 AIR FLOW 56.13 40.64 5.268 UG:115 3 4 A COMPLETE SET OF MATING CONNECTORS CAN BE PURCHASED FROMWESTCOR BY SPECIFYING CONNECTOR KIT P/N: 19-130047 REF DESIGNATION LEGEND MB = MOTHER BOARD S1 = (SLOT 1) DAUGHTERBOARD MODULES E/D 1. S2 = (SLOT 2) DAUGHTERBOARD MODULES E/D 2. S3 = (SLOT 3) DAUGHTERBOARD MODULES E/D 3. WITH OPTIONAL BUSBAR. 2 1. INTERPRET DRAWING PER ANSI Y14.5-1994. NOTES: UNLESS OTHERWISE SPECIFIED MBJ1 INPUT CONNECTIONS MBJ1-1 EARTH GROUND MBJ1-2 L2 / NEUTRAL MBJ1-3 L1 DO NOT OPERATE WITHOUT EARTH GND NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS. 115-230 VAC 10A 47 TO 500 Hz 300VDC --- CLAMPING SCREWS 14 AWG WIRE J3 INTERFACE CONNECTION MATING HDWR: (AMP P/N: OR EQUIVALENT) HOUSING: AMP P/N: 205204-4 TERMINALS: AMP P/N: 66506-9 SCREW LOCK: AMP P/N: 205980-4 CRIMP TOOL: AMP 58448-3 J3 INTERFACE PIN OUT 5 1 J3-1 E/D-1 9 6 J3-2 E/D-2 J3-3 E/D-3 J3-4 SIGNAL GROUND J3-5 VCC +5V 300mA J3-6 ACOK AC POWER OK J3-7 GSD GENERAL SHUTDOWN J3-8 SPARE J3-9 SPARE 1.72 ±.02 1.00 4.00 25.40 101.60 8.00 203.20 12.03 305.56 317.29 ±0.51 308.86 12.49 ±.02 12.16 2 203.20 SCALE: 1:2 BOTTOM VIEW 8.00 .47 50.80 11.94 152.40 2 S1JX CSB-01 CSB-02 3 SEE PAGE 21 AND 22 FOR MORE INFORMATION ON CURRENT SHARE BOARDS. WITH VI-200/VI-J00 MODULES WITH MAXI/MINI MODULES 3 S2JX NOTE: FOR INCREASED OUTPUT POWER, CURRENT SHARE BOARDS ARE AVAILABLE. CUSTOMER MOUNTING HOLES: 4X #8-32 X .156 or M4 X 4mm MAX LG. FROM OUTSIDE OF POWER SUPPLY 50.80 8.64 ±0.51 All Westcor power supplies can now be configured online using VSPOC, the online configurator tool available on vicorpower.com 2.00 CUSTOMER MOUNTING HOLES: 2X #8-32 X .156 or M4 X 4mm MAX LG. FROM OUTSIDE OF POWER SUPPLY 2.00 6.00 .34 ±.02 S3JX 4 4 SEE PAGE 11 FOR DETAILED OUTPUT CONNECTION INFORMATION 3 4 PFC Mini™ Mechanical Drawing Page 9 Output Connectors for PFC Mini™ A. OUTPUT STUDS - SINGLE OUTPUT (when populated with full-size modules) –VOUT 10-32 OUTPUT STUDS SxJ2 REMOTE SENSE/TRIM PIN CONNECTOR +VOUT 3 2 1 –SENSE +SENSE TRIM MATING CONNECTOR: HOUSING: MOLEX P/N 50-57-9403 TERMINALS: MOLEX P/N 16-02-0103 USE CRIMP TOOL: MOLEX P/N 11-01-0208 B. MOLEX CONNECTOR - SINGLE OR DUAL OUTPUT - (when populated with half-size modules) 18-pin Housing 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1 10 PIN 1 2 3 4 5 6 7 8 9 SxJ1 (18-PIN OUTPUT, REMOTE SENSE AND TRIM PIN CONNECTOR) DESCRIPTION PIN DESCRIPTION +VOUT M1 10 +VOUT M1 –VOUT M1 11 +VOUT M1 –VOUT M1 12 –VOUT M1 +SENSE M1 13 + SENSE M2 –SENSE M1 14 TRIM M1 TRIM M2 15 –SENSE M2 +VOUT M2 16 +VOUT M2 +VOUT M2 17 –VOUT M2 –VOUT M2 18 –VOUT M2 MATING CONNECTOR: 18-PIN HOUSING: MOLEX (39-01-2180) TERMINAL FEM CRIMP 18 – 24AWG: MOLEX (39-00-0039) USE CRIMP TOOL: MOLEX (11-01-0197) The Molex connectors are limited to 9A/pin (27A per output.) M1 Output M2 Output C. MOLEX CONNECTOR - SINGLE OR DUAL OUTPUT SLOT (14-pin Housing - PFC Minis built prior to 1/2001) 7 14 6 13 5 12 4 11 3 10 2 1 9 8 PIN 1 2 3 4 5 6 7 SxJ1 (14-PIN OUTPUT, REMOTE SENSE AND TRIM PIN CONNECTOR) DESCRIPTION PIN DESCRIPTION +SENSE M1 8 –SENSE M1 +OUTPUT M1 9 +OUTPUT M1 –OUTPUT M1 10 –OUTPUT M1 TRIM M1 11 TRIM M2 +OUTPUT M2 12 +OUTPUT M2 –OUTPUT M2 13 –OUTPUT M2 +SENSE M2 14 –SENSE M2 MATING CONNECTOR: 14 PIN HOUSING: MOLEX (39-01-2140) TERMINAL FEM CRIMP 18 – 24AWG: MOLEX (39-00-0039) USE CRIMP TOOL: MOLEX (11-01-0197) UG:115 Page 10 PFC Mini™ Connector Kit (19-130047) Listing (Available for purchase) Item Qty Vendor #1 Part # 1 3 HOUSING 3 POS .100 CTR W/LATCH MOLEX 50-57-9403 10 TERM FEM CRIMP 22-24AWG SEL GOLD MOLEX 16-02-0103 CRIMP TOOL FOR ITEM 2 MOLEX 11-01-0208 2 ** Description 3 1 HOUSING FEMALE D-SUB 09 PIN AMP 205204-4 3 10 TERM MALE CRIMP 22 – 24 AWG TIN AMP 66506-9 1 SCREW LOCK MALE (1 PAIR) AMP 205980-4 CRIMP TOOL FOR ITEM 3 AMP 58448-3 3 ** 4 3 HOUSING 18 POS .165 CTR W/LATCH MOLEX 39-01-2180 5 60 TERM FEM CRIMP 18 – 24AWG SEL GOLD MOLEX 39-00-0039 CRIMP TOOL FOR ITEM 5 MOLEX 11-01-0197 TERM FEM CRIMP 16AWG SEL GOLD MOLEX 45750-3211 CRIMP TOOL FOR ITEM 6 MOLEX 11-01-0199 ** 6 60 ** ** ITEMS FOR REFERENCE ONLY (NOT INCLUDED IN KIT) Interface Connections Chassis Input Power Terminals (MBJ1) Input AC power is applied to terminal block MBJ1 using a pressure screw terminal that accepts a maximum wire size of 14AWG. The insulation should be stripped 0.35 inches and the maximum torque applied to the screws should not exceed 4.4in.lbs. The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N 32-00-58-0, provided in optional connector kit) can be used to prevent fraying. MBJ1-1 (GND) is Earth Ground for safety; MBJ1-2 (L2) and MBJ1-3 (L1) are the other "hot" connections. A fault clearing device, such as a fuse or circuit breaker, with a maximum 15A rating at the power supply input is required for safety agency compliance. It should be sized to handle the start up inrush current of 8.5APK at 115VAC and 17APK at 230VAC. Figure 2 Input power terminal MBJ1 NOTE: SET SCREW MAX TORQUE = 4.4 IN. LBS. 115-230 VAC 10A 47 TO 500 Hz 300VDC --- L1 L2/N DO NOT OPERATE WITHOUT EARTH GND INPUT CONNECTIONS MBJ1-1 EARTH GROUND MSJ1-2 L2-NEUTRAL MBJ1-3 L1 Output Power Connections There are two types of output power terminals available in the PFC Mini. Outputs from full-sized converters are terminated in two 10-32 plated steel bolts. The positive polarity of the output is the right bolt when viewed from the output end. Outputs from half-sized converters terminate in a Molex connector. Note: The Molex connectors are limited to 9A/pin (27A/output). Each power output is isolated, so outputs of positive or negative polarity can be configured through proper selection of the output reference terminal. UG:115 Page 11 In order to minimize parasitic-cable inductance and reduce EMI, the output power cables should be routed in close proximity to one another and large current loops should be avoided. To avoid excessive voltage drop, do not undersize power cables, especially for high-current outputs. Excessive cable inductance coupled with large-capacitive loading can introduce instability in switching power supplies. This problem can be avoided with proper system design. Consult the Vicor Applications Engineering Department for assistance with applications that use long cable lengths and excessive load capacitance. Note: Effective January 2001, PFC Minis using VI-J00 modules on a dualboard (dual output) now require an 18-pin connector (Molex PN# 39-01-2180) vs. a 14-pin (Molex PN# 39-01-2140), making them the same as dualboards with Mini converters. If you already have a 14-pin design in, the change to the 18-pin should not affect your design in. Remove the harness assembly from the 14-pin connector housing and insert the harness connector pins into the 18‑pin connector housing. Contact Field Applications for further information. Figure 3 Power connections for single output Output Output Return SxJ2 Figure 4 Power connections for dual output 14 13 12 11 10 7 6 5 4 3 9 8 2 1 18 17 16 15 9 8 7 6 14 13 12 11 10 5 4 3 2 1 14 PIN DUAL MODULE OUTPUT CONNECTIONS 18 Pin DUAL MINI AND JR. MODULE OUTPUT CONNECTIONS PIN DESCRIPTION PIN DESCRIPTION PIN DESCRIPTION PIN DESCRIPTION SxJ1-1 +SENSE M1 SxJ1-2. +OUTPUT M1 SxJ1-3. –OUTPUT M1 SxJ1-4. TRIM M1 SxJ1-5. +OUTPUT M2 SxJ1-6. –OUTPUT M2 SxJ1-7. +SENSE M2 SxJ1-8. –SENSE M1 SxJ1-9. +OUTPUT M1 SxJ1-10. –OUTPUT M1 SxJ1-11. TRIM M2 SxJ1-12. +OUTPUT M2 SxJ1-13. –OUTPUT M2 SxJ1-14. –SENSE M2 SxJ1-1. SxJ1-2. SxJ1-3. SxJ1-4. SxJ1-5. SxJ1-6. SxJ1-7. SxJ1-8. SxJ1-9. SxJ1-10. SxJ1-11. SxJ1-12. SxJ1-13. SxJ1-14. SxJ1-15. SxJ1-16. SxJ1-17. SxJ1-18. UG:115 +OUTPUT M1 –OUTPUT M1 –OUTPUT M1 +SENSE M1 –SENSE M1 TRIM M2 +OUTPUT M2 +OUTPUT M2 –OUTPUT M2 +OUTPUT M1 +OUTPUT M1 –OUTPUT M1 +SENSE M2 TRIM M1 –SENSE M2 +OUTPUT M2 –OUTPUT M2 –OUTPUT M2 Page 12 +SENSE/ –SENSE (SxJ2/SxJ1) Current PFC Mini™ units are shipped with Autosense installed. If the unit does not have Autosense, sense selection is very important. In units without Autosense, the sense lines for the outputs are shipped from the factory with local sense installed. If remote sense is desired the local-sense jumpers can be removed for individual outputs. If the local-sense jumpers are removed, the sense lines must be connected for remote sense. Leaving the sense lines open will prevent proper output regulation and can result in damage to the unit. When local sense is used, the power supply will regulate the output at the output terminals. The voltage appearing at the load may drop slightly due to voltage drop in the power cables. If it is necessary to compensate for voltage drop along the output power cables, the output can be trimmed up or configured for remote sense. Use stranded twisted pair 20 – 22AWG wire for the remote-sense lines. Remote sense can compensate for a voltage drop of up to 0.5V, or 0.25V on each leg. Installing remote sense requires the local-sense jumpers to be removed. On single output cards, the local-sense jumpers are located behind the sense connector on MBJ1 and J3. To remove the jumpers, make certain the power to the supply is off and pull them off the connectors MBJ1 and J3. On dual output cards, the local-sense jumpers are on either side of the output connector at MBJ1 and J3. The jumpers at MBJ1 are for output #1 and the jumpers at J3 are for output #2. The sense connector for a single output board is a 3-pin connector providing the +SENSE connection on SxJ2-2 and the –SENSE connection on SxJ2-3. The sense connector for a dual output board is an 18-pin connector that also provides the output and trim connections. +SENSE and –SENSE for the first output are located on SxJ1-4 and SxJ1-5, respectively. +SENSE and –SENSE for the second output are located on SxJ1-13 and SxJ1-15, respectively. Figure 5 Removing local-sense jumpers TOP VIEW Dual Output Sense Connections Single Output Sense Connections Remove jumpers for Remove jumpers for Remote Sense on Remote Sense on Output # 1 Output # 2 Connector SxJ1 Local Sense jumpers located behind the Sense Connector. END VIEW 14 Pin Dual Output Sense Connectors Local Sense jumpers are to the left of the output connector for Output # 2. 14 13 12 11 10 7 6 5 4 3 9 8 2 1 18 Pin Dual Output Connectors Local Sense jumpers are to the left of the output connector for Output # 1 Local Sense jumpers are to the left of the output connector for Output # 2 Local Sense jumpers are to the left of the output connector for Output # 1 18 17 16 15 9 8 7 6 14 13 12 11 10 5 4 3 2 1 Single Output Sense Connections Local Sense jumpers located behind the Sense Connector. UG:115 Page 13 Figure 6 Remote sense +OUT +SENSE Load –SENSE –OUT Use 20 – 22AWG Twisted Pair Wires Figure 7 External trim +P +OUT Use 20 – 22AWG Twisted Pair Wires (Remote Sense) R1 SxJ2-2 +SENSE To Error Amplifier + RTH V1 – R2 R5 VREF R3 R8 SxJ2-1 R6 SxJ2-3 –SENSE R7 + Load V2 – R4 –P –OUT Use 20 – 22AWG Twisted Pair Wires Table 1 Module internal reference voltages and Thevenin resistances Output Module VREF RTH VI-200™/VI-J00™ ≥3.3V 2.5V 10.0kΩ VI-200/VI-J00 80% Safety Approvals cURus – UL 60950-1, CSA 60950-1; cTÜVus – EN 60950-1, UL 60950-1, CSA 60950-1 CE Mark – Low Voltage Directive, 73/23/EEC amended by 93/68/EEC Note: certain MI chassis may not carry all safety approvals Maximum Output Power+ (+Not to exceed an input current of 10A) >800W at 115VAC; 1,500W at 230VAC Note: Only PFC Minis™ populated with 12V Maxi modules are limited to 500W max. per slot. With 12V Mini modules, it is limited to 250W. Input Input 85 – 264VAC, 47 – 500Hz; 100 – 380VDC Line/Load Regulation VI-200™/VI-J00™: ±0.2% max, 10% to full load; ±0.5% max, 0 – 10% load Line Regulation Maxi/Mini: ±0.20% max to 0.3% max LL to HL, Full Load Inrush Current 8.5APK at 115VAC; 17APK at 230VAC Ride Through Time 20ms at 1,200W load Conducted EMI VI-200/VI-J00 Ss: Maxi, Mini EN55022 Class B EN55022 Class A (some configurations may meet Class B): Mil-STD 461 will require external filter Power Factor 0.99 at 115VAC; 0.95 at 230VAC Voltage Fluctuations and Flicker EN61000-3-3 ESD Susceptibility EN61000-4-2, Level 3, Performance Criteria A RF Radiated Immunity, 10v/m EN61000-4-3, Performance Criteria A Transient Burst Immunity EN 61000-4-4, Level 3, Performance Criteria B Surge Immunity EN 61000-4-5 Installation Class 3, Performance Criteria B RF Conducted Immunity EN61000-4-6, Limit Class 3 Performance Criteria A Voltage Dips and Interrupts EN61000-4-11 Dielectric Withstand Primary to Chassis GND = 2,121VDC Primary to Secondary = 4,242VDC Secondary to Chassis GND = 750VDC MI Chassis Overvoltage and Transients Compliant to Mil-STD 704 and 1399 Note: See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal output voltage. UG:115 Page 20 Specifications (Cont.) Environmental Storage Temperature –40 to +85°C Operating Temperature Full Power Half Power –20 to +45°C [c] (–40 to +45°C optional with MI chassis) –20 to +65°C (–40 to +65°C optional with MI chass) Specific temperature data on all module configurations can be obtained by contacting Applications Engineering. Shock and Vibration (MI Chassis) Altitude Mil-STD 810 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. 75% maximum load Humidity 0 – 95% non condensing Product Weight 5.5lbs (2,5kg) Dimensions 1.72 x 6.0 x 12.2in [43,6 x 152,4 x 309,9mm] Warranty [d] 2 years limited warranty. See vicorpower.com for complete warranty statement. Output VI-200™/VI-J00™ Modules Parameter Min Typ Max Set-Point Load/Line Regulation Load/Line Regulation 0.5 1 ±0.2 ±0.5 % % % Temperature Regulation 0.01 0.02 %/°C Over rated temperature Long-Term Drift Output Ripple & Noise: ≤10VOUT >10VOUT 100 1.0 mV % VOUT 20MHz bandwidth 20MHz bandwidth 50 – 110 % VOUT ±10% on 10 – 15VOUT Volts Autosense. See Pages 8 & 14 Accuracy [e] Voltage Trim Range VI-200/VI-J00 series slots Units Notes of VNOM 10% to full load No load to 10% load Total Remote Sense Compensation 0.5 OVP Set Point [f] 115 125 135 % VOUT Recycle Power Current Limit 105 115 125 % of IMAX Auto Recovery 130 % Short Circuit Current 20 (105 [g]) Overtemperature Limiting Not available on VI-J00 [c] 45°C is the maximum operating temperature. If one is using a Maxi/Mini module less than 24V output and more than 500W, the maximum operating temperature is 40°C. [d] 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. [e] For special, adjustable voltages and 48V DC outputs, maximum setpoint accuracy is 2% of VNOM. Note: See individual module data sheets for specific module specifications. [f] 131% Nominal for Booster Modules. No OVP for VI-J00 [g] VI-J00 modules only UG:115 Page 21 Specifications (Cont.) Maxi, Mini, Micro Series Modules (Maxi and Mini Modules Only) Parameter Min Typ Max Units Set-Point Load Regulation ±0.5 ±0.1 ±1 % of VNOM % of VNOM Temperature Regulation 0.002 0.005 %/°C Long-Term Drift Output Ripple & Noise: ≤10VOUT >10VOUT 100 1.0 mV % VOUT 20MHz bandwidth 20MHz bandwidth 10 – 110 % VOUT Preload may be required Accuracy [e] Voltage Trim Range Maxi/Mini Slots Total Remote-Sense Compensation 0.5 OVP Set Point 112 Current Limit Overtemperature Limiting Volts 115 100 115 Notes See module design guide for exact specifications –20 to 100°C Autosense. See Pages 8 & 14 135 % VOUT Recycle Power 135 % of IMAX Auto Recovery MMM OTL is non-latching [c] 45°C is the maximum operating temperature. If one is using a Maxi/Mini module less than 24V output and more than 500W, the maximum operating temperature is 40°C. [d] 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. [e] For special, adjustable voltages and 48V DC outputs, maximum setpoint accuracy is 2% of VNOM. Note: See individual module data sheets for specific module specifications. [f] 131% Nominal for Booster Modules. No OVP for VI-J00 [g] VI-J00 modules only UG:115 Page 22 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 5-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 14 CSB interconnect example D* +OUT Power Supply 1 24V@1kW +VOUT +S TRIM Yellow –S –OUT T1 –V1 Brown D* +OUT Power Supply 2 24V@1kW T2 –V2 –S Red CSB02 +S TRIM Power –VOUT White Black –OUT Figure 1. CSB Interconnect Example UG:115 Page 23 Current Share Boards – Optional Feature (Cont.) Requirements: 1. For proper operation, the power supplies being paralleled should be enabled at the same time. 2. –OUT conductors must be of equal length and wire gauge. Separate –OUT conductors must be used from each supply to the load, or the use of a "Y" connection to a common point must be used as shown in Figure 1. Each leg of the "Y" must have a minimum of a few millivolts of drop in order for proper operation. 50 – 100mV of drop will provide from 5 to 1% accuracy. 3. –V1 and –V2 for all box-to-box circuits must be connected directly at the negative output power studs or terminals to achieve accurate current sharing. 4. D* can be added if redundancy is needed. If redundancy is not required, D* can be replaced with direct wire connections. 5. When using D*, the Power input should be connected on the cathode side of the paralleling diodes as shown in Figure 14. 6. Terminate Sense Leads either locally or remotely as shown in Figure 1. 7. For paralleling more than two supplies consult Applications Engineering for assistance. UG:115 Page 24 Current Share Boards – Optional Feature (Cont.) 0.13" [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 Power T1 –V1 T2 –V2 No Connection 0.12" [3.0mm] 0.12" [3.0mm] 0.900" [22.9mm] 1.14" [29.0mm] Figure 15. Mechanical Drawing 24.0" +/– 1.0" Red, 22 AWG P1 Power Yellow, 22 AWG T1 Brown, 22 AWG –V1 White, 22 AWG T2 Black, 22 AWG –V2 Figure 16. 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, Mini, Micro series). 4. Use four non-plated through holes with standoffs for mounting. 5. CSB01 MUST be used for current sharing VI-200™/VI-J00™ series converters (VI-200/J00). 6. CSB02 MUST be used for current sharing Maxi, Mini, Micro series converters (Maxi, Mini and Micros). PLEASE NOTE: THE CSB IS NOT INTENDED FOR HOT-SWAP APPLICATIONS. UG:115 Page 25 Low-Leakage Version (Available upon request) If low leakage is required, Vicor has a PFC Mini™ model variant (must be requested). This model enables the user to meet various additional specifications. The advantage of the low-leakage PFC Mini power supply is in multiple power supply systems that have one AC input. This option will lower the input leakage current for these products to 500μA or less (may vary if Maxi, Mini, Micro series modules are used. Contact Applications Engineering for more details.) An additional external EMI filter is typically required. How Low-Leakage is Obtained Low leakage is obtained with the removal of the "Y" capacitors from within the EMI filter of the PFC Mini. This reduces the leakage current from the AC input to AC ground (chassis) to below 500μA. At the same time, since the "Y" capacitors are a vital component of the EMI filter, without them, the EMI will go up. When this happens, the unit may no longer meet Vicor published specifications for conducted EMI. In order to reduce the EMI to within an acceptable limit, an additional external EMI filter may be required. All safety agency certifications for the PFC Mini remains intact. [h] Contact Applications Engineering for more information. [h] Please note that the PFC Mini (including low leakage version) is NOT UL2601 compliant. Low Output Ripple If output ripple of 10mVP-P or 0.15% (whichever is greater) is required, a PFC Mini with RAM™ modules can be configured if the maximum output power per output does not exceed 100W. If this configuration is required, please contact: apps@vicorpower.com to have it configured. If there are space restrictions, an external RAM™/µRAM™ can also be used. Office Environment Fan A PFC Mini using an office environment fan is available. Please note that the maximum output power for this version is 1,200W. The maximum output power per slot is limited to 500W. Molex Connector Limitation Please note that those PFC Mini configurations that use Molex connectors are limited to 9A/pin (27A per output). This is a Molex connector limitation, NOT a module power limitation. UG:115 Page 26 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 4kW MegaPAC-EL™ (Low Noise) nn PFC MegaPAC™ (High Power) nn PFC MegaPAC™ (Low Noise/High Power) nn PFC MegaPAC-EL™ nn Autoranging MegaPAC™ nn Mini MegaPAC™ nn ConverterPACs™ Others: nn FlatPAC-EN™ nn PFC FrontEnd™ nn MicroPAC™ nn Conduction Cooled MicroPAC™ Rugged COTS versions (MI) are available for the PFC Micro, PFC MicroS, PFC Mini, PFC MegaPAC, Standard MicroPAC and Conduction Cooled MicroPAC. UG:115 Page 27 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 07-130245-01A Rev 1.3 Page 28