DESIGN GUIDE VIPAC - Vicor

1 DESIGN GUIDEVIPAC CONTENTSPRODUCTOVERVIEWFEATURESINPUT/ OUTPUTOPTIONSSPECIFICATIONSTECHNICALOVER VIEWINPUTCONNECTIONSOUTPUTCONNECTIONOPTI ONSCHASSISCONFIGURATIONSMOUNTINGOPTIONSM ECHANICALDRAWINGSMECHANICALINFORMATIONTH ERMALMANAGEMENTGENERALINFORMATIONAPPLICA TION TIPS2 34567 8910 1213 1415 1617 2021222324 Vicor s VIPAC is an integrated power system leveraging thelatest advances in DC-DC converter technology and modularfront-ends. VIPAC combines application specific power processing units (PPU), a choiceof chassis styles and remotelylocated hold up capacitors to provide fast, flexible and highlyreliable power solutions for a wide range of demanding PPU is the core element of the system and may be specified for 115/230 Vac operation. The PPU incorporatesVicor s autoranging FARM modular front-end to provide transient protection, EMI filtering and inrush current limiting.

2 The web-based PowerBench enables designers to configure thePPU with up to three independently regulated outputs havingpower levels from 50 to 500 W and with as much as 900 Wtotal output power. Vicor s Maxi, Mini, Micro Family DC-DCconverters, in industry standard quarter, half and full brickpackages, are used to deliver output voltages from 2 to 48 , the wide trim range of the modules can provideoperating voltages as low as 500 mV. The PPU is comprised of: AC input modular front end Vicor s Maxi, Mini, Micro Family high densityDC-DC converters Coldplate or finned chassis Choice of output termination stylesThe VIPAC is offered in several chassis configurations facilitatingits use in a variety of applications using either conduction, convection or forced convection cooling. The low profile, conduction cooled version may be mounted to an existing cabinet wall, coldplate or heat sink.

3 The " or 1" finned versions, available in longitudinal or transverse configurations,are ideal for use in free or forced convection environments. Theuse of standard chassis footprints allows different input voltageconfigurations of the VIPAC to be used interchangeably dependingon system and market use remotely located capacitors to facilitate packagingand placement options not previously available. The low profilePPU can be placed closer to the load or attached to cabinetwalls while the capacitors may be integrated into the host systemaway from heat sources for improved reliability. System hold up /ride-thru requirements can also be tailored for specificapplications via different value capacitors. The hold upcapacitors may be obtained from Vicor as a prepackaged hold upbox (HUB). VIPAC is a new class of flexible, high density 3AC Input Autoranging 115/230 Vac 50/60 Hz (400 Hz optional) Input115/230 Vac AutorangingI/O Interface Output SequencingBUS-OKOutput Enable / DisableProtective FeaturesAuto RestartInrush Current LimitingEMI FilteringInput Transient ProtectionVicor s Maxi, Mini, Micro FamilyDC-DC ConvertersOutput Voltages 48 Vdc50 500 W / Output(1/4 Brick Modules Shown) Choice of Output Termination(LugMate Shown)Platform OptionsLow Profile " and 1" Optional Finned ConfigurationsPre-assembled and Tested Front EndFARM Filter Autoranging Rectifier Module4 FEATURES Analog User InterfacePower Up / Down controlBUS-OK Partitioned Power ArchitectureMaximizes packaging flexibilityRemote hold-up capacitors (AC input)User-definable hold-up characteristics (AC input)

4 Enhanced reliabilityWide operating temperature range 20 to +95 C chassis C Grade 40 to +95 C chassis T Grade Secondary ControlOutput voltage trimming10 110% Vout+ + +ST +ST Out SSC+S+OutLoadRDTrim DownErrorAmp1k F OutSC+OutLoadRDTrim DownErrorAmp1 k FMini and MaxiMicroTop view, 5 Output Voltage Selection2 V5 V12 V15 V24 V28 V36 V48 VTotalMicro Maximum Output Power (W)*507510015015015015015015015010015020 0300300300300300300300507510015015015015 0150150300507510015015015015015015010015 0200300300300300300300450507510015015015 0150150150 5075100150150150150150150 5075100150150150150150 150 4505075100150150150150150150 OUTPUT OPTIONSMiniMaximum Output Power (W)*100150200250250250250250250250200300 4005005005005005005005001001502002502502 5025025025050010015020025025025025025025 0 Maxi Maximum Output Power (W)*160264400500500500500500500500320528 800900900900900900 9009001602644005005005005005005009001602 64400500500500500500500 VIPACC onfiguration*Model numbers and total output power capability are application tolerances may effect total output power ( 5%) in parallel (//) configurations.

5 See VIPAC configuration tool at: llDualSingleSingle llDualVP-AVP-EVP-BVP-FVP-CVP-DVP-GSingle SinglellDualDual llTriple# Outputs# Outputs# Outputs6 ParameterMinTypMaxUnitNotesDielectric withstand2,121 VdcVdc test recommended due to Y-capsInput to chassis1,500 VrmsClass 1 product. Isolation componentsInput to output3,000 Vrmstested prior to assembly. Do not testfinished product at this temperature chassisC-Grade-2095 CT-Grade-4095 CShock50gGR 6063, NEBS, Zone 4 (designed to meet)Vibration1gGR 6063, NEBS, Zone 4 (designed to meet)Humidity595%Non-condensingSafety approvals cT Vus EN 60950-1,UL 60950-1,CE Marked (LVD)ParameterMinTypMaxUnitNotesOutput voltage set point 1%Vout nomLine regulation line to high line; full loadTemperature regulation COver operating temp. rangeOver temperature shut down 115 CPower sharing accuracy 2 5 %10% to 100% of full loadProgramming range10110%Of nominal output voltage.

6 (For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required)Current limit115% Iout voltage 95% of nominalShort circuit current115% Iout voltage <250 mVSPECIFICATIONSP arameterMinTypMaxUnitNotesOperating input voltage90132 VacAutoranging doubler mode180264 VacAutoranging bridge modeInput undervoltage shut down90 VacNo damageAC line frequency4763 HzC-Grade47440 HzT-GradePower LineInrush current30 Amps264 Vac peak line, cold startInput surge withstandEN61000-4-52 kV 50 s common modePerformance Criteria B1 kV 50 s differential modeHold-up capacitance1,8003,300 FRefer to VCAD calculatorLeakage 264 Vac inputEMIA dditional filter components are required for compliance to EN55022 and FCC conducted emissions Vac Autoranging InputOutput Specifications Generalat 25 C, nominal line and nominal load, per module unless otherwise specifiedEnvironmentalTypeOutputOutputBu sEnable /DisableSequencingOKRemote444 Interface Control Functions(See technical description)See 300 V Maxi, Mini, Micro Family data sheets for detailed module 7 TECHNICAL OVERVIEWO verviewVicor s VIPAC offers a 115 / 230 Vac autoranging front-end section utilizes Vicor s FARM input module to provide EMI filtering, transient protection, inrush current limiting and rectification.

7 The VIPAC has provisions to allow controlling the operation of the individual outputs and providing a BUS OK status indication. Reference the figurebelow for circuit to three individually fused Maxi, Mini, Micro Family DC-DC converters are combined with the front end in anintegratedmechanical assembly providing a high efficiencypower supply delivering up to 900 W of output OperationThe AC autoranging input VIPAC utilizes the FARM modulewhich provides inrush current limiting, transient protection,EMI filtering and rectification. The AC line voltage is appliedvia an agency approved 6 pin connector. A fuse in the L1 lead protects the VIPAC from damage due to internal shorts. At start-up, AC inrush current is limited by a PTC PTC thermistor serves as both an inrush current limiteron power up and a current limiting shut-down device in theevent of an input over voltage condition.

8 The PTC is shuntedout shortly after initial power up by a DC bus voltage sense circuit. The main energy storage capacitors are locatedremotely in the HUB (Hold-up Box) or as customer suppliedhold-up capacitors. The main rectifiers and filter capacitorsact as either a full wave bridge or voltage doubler (dependingon the applied AC voltage) delivering a nominal 300 Vdc toone or more Vicor Maxi, Mini, MicroFamily DC-DC DC-DC converters deliver theselected output voltage and currentlevels, provide output over voltageprotection, output current limiting,voltage regulation, trim capabilityand input to output isolation. At initial power up, the front end is configuredfor 230 Vac operation and the PTC inrushlimiter permits the main storage capacitors tocharge up at a controlled rate toward full operating DC buspotential. If the bus voltage settles below the operatingthreshold, the unit will auto-strap for 115 Vac operation.

9 Thestrapping function is performed by an SCR that configures thefront end as either a full wave bridge or a voltage doubler. Ifthe unit is operating in the 115 Vac mode and a longduration transient is applied to the VIPAC (>150 Vac for 50ms), the unit will auto-strap for 230 Vac operation. Inputpower must be removed for approximately one minute torestore normal operation from 115 Vac. A control circuitholds the DC-DC converter PC pins low, DC outputs off, thePTC shunt inactive and the BUS-OK output in FAIL statusuntil the DC bus potential reaches a minimum PC terminals of all converter modules internal to theVIPAC are FET controlled by a logical replica of the BUS-OKstatus line, and therefore inhibit converter operation atpower up until the DC bus potential has settled to a properoperating level. At this point, the converters are enabled andthe PTC shunt activated.

10 A voltage sensing circuit connectedacross the DC bus performs input over voltage sensing andprotection. In the event of an over voltage condition, anSCR/PTC combination will simultaneously disable the DC-DCconverters and hold down the DC bus. Normal operationwill resume when the input voltage returns withinsteady-state ConverterOutput #1 FARM6 PinConnector+ V BUSS trap- V BUSL1L2/NHUBHold-up Box+PCPR +PCPR +PCPR +SC DC-DC ConverterOutput #2+SC Line FilterAC-DC Power RectificationInput AutorangingInrush Current LimitingST+_Control Circuit Output Sequencing BUS-OKControl 1 Control 2 Control 3DC-DC ConverterOutput #3+SC Terminals onInput Connector J2+_STLocal ControlI/OInterfaceOutput115/230 VacInputJ2J3 GNDVIPAC BLOCK DIAGRAM - AC INPUT8 BUS-OKAn internal replica of BUS-OK is wired to the PC pin of allinternal driver modules. The modules will be disabled (noDC output) during initial power up of the VIPAC until theinternal DC input bus voltage to the DC-DC converters issufficient to support fully-loaded operation.