VIPAC Data Sheet Design Guide · Overview Vicor’s VIPAC offers the choice of 115/230Vac...
Transcript of VIPAC Data Sheet Design Guide · Overview Vicor’s VIPAC offers the choice of 115/230Vac...
VIPAC™
POWER SYSTEMS
DESIGN GUIDE
2nd Generation Components
CONTENTS
PRODUCT OVERVIEW
FEATURES
INPUT / OUTPUT OPTIONS
SPECIFICATIONS
TECHNICAL OVERVIEW
INPUT CONNECTIONS
OUTPUT CONNECTION OPTIONS
CHASSIS CONFIGURATIONS
MOUNTING OPTIONS
MECHANICAL DRAWINGS
MECHANICAL INFORMATION
THERMAL MANAGEMENT
GENERAL INFORMATION
APPLICATION TIPS
NOTES
TECHNICAL SUPPORT CONTACTS
2-3
4
5
6-7
8-11
12
13-15
16-17
18-19
20-21
22
23
24
25
26
27
PRODUCT OVERVIEW
2
PPU
HUB
Vicor’s VIPAC™ is a new type of integrated power system leveraging the
latest advances in DC-DC converter technology and modular front ends.
VIPAC combines application specific power processing units (PPU),
a choice of chassis styles and, in AC input versions, remotely located
hold-up capacitors to provide fast, flexible and highly reliable power
solutions for a wide range of demanding applications.
The PPU is the core element of the system and may be specified for
operation from 48Vdc or 115/230Vac. The PPU incorporates Vicor’s FIAM
(for DC input) or autoranging FARM (for AC input) modular front end to
provide transient protection, EMI filtering and inrush current limiting. The
WEB based VIPAC Design Center enables designers to configure the PPU
with up to three independently regulated outputs having power levels from
50 to 500W and with as much as 900W total output power. Vicor’s 2nd
Generation DC-DC converters, in industry standard quarter, half and full
brick packages, are used to deliver output voltages from 2 to 48Vdc.
Additionally, the wide trim range of the modules can provide operating
voltages as low as 500mV.
The PPU is comprised of:
• AC or DC input modular front end
• Vicor’s 2nd Generation, high density DC-DC converters
• Interface board
• Cold plate or finned chassis
• Intelligent communications port
• Choice of 3 output termination styles
The VIPAC is offered in several chassis configurations facilitating its 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.
The 0.5" or 1" finned versions, available in longitudinal or transverse
configurations, are ideal for use in free or forced convection environments.
The use of standard chassis footprints allows different input voltage
configurations of the VIPAC to be used interchangeably depending on
system and market requirements.
AC Input VIPACs use remotely located capacitors to facilitate packaging and
placement options not previously available. The low profile PPU can be
placed closer to the load or attached to cabinet walls while the capacitors
may be integrated into the host system away from heat sources for improved
reliability. System hold-up / ride-thru requirements can also be tailored for
specific applications via different value capacitors. The hold-up capacitors
may be obtained from Vicor as a prepackaged hold-up box (HUB).
VIPAC is a new class of flexible, high density power solutions.
3
DC Input• 36-75Vdc
AC Input Autoranging• 115/230Vac• 50/60Hz (400Hz optional)
Pre-assembled and Tested Front EndsFIAM – Filter Input Attenuator ModuleFARM – Filter Autoranging Rectifier
Module
Platform OptionsLow Profile Coldplate0.5" and 1" Optional Finned Configurations
Choice of Output Termination(CableMate Shown)
Vicor’s 2nd GenerationDC-DC Converters
Output Voltages 0.5 – 48Vdc50 – 500W / Output
(1/4 Brick Modules Shown)
RS-232 Style MicroprocessorControlled Communications Port
Output Voltage SequencingBUS-OK /Bus Voltage Monitor
Output Enable / Disable
Input Options115/230Vac Autoranging48Vdc
Protective FeaturesAuto Restart
Inrush Current LimitingEMI Filtering
Input Transient Protection
Rugged Interconnect BoardSelectable for Single, Multipleor Parallel Outputs
v i c o r p o w e r . c o m / v c a d
FEATURES
4
• Microprocessor Based Intelligent Interface
Selectable for digital or RS-232 style
Power Up/Down control
Selectable output sequencing for Turn-on,
Turn-off, up to 2.5 sec. delay
BUS-OK
Bus voltage readback
Output status
Serial number readback
• Partioned Power Architecture
Maximizes packaging flexibility
Remote hold-up capacitors (AC input)
User definable hold-up characteristics (AC input)
Enhanced reliability
Wide operating temperature range
–20˚ to +65˚C ambient C-Grade
–40˚ to +65˚C ambient T-Grade
+95˚C chassis
• Secondary Control
Output voltage trimming
10 - 110% Vout
+
–
+
–
+
ST
–
+ST
–
–Out
–S
SC
+S
+Out
LoadRD Trim DownError
Amp
1kΩ
1.23V
0.033µF
–Out
SC
+Out
LoadRD Trim Down
ErrorAmp
1kΩ
1.23V
0.033µF
Mini and Maxi
Micro
Top view, HUB
Output Voltage Selection
2V 3.3V 5V 12V 15V 24V 28V 48V Total
Micro Maximum Output Power (W)*
50 75 100 150 150 150 150 150 150
100 150 200 300 300 300 300 300 300
50 75 100 150 150 150 150 150 30050 75 100 150 150 150 150 150
100 150 200 300 300 300 300 300 45050 75 100 150 150 150 150 150
50 75 100 150 150 150 150 150 50 75 100 150 150 150 150 150 45050 75 100 150 150 150 150 150
INPUT / OUTPUT OPTIONS
5
Mini Maximum Output Power (W)*
100 150 200 250 250 250 250 250 250
200 300 400 500 500 500 500 500 500
100 150 200 250 250 250 250 250 500100 150 200 250 250 250 250 250
Maxi Maximum Output Power (W)*
160 264 400 500 500 500 500 500 500
320 528 800 900 900 900 900 900 900
160 264 400 500 500 500 500 500 900160 264 400 500 500 500 500 500
VIPACConfiguration
*Model numbers and total output power capability are application specific. See VIPAC configuration tool at: vicorpower.com/vcad
Single
Single ll
Dual
Single
Single ll
Dual
VP-A
VP-E
VP-B
VP-F
VP-C
VP-D
VP-G
Single
Single ll
Dual
Dual ll
Triple
# Outputs
v i c o r p o w e r . c o m / v c a d
Parameter Min Typ Max Unit NotesOperating Input Voltage 36 48 75 Vdc ContinuousTurn on 40 VdcInrush Current 5.0 A pkTransient Immunity
Telcordia GR-499-CORE, Section 13-2 200 Vdc 1µsec durationETS 300 386-1 Class 2 (1994) 200 Vdc 5.0µsec rise time, 50µsec durationsurge
250 Vdc 1-100nsec burstEMI Additional filter components may be
required for compliance to EN55022 - BReverse Polarity Protection Internally fused
Parameter Min Typ Max Unit NotesDielectric Withstand
Input to Chassis 1,500/2,121 Vrms/VdcInput to Output 3,000/4,242 Vrms/VdcOutput to Chassis 500/707 Vrms/Vdc Dependent upon output termination style
Operating Temperature - AmbientC - Grade -20 65 °C Max. chassis temperature, 95°CT - Grade -40 65 °C
Shock 50 g GR 6063, NEBS, Zone 4Vibration 1 g GR 6063, NEBS, Zone 4Humidity 5 95 % Non-condensingSafety Approvals Pending
UL 1950, CSA 22.2 No. 950,TÜV, VDE, EN60950, CE Marked
Parameter Min Typ Max Unit NotesOutput Voltage Setpoint ±1 % Vout nomLine Regulation ±0.02 ±0.2 % Low line to high line; full loadTemperature Regulation ±0.002 ±0.005 %/˚C Over operating temp. rangeOver Temperature Shutdown 115 ˚CPower Sharing Accuracy ±2 ±5 % 10% to 100% of full loadProgramming Range 10 110 % Of nominal output voltage.
(For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required)
Current Limit 115 % Iout max. Output voltage 95% of nominalShort Circuit Current 115 % Iout max. Output voltage <250mV
SPECIFICATIONS
6
Parameter Min Typ Max Unit NotesOperating Input Voltage 90 132 Vac Autoranging doubler mode
180 264 Vac Autoranging bridge modeInput Undervoltage Shutdown 90 Vac No damageAC Line Frequency 47 63 Hz C - Grade
47 440 Hz T - GradePower Factor 0.60 Nominal LineInrush Current 60 Amps 264Vac peak line, cold startInput Surge Withstand EN61000-4-5 2kV–50 µs common mode
1kV–50 µs differential moduleHold-up Capacitance 1,800* 3,300 µF *Refer to VCAD calculatorLeakage Current 2 mA at 264Vac inputEMI Additional filter components may be
required for compliance to EN55022 - B
115/230Vac Autoranging Input
48Vdc Input
Output Specifications - General at 25°C, nominal line and nominal load, per module unless otherwise specified
Environmental
Micro
Parameter 1.8V1
2V 2.5V2
3.3V 5V 12V 15V 24V 28V 48V Unit Notes
Efficiency (typ) 71 71 75 77 81 85 86 87 87 88 %
Ripple & Noise, p-p (typ) 100 100 100 100 100 170 120 150 150 60 mV 20MHz BW
Output Power (max) 45 50 57 75 100 150 150 150 150 150 Watts 95˚C Chassis
Output OVP Setpoint (nom) 2.8 2.8 4.3 4.3 6.3 14.3 17.8 28.1 32.7 55.7 Volts Recycle input voltage
to restart (1 min. off)
Dissipation, Standby (typ) 3 3 3 3 4 4 5 4 4 3 Watts No load
Load Regulation (max) 0.5 0.5 0.4 0.4 0.2 0.2 0.2 0.2 0.3 0.2 ±%Vout No Load to full load
Mini
Parameter 1.8V1
2V 2.5V2
3.3V 5V 12V 15V 24V 28V 48V Unit Notes
Efficiency (typ) 71 72 75 78 82 86 87 88 88 89 %
Ripple & Noise, p-p (typ) 100 100 100 100 80 160 145 120 100 80 mV 20MHz BW
Output Power (max) 90 100 114 150 200 250 250 250 250 250 Watts 95˚C Chassis
Output OVP Setpoint (nom) 2.8 2.8 4.3 4.3 6.3 14.3 17.8 28.1 32.7 55.7 Volts Recycle input voltage
to restart (1 min. off)
Dissipation, Standby (typ) 4 4 4 4 4 4 5 5 5 4 Watts No load
Load Regulation (max) 0.3 0.3 0.3 0.3 0.2 0.2 0.2 0.3 0.3 0.3 ±%Vout No Load to full load
Maxi
Parameter 1.8V1
2V 2.5V2
3.3V 5V 12V 15V 24V 28V 48V Unit Notes
Efficiency (typ) 73 74 76 80 83 85 87 88 89 90 %
Ripple & Noise, p-p (typ) 75 75 75 65 60 110 80 75 60 50 mV 20MHz BW
Output Power (max) 144 160 200 264 400 500 500 500 500 500 Watts 95˚C Chassis
Output OVP Setpoint (nom) 2.8 2.8 4.3 4.3 6.3 14.3 17.8 28.1 32.7 55.7 Volts Recycle input voltage
to restart (1 min. off)
Dissipation, Standby (typ) 5 5 6 6 7 7 7 6 7 8 Watts No load
Load Regulation (max) 0.3 0.3 0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.2 ±%Vout No Load to full load
7
Output Specifications - Voltage Specific at 25°C, nominal line and nominal load, per module unless otherwise specified.
1 Nominal 2V output trimmed to 1.8V by adding external 9,000 ohm resister from the SC Pin to -S (-Out for Micros)2 Nominal 3.3V output trimmed to 2.5V by adding external 3,125 ohm resister from the SC Pin to -S (-Out for Micros)
*See page 9 for detailed information
Type Master Output Output Output Bus Bus VIPAC EmergencyEnable Enable/Disable Sequencing Status OK Voltage S/N Off
Local Remote
Interface Control Functions
v i c o r p o w e r . c o m / v c a d
*RS 232 Style
TECHNICAL OVERVIEW
8
OverviewVicor’s VIPAC offers the choice of 115/230Vac autoranging or48Vdc input. The front end section utilizes Vicor’s FARM orFIAM input module to provide EMI filtering, transient protection,inrush current limiting and rectification as appropriate. The frontend also contains input connectors, fusing and control circuitryto which the user can interface with either an RS-232 stylecommunication bus or discrete circuitry depending upon thedesired mode of operation.
Up to three Vicor 2nd Generation DC-DC converter modulesare combined with the front end in an integrated mechanicalassembly providing a high efficiency power supply deliveringup to 900W of output power.
Circuit Operation – DC Input VersionThe DC input version of the VIPAC utilizes the 48Vin FIAMmodule which provides inrush current limiting, transient protection and EMI filtering. The DC voltage is applied via anagency approved 3-pin connector; a fuse in the the “+” leadprotects the VIPAC from damagedue to internal shorts. At start up,inrush current is limited by a FET.This FET serves as both an inrushcurrent limiter at power up and avoltage limiting device in the eventof an input transient over voltagecondition. The FET, driven by a DCbus voltage sense circuit, is broughtto a low impedance after initialpower up.
The 48Vdc is applied to one or moreVicor 2nd Generation DC-DC converters which deliver the selectedoutput voltage and current levels.TheDC-DC converters provide outputover voltage protection, output current limiting, voltage regulationtrim capability and input to outputisolation.
Circuit Operation – AC InputVersionThe AC autoranging input version ofthe VIPAC utilizes the FARM modulewhich provides inrush current limiting, transient protection, EMI filtering and rectification.
DC-DC ConverterOutput #1
FIAM
+DC
-DC
+PC
PR
–
+PC
PR
–
+PC
PR
–
+
SC
–
DC-DC ConverterOutput #2
+
SC
–
Line FilterTransient Protection
Inrush Current LimitingReverse Polarity Protection
Logic Control
– Master Disable (Local mode)– Output Sequencing– Module Status– BUS-OK
Control 1
Control 2
Control 3 DC-DC ConverterOutput #3
+
SC
–
+
_
RemoteRS232
Local Control
ORUserInterface
Output
36-75VdcInput
VIPAC BLOCK DIAGRAM - DC INPUT
J1
J3
GND
DC-DC ConverterOutput #1
FARM
6 PinConnector
+ V BUS
Strap
- V BUS
L1
L2/N
HUBHold-up Box
+PC
PR
–
+PC
PR
–
+PC
PR
–
+
SC
–
DC-DC ConverterOutput #2
+
SC
–
Line FilterAC-DC Power Rectification
Input AutoRangingInrush Current Limiting
ST + _
Logic Control
– Master Disable (Local mode)– Output Sequencing– Module Status– BUS-OK
Control 1
Control 2
Control 3 DC-DC ConverterOutput #3
+
SC
–
Terminals onInput Connector J2
+
_
ST
RemoteRS232
Local Control
ORUserInterface
Output
115/230VacInput
J2
J3
GND
VIPAC BLOCK DIAGRAM - AC INPUT
The AC line voltage is applied via an agency approved 6 pin connector (see page 12). A fuse in the “L1” lead protects theVIPAC from damage due to internal shorts.
At start-up, AC inrush current is limited by a PTC thermistor. The PTC thermistor serves as both an inrush current limiter on power up and a current limiting shut-down device in the event of an input over voltage condition.
The PTC is shunted out shortly after initial power up by a DC busvoltage sense circuit. The main energy storage capacitors arelocated remotely in the HUB (Hold-up Box) or as customer supplied hold-up capacitors. The main rectifiers and filter capacitorsact as either a full wave bridge or voltage doubler (depending onthe applied AC voltage) delivering a nominal 300Vdc to one ormore Vicor 2nd Generation DC-DC converters.
The DC-DC converters deliver the selected output voltageand current levels, provide output over voltage protection,output current limiting, voltage regulation, trim capabilityand input to output isolation.
At initial power up, the front end is configured for 230Vac operation and the PTC inrush limiter permits the main storage capacitors to charge up at a controlled rate towardfull operating DC bus potential. If the bus voltage settlesbelow the operating threshold, the unit will auto-strap for115Vac operation.
The strapping function is performed by an SCR that configures the front end as either a full wave bridge or a voltage doubler. If the unit is operating in the 115Vac modeand a long duration transient is applied to the VIPAC(>150Vac for 50ms), the unit will autostrap for 230Vacoperation. Input power must be removed for approximatelyone minute to restore normal operation from 115Vac.
A control circuit holds the DC-DC converter PC pins low,DC outputs off, the PTC shunt inactive and the BUS-OKoutput in FAIL status until the DC bus potential reaches aminimum threshold. The PC terminals of all convertermodules internal to theVIPAC are FET controlled by a logical replica of the BUS-OK status line, and thereforeinhibit converter operation at power up until the DC buspotential has settled to a proper operating level. At this point,the converters are enabled and the PTC shunt activated.
A voltage sensing circuit connected across the DC bus performs input over voltage sensing and protection. In theevent of an over voltage condition, an SCR/PTC combinationwill simultaneously disable the DC-DC converters and holddown the DC bus. Normal operation will resume when theinput voltage returns within steady-state limits.
VIPAC RS-232 Style InterfaceThe VIPAC incorporates a microprocessor for communicatingstatus and allowing user control. Operation in this moderequires the removal of a jumper located on the front endPCB. The jumper is identified on the “Input Connections”page 12 of this guide.
Communication is accomplished via a microcontroller witha Universal Asychronous Receive/Transmit (UART) and two optocouplers to provide receive and transmit functions. AnRS-232 style interface requires the addition of an interfacecircuit, such as a Maxim MAX203, a transistor, two resis-tors and a voltage source.This interface circuit schematic is shown in Fig 1. Itemsshown to the left of connector J3 are internal to the VIPAC.A suitable Terminal Emulator must be used to communicatewith this circuit. A free emulator can be downloaded frommany sites such as:
http://download.cnet.com/downloads/0-10061-100-890547.html?tag=st.dl.10001_103_1.lst.td_890547
Communications ProtocolThe protocol is an ASCII character stream that will be sentback and forth between the module and the user. The VIPAC will be considered a slave in that it will onlyrespond to commands and requests and will not initiateconversations. Communications are half-duplex in thatonly the VIPAC receiver or transmitter may be active at onetime. The unit will reply to all commands or requests witha defined response followed by a carriage return and linefeed character pair (CR/LF). The user must wait for the replyfrom the VIPAC before issuing the next command or request.The data bytes will have a format of 1 start bit, 8 data bits, 1 stop bit and no parity at 9600 Baud.
The VIPAC also has the option of being locally controlledfrom a single digital line. This option is jumper selectableand will disable the communications. The VIPAC receiverbecomes the digital input if the jumper is left installed onthe Front End Board. A more detailed description of thisoperational mode can be found later in this document.
—Master Disable (Local mode)—Output Sequencing
—Module Status—BUS-OK
RemoteRS232
Control 1
Control 2
Control 3
OR
Local Control
9
1
2
3
6
5
4
SFH636
U4
1
2
3
6
5
4
SFH636U5
1
2
4
3
U3
MPS2222
1.6k
10k
GNDGND
GND
J3
7
6
1
5
4
3
2
SFH618A
MAX203
20
1
19
18
17
16
10
15
1196
7 Rx
Tx
GND
12
+5V
+5V
Typical Interface Circuitry
Logic Control
v i c o r p o w e r . c o m / v c a d
Fig 1
TECHNICAL OVERVIEW
10
Commands, Status Requests and Module RepliesAll commands and requests will have a reply. The reply will beone of the following character strings followed by a CR/LF character pair.
“OK”– Issued when a command has been received and actedupon and the command has no return data associated with it.“Inv Command”– Issued when an unrecognized command hasbeen received or a command cannot be executed at this time.“Inv Range”– Issued when a command argument is not withina valid range.
The following is the list of commands and their definitions.All commands must be followed with a CR/LF character pair.
PUP – Power UpThis command starts the automatic turn on timed sequence for the modules. If a Power Down sequence is active at the time thiscommand is received, a reply of “Inv Command” is returned. The Bus Voltage must be within range for the type of module,AC or DC, for this command to take effect or the reply of “InvCommand” is returned; otherwise “OK” is returned.
PDN – Power DownThis command starts the automatic turn off timed sequence forthe modules. This command can be given at any time and willcancel any uncompleted automatic power up sequences. “OK”is returned.
EMO – Emergency OffThis command turns all modules off. If either a Power Up orPower Down sequence is active at the time, it will be terminatedimmediately. A response of “OK” is returned.
TON1, TON2, TON3 – Turn On commands formodules 1, 2 or 3.These commands turn on the module identified by the trailingdigit. If an automatic sequence is in effect at the time this command is received, a reply of “Inv Command” is returned.The Bus Voltage must be within range for the type of module,AC or DC, for this command to take effect or the reply of “Inv Command” is returned; otherwise “OK” is returned.
TOFF1, TOFF2, TOFF3 – Turn Off commands for modules 1, 2 or 3.These commands turn off the module identified by the trailingdigit. If an automatic sequence is in effect at the time this command is received, a reply of “Inv Command” is returned;otherwise “OK” is returned.
SDON1, SDON2, SDON3 – Set Delay On Time formodules 1, 2 or 3.These commands set the associated time delays for the DC-DCconverters to be activated via “PC” pin release. There is anadditional delay of up to 7ms inherent in the DC-DC converters.These commands are entered with a trailing argument. The validrange of the argument is from 1 to 255 and is in 10 millisecondincrements. The effective range of delay then becomes 10 to2550 milliseconds or 0.01 to 2.55 seconds. Out of range arguments are replied to with an “Inv Range” message; otherwise“OK” is returned. The delay times are effective and run concurrentfrom either power up of the unit or from receipt of the Power Upcommand. If these commands are entered without an argumentthen the unit will report the present settings of these variables.
SDOFF1, SDOFF2, SDOFF3 – Set Delay Off Timefor modules 1, 2 or 3. These commands set the associated time delays for the DC-DCconverters to be deactivated via “PC”pin release. These commandsare entered with a trailing argument. The valid range of theargument is from 1 to 255 and is in 10 millisecond increments.The effective range of delay then becomes 10 to 2550 milliseconds or 0.01 to 2.55 seconds. Out of range argumentsare replied to with an “Inv Range” message; otherwise “OK” is returned.
The delay times are effective and run concurrent from either receipt of the Power Down command or from an error conditionwith the unit. If these commands are entered without an argumentthen the unit will report the present settings of these variables.
11
BV – Bus Voltage ReadbackThis command returns the current Bus Voltage reading.
MS – Module StatusThis command returns the module status as shown.
SN – Serial NumberThis command returns the serial number (as set by factory).
VIPAC Digital InterfaceThe VIPAC provides the user with choices with respect tohow the unit is operated. It can be remotely operated andqueried via an RS-232 style interface as described above orit can be controlled locally by applying the appropriate“digital” signals to the device. Disabling the remote controlis accomplished by leaving the jumper located on the frontend board installed.
BUS-OKAn internal replica of BUS-OK is wired to the PC pin of allinternal DC-DC converter modules. The modules will bedisabled (no DC output) during initial power up of theVIPACuntil the internal DC input bus voltage to the DC-DC converters is sufficient to support full load operation. The BUS-OK status output reflects the status of this inhibit function. This same logic circuit will shut down the converters when the internal DC bus voltage is insufficientto support proper operation.
This shutdown will occur during normal power down, linedropouts exceeding the hold-up time, or internal faultscausing the internal DC bus voltage at the input of the converters to collapse. The BUS-OK output provides theuser with an optically isolated status indication of the internal DC bus. This output, in AC powered systemapplications, can provide power supply status, switch inbackup (standby) sources or initiate “power down”sequences to save volatile memory contents in the event ofa power loss. The time from BUS-OK deassertion to outputshut down is dependent upon the value of hold-up capacitorsused. The VIPAC on-line design tool contains a hold-upcapacitor calculator which provides appropriate values.
MOD-DIS+, MOD-DIS–The MOD-DIS input is an optically coupled input and allowsfor remote disabling of the output(s) of the VIPAC. Applyingcurrent to the MOD-DIS+, MOD-DIS– input disables thesupply. The minimum input current for disabling the suppliesis 3mA. The maximum allowable current is 20mA.
Electrical ConnectionsStatus output pair BUS-OK+, BUS-OK– are the collector (+)and emitter (–) of an NPN optoisolator output transistor. In atypical application, the collector terminal BUS-OK+ of theoptocoupler can be connected via current limiting resistors toa source no greater than 70Vdc. These resistors should limitthe maximum current to the optocoupler output transistors to1.5mA. The emitter terminal BUS-OK– is connected to thereturn of the external source. The status OK condition will setthe optocoupler output transistors in saturation and are capable of sinking up to 1.5mA with a Vce saturation voltageof 0.4V. Users should be cautioned that although the outputof the VIPAC can be used as the pull-up source, shortly afterBUS-OK changes from OK (saturated) to NOT OK (high Z),the pull-up voltage will be shut down. If the pull-up source isone of the VIPACs outputs, it is advisable to provide a capacitive reservoir in order to maintain the pull-up potentialafter loss of DC current output. Use edge sensing logic to detectassertion of logic outputs, or a separate source of bias supplyvoltage (i.e., backup batteries) to provide a safe pull-up voltagesource regardless of the line status.
v i c o r p o w e r . c o m / v c a d
1.5mAmax.
V
+r
BUS-OK
+
–
20mA max.
Disable
MOD-DIS
V
+
+
–
VIPAC
J3
3
2
7
6
MOD-DIS InputApply a current of 3-20mAto disable output.
BUS-OK - Status OutputTransistor on when OK.
Vce sat. = < 0.4V @ 1.5mAmaximum external pull-up is 70Vdc.
BUS-OK signal is isolated
Description Returned Value
Status NOT OK 00Status OK (no outputs on) 10Status OK (output 1 on) 11Status OK (output 2 on) 12Status OK (output 3 on) 14Status OK (output 1 and 2 on) 13Status OK (output 1 and 3 on) 15Status OK (output 2 and 3 on) 16Status OK (output 1, 2 and 3 on) 17
Conn. Pin# Funct. Mating Conn.
J1 1 GND P/N 21394 2 – Vin 3 + Vin
INPUT CONNECTIONS
12
48Vdc Input
48Vdc Input
AC Input/V Bus
I/O Interface*
115/230Vac Autoranging
Conn. Pin# Funct. Mating Conn.
J2 1 V Bus+ P/N 224992 Strap 3 V Bus–4 L2/N5 L16 GND
Conn. Pin# Funct. Mating Conn.
J3 1 +5V P/N 229882 GND/MOD-DIS- 3 RX/MOD-DIS+4 GND5 TX6 GND/BUS-OK-7 Status/BUS-OK+
J2
J3
123
123456
J1
J3
I/O InterfaceRemovable JumperIN= Local Control
OUT= Remote Control
I/O InterfaceRemovable JumperIN= Local Control
OUT= Remote Control
*See detailed description on Pg 10-13
L2/N L1 GND
P/N 21393
P/N 22988
7
1
P/N 22499
HUB 2200-s2700-s3300-s
HUB 820-s1200-s1800-s
P/N 21394
GND –Vin +Vin
P/N 22988
7
1
V Bus+StrapV Bus-
P/N 21394
Maximum cable length betweenthe HUB and VIPAC ≤ 3'
13
OUTPUT CONNECTION OPTIONS
1
5
1
5
Micro LugMate
Ring LugsLugMate (Factory Installed Option)
#4-40 Torque 4 in. lbs.
J4
1
5
1
5
Mini/Maxi LugMate
#10-32 Torque 16 in. lbs.
*Removable jumper is factory installed for local sensing.See Pg 25 for details
1
3
1
3
1
3
J4 P/N 16385
SolderPin # Pad Function
1 – Vout
Rd Trim Down
SC Secondary Control
Ru Trim Up
3 + Vout
Discrete Output Configurations
Pin # Conn. Function Mating Conn.
1 – Vout
J4-1 – Vout
J4-2 – Sense
J4-3 Secondary Control P/N 16385
J4-4 + Sense
J4-5 + Vout
5 + Vout
*RemovableJumper
*RemovableJumper
Micro LugMate - with Rd/Ru trim resistor solder pads.(Design calculator for trim resistors located at vicr.com)
RuSC
Rd
1
3
Pin # Conn. Function Mating Conn.
1 – Vout
J4-1 – Vout
J4-2 – Sense
J4-3 Secondary Control P/N 16385
J4-4 + Sense
J4-5 + Vout
5 + Vout
OUTPUT CONNECTION OPTIONS
14
1
5
1
5
Micro LugMate
Ring LugsLugMate (Factory Installed Option)
#4-40 Torque 4 in. lbs.
J4
1
5
1
5
Mini/Maxi LugMate
#10-32 Torque 16 in. lbs.
*Removable jumper is factory installed for local sensing.See Pg 25 for details
1
3
1
3
1
3
SolderPin # Pad Function
1 – Vout
Rd Trim Down
SC Secondary Control
Ru Trim Up
3 + Vout
J4P/N 16385
Parallel Output Configurations Shown with the output of two modules connected in parallel using BUS BARS.
v i c o r p o w e r . c o m / v c a d
*RemovableJumper
*RemovableJumper
RuSC
Rd
Micro LugMate - with Rd/Ru trim resistor solder pads.(Design calculator for trim resistors located at vicr.com)
1
3
Pin # Function
1 – Vout
2 Secondary Control
3 + Vout
Pin# Function
1 – Vout
2 – Sense 3 Secondary Control4 + Sense
5 + Vout
Micro
Mini/Maxi
CableMatePins*
OUTPUT CONNECTION OPTIONS
15
1
234
5
1
234
5
123
123
123
*Use of CableMate requires compatible module pins, specified with VCAD Design Tool.
v i c o r p o w e r . c o m / v c a d
CHASSIS CONFIGURATIONS
16
VP-G VP-E
VP-B
VP-D
VP-A
2 MINI 4.96" x 6.8" (126,0 x 172,7mm) Single or Dual Output Up to 500W Up to 100A
3 MICRO 4.96" x 6.8" (126,0 x 172,7mm) Dual or Triple Output Up to 450W Up to 75A
2 MICRO 3.15" x 6.8" (80,0 x 172,7mm) Single or Dual Output Up to 300W Up to 50A
1 MICRO 3.15" x 6.8" (80,0 x 172,7mm) Single Output Up to 150W Up to 25A
1 MINI 3.15" x 6.8" (80,0 x 172,7mm) Single Output Up to 250W
17
VP-F
Cold Plate
Optional 0.5" Fin
Optional 1" FinVP-C
2 MAXI 4.96" x 9.15" (126,0 x 232,4mm) Single or Dual Output Up to 900W Up to 160A
1 MAXI 3.15" x 9.15" (80,0 x 232,4mm) Single Output Up to 500W Up to 80A
TransverseLongitudinal
Finned Chassis Configurations
v i c o r p o w e r . c o m / v c a d
MOUNTING OPTIONS
VIPAC with integral finned heat sink thru-hole mounted
Thru-hole Mounting
VIPAC with external user supplied heat sink
VIPAC with integralfinned heat sinkthru-holemounted
External usersupplied heat sink
Thermalcompoundboth sides
Surface Mounting
18
VIPAC with integralfinned heat sink (down)
VIPAC with integralfinned heat sink (up)
19
Coldplate VIPAC
Coldplate VIPAC mountedto custom thermal interface
For proper clearance use:
Long standoff (P/N 23709) formounting 1" heat sink fins down.
Short standoff (P/N 23710) formounting 0.5" heat sink fins downor either heat sink fins up.
Thermal compound
v i c o r p o w e r . c o m / v c a d
2.28057,91 4.560
115,82
0.200 5,08
6.000152,40
6.80172,7
2.68068,07
0.6316,0 0.03
0,8
4.96126,00.08
2,0
MECHANICAL DRAWINGS
20
4.560115,82
3.04077,22
1.52038,61
0.200 5,08
6.000152,40
6.80172,7
2.68068,07
0.6316,0 0.03
0,8
4.96126,00.08
2,0
6.000152,40
6.80172,7
2.82871,83
0.161 4,09
3.1580,00.048
1,22
2.68068,07
0.6316,0 0.03
0,8
2.82871,83
0.161 4,09
3.1580,00.048
1,22
6.80172,7
6.000152,40
2.68068,07
0.6316,0 0.03
0,8
1.41435,91
VP-A VP-B
VP-DVP-G
Note 1: (6 locations)Coldplate versions includeclearance holes for 8-32 90˚CS to θ 0.30
Finned versions includethreaded holes for 8-32Torque #8-32 to 12 in. lbs
Note 2: (2 locations)Mounting holes indicated notavailable on Finned versions
Note 2: (2 locations)
Note 2: (1 location)
Note 1:(8 locations)
Note 1:(7 locations)
Note 1:(7 locations)
inmm
Note 3: Use of suitable thermal interface materialrequired on coldplate version.
Note 4: Max. chassis temp. 95°C
9.15232,4
8.350212,09
4.560115,82
0.200 5,08
2.68068,07
0.6316,0 0.03
0,8
4.96126,00.08
2,0
2.28057,91
8.350212,09
9.15232,4
2.82871,83
0.161 4,09
3.1580,00.048
1,22
2.68068,07
0.6316,0 0.03
0,8
2.82871,83
0.161 4,09
3.1580,00.048
1,22
6.80172,7
6.000152,40
2.68068,07
0.6316,0 0.03
0,8
21
VP-CVP-F
VP-E
1" Fin Option
0.8120,57 0.50
12,70
1.0025,40
1.3133,27
0.328,13
0.08 2,0
0.220 5,59
4.32109,73
0.7519,1
0.5614,2
v i c o r p o w e r . c o m / v c a d
0.5" Fin Option
Coldplate
Note 2: (1 location)
Note 1:(6 locations)
Note 1:(6 locations)
Note 1:(7 locations)
3.45
1.55
87,63
39,37
MECHANICAL INFORMATION
22
VIPAC Product Weight
Chassis Configuration
VIPAC Chassis Cold Plate 0.5" Fins 1" FinsModel Prefix Configuration
Pounds Grams Pounds Grams Pounds Grams
VP-G 1 Micro 0.9 411 1.4 640 1.6 731
VP-D 2 Micro 1.0 457 1.5 686 1.7 777
VP-A 3 Micro 1.4 640 2.2 1006 2.5 1143
VP-E 1 Mini 1.0 457 1.4 640 1.6 731
VP-B 2 Mini 1.4 640 2.2 1006 2.6 1189
VP-F 1 Maxi 1.3 594 2.0 914 2.3 1051
VP-C 2 Maxi 2.2 1006 3.0 1371 3.5 1600
For use with 115/230Vac input VIPAC
Description* Height Part(Inches ±.06") Number
820µF 1.55 HUB820-S
1200µF 1.75 HUB1200-S
1800µF 2.14 HUB1800-S
2200µF 2.85 HUB2200-S
2700µF 3.52 HUB2700-S
3300µF 3.52 HUB3300-S
* Each HUB contains two (2) capacitors of the value shown.
Hold-up Box (HUB)
Top view, HUB
Maximum cable length between the HUB and VIPAC ≤ 3'
THERMAL MANAGEMENT
23
Thermal Impedance Specifications (˚C/W)
Air Flow
VIPAC Chassis Natural 200 400 600 800 1000 1200Model Prefix Config. Heat Sink Convection (LFM) (LFM) (LFM) (LFM) (LFM) (LFM)
VP-G 1 Micro 0.5" L 3.13 1.28 0.89 0.74 0.66 0.59 0.54
0.5" T 2.40 1.02 0.73 0.63 0.56 0.51 0.47
1.0" L 2.81 0.97 0.70 0.60 0.54 0.50 0.46
1.0" T 1.87 0.75 0.55 0.47 0.42 0.39 0.35
VP-D 2 Micro 0.5" L 3.13 1.28 0.89 0.74 0.66 0.59 0.54
0.5" T 2.40 1.02 0.73 0.63 0.56 0.51 0.47
1.0" L 2.81 0.97 0.70 0.60 0.54 0.50 0.46
1.0" T 1.87 0.75 0.55 0.47 0.42 0.39 0.35
VP-A 3 Micro 0.5" L 1.98 0.77 0.53 0.45 0.39 0.36 0.33
0.5" T 1.71 0.68 0.48 0.40 0.36 0.33 0.30
1.0" L 1.68 0.58 0.42 0.36 0.32 0.30 0.28
1.0" T 1.27 0.46 0.33 0.28 0.25 0.23 0.21
VP-E 1 Mini 0.5" L 3.11 1.26 0.88 0.74 0.65 0.59 0.54
0.5" T 2.39 1.01 0.73 0.62 0.56 0.51 0.47
1.0" L 2.51 0.87 0.64 0.56 0.51 0.48 0.45
1.0" T 1.76 0.70 0.52 0.44 0.40 0.37 0.33
VP-B 2 Mini 0.5" L 1.90 0.77 0.53 0.44 0.39 0.36 0.33
0.5" T 1.67 0.69 0.48 0.41 0.37 0.33 0.31
1.0" L 1.49 0.54 0.39 0.34 0.31 0.28 0.27
1.0" T 1.22 0.47 0.33 0.28 0.25 0.23 0.21
VP-F 1 Maxi 0.5" L 2.42 1.02 0.69 0.57 0.50 0.45 0.41
0.5" T 1.72 0.77 0.55 0.47 0.42 0.38 0.37
1.0" L 2.01 0.72 0.52 0.45 0.41 0.38 0.36
1.0" T 1.26 0.53 0.38 0.33 0.29 0.27 0.25
VP-C 2 Maxi 0.5" L 1.50 0.62 0.42 0.35 0.31 0.28 0.25
0.5" T 1.19 0.52 0.36 0.31 0.27 0.25 0.23
1.0" L 1.17 0.43 0.31 0.27 0.24 0.22 0.20
1.0" T 0.86 0.35 0.25 0.21 0.19 0.17 0.16
v i c o r p o w e r . c o m / v c a d
Mating Connector Cross Reference
Designator Description Vicor P/N Manufacturer Part NumberPin & Housing Pin Housing
J1 VIPAC DC Input - 3 Pin 21394 AMP 193842-1 770018-1
J2 VIPAC AC Input - 6 Pin 22499 AMP 350551-1 640585-1
J3 VIPAC I/O Interface - 7 Pin 22988 JST 07KR-6S
J4 VIPAC Output Control - 5 Pin 16385 AMP MTA100-IDC644083-5
HUB-820-s, 1200-s, 1800-s 3 Pin 21393 AMP 770248-1 770018-1
HUB-2200-s, 2700-s, 3300-s 3 Pin 21394 AMP 193842-1 770018-1
GENERAL INFORMATION
24
Mating Connector Kits
Part Number Description
23485 15/230 Autoranging Input VIPAC use with HUB 820-s, 1200-s, or 1800-s
Contains: One HUB connector #21393
OneAC Input connector #22499
One I/O Interface connector #22988
23486 115/230 Autoranging Input VIPAC use with HUB 2200-s, 2700-s or 3300-sContains: One HUB connector #21394
One AC Input connector #22499 One I/O Interface connector #22988
23487 48Vdc Input VIPAC use with all 48Vdc input VIPACsContains: One DC Input connector #21394
One I/O Interface connector #22988
23488 Mini/Maxi LugMate connectorContains: One control connector #16385
Two Ring Lugs
23489 Micro LugMate connectorContains: Two Ring Lugs
Suggested Wire Gauge
Function Wire Gauge Application
AC Input Leads #12 All AC and earth GND
leads(VIPAC power systems)
DC Input/Output Leads #20 0A - 3A
#18 4A - 6A
#16 7A - 10A
#14 11A - 15A
#12 16A - 25A
#10 26A - 40A
#8 41A - 65A
#6 66A - 104A
#4 105A - 160A
Selecting Heat Sinks
VIPAC Power Systems are rated for operation in ambient
temperatures up to 65˚C with a maximum chassis temperature
of 95˚C. Operation within these limits is essential for long
life and users should select an appropriate thermal
management system. The thermal performance of a particular
VIPAC chassis configuration can be approximated from the
thermal resistance of the chassis, ambient operating
temperature and total power dissipation, using a few simple
formulas shown below.
Thermal Resistance: refer to page 23
Ambient Temperature: user specified, not to exceed 65˚C
Power Dissipation: is calculated as: (Pout/Efficiency) –Pout
Example:
Verify a 500W, 28Vdc output VIPAC does not exceed
95˚C chassis temperature (Tc).
• VP-C chassis configuration with 1" transverse heat
sink is selected and 200lfm air flow is provided.
• Thermal resistance (θ) of 0.35˚C/W is obtained from
the chart on page 23.
• Ambient operating temperature (TA) specified by the
user is 40˚C.
• VIPAC Power System efficiency (η) is 80% overall.
Formula:
Tc = (( - Pout ) x θ) + TA
= (( - 500) x 0.35) + 40
= 83.75˚C
Conclusion:
ThisVIPAC will operate in the conditions specified and
not exceed maximum chassis temperature.
Comment:
Efficiency of a particular VIPAC will depend on the specific
output voltages and operating load conditions. In general
the efficiency of VIPACs with outputs of 5Vdc or less is
approximately 70% and those with outputs greater than
5Vdc is 80%. A more accurate calculation can be derived
by summing dissipation of each DC-DC converter module
used in theVIPAC and the front end section of the
VIPAC (using 95% efficiency for the front end).
5000.8
Poutη
APPLICATION TIPS
25
VIPAC Power System Dissipation
Pdiss =∑ - Pout (n)1- n 0.95
Remote Sense
A remote sense feature is provided on outputs config-
ured with Mini or Maxi sized DC-DC converters. The
output sense connections must be terminated either
locally or remotely and may not be left open. VIPACs
provided with the optional LugMate connectors are
configured for local sensing via removable jumpers
installed at the factory. The jumpers will need to be
removed if access to the secondary control function is
made via mating connector 16385 and connections will
need to be established for local or remote sensing.
Hold-up Capacitors
Hold-up capacitors can be located remotely with up to
3' of cable. Vicor applications engineering should be
consulted for projects requiring greater separation.
Wire Routing
Avoid routing wires over VIPAC Power System.
Do not bundle Input and Output leads together.
Crimping Tool
Parallel Outputs
The VIPAC can be configured with parallel modules for
increased power or redundancy. When output terminations
other than the LugMate are specified the user must
properly connect the output and sense terminals.
At no time operate a paralleled output with a load applied
only to one module! (See Output Connection Options)
v i c o r p o w e r . c o m / v c a d
Pout (n)η(n)
Amp Hand Tool P/N Die Set # Wire Size
90298-2 20-18 AWG
90299-2 16-14 AWG
69710-1 58380-1 12 AWG
58380-2 10 AWG
NOTES
26
TECHNICAL SUPPORT CONTACTS
27v i c o r p o w e r . c o m / v c a d
USAVicor Corporation (Corporate Headquarters)25 Frontage RoadAndover, MA 01810-5413
For General InformationTel: 978-470-2900Fax: 978-475-6715
For Technical Support Tel: 800-927-9474Fax: 978-749-3341E-mail: [email protected]
For Sales Support (Vicor Express)In U.S. and Canada: 800-735-6200Fax: 978-475-6715E-mail: [email protected]
Vicor Corporation 377 E. Butterfield RoadLombard, IL 60148Tel: 630-769-8780Fax: 630-769-8782
Vicor Corporation1601 Rutherford Lane, Suite H-2Austin, TX 78754Tel: 512-833-6177Fax: 512-833-6181
Vicor Westcor Division 560 Oakmead ParkwaySunnyvale, CA 94085-4022Tel: 408-522-5280Fax: 408-774-5555
Latin AmericaCall the number below and ask the operator to connect you to 800-735-6200.Argentina: 001-800-200-1111Brazil: 000+8010Mexico: 95-800-462-4240
EuropeVicor France 6, Parc ArianeBâtiment "Le Mercure"78284 Guyancourt CedexFranceTel: +33-1-3452-18300800 419 419 (in France)Fax: +33-1-3452-2830E-mail: [email protected]
Vicor GermanyAdalperostraße 2985737 Ismaning, GermanyTel: +49-89-962439-00800 018 29 18 (in Germany)Fax: +49-89-962439-39E-mail: [email protected]
Vicor ItalyVia Milanese, 2020099 Sesto S. GiovanniMilano, Italy Tel: +39-02-2247-2326800 899 677 (in Italy)Fax: +39-02-2247-3166E-mail: [email protected]
Vicor U.K.Coliseum Business CentreRiverside Way, CamberleySurrey GU15 3YLEngland Tel: +44-1276-678-222
In UK: 0800-980-8427In Denmark: 80 88 11 41In Norway: 800 11083In Sweden: 020 798236
Fax: +44-1276-681-269E-mail: [email protected]
Asia-PacificVicor Japan Co., Ltd.6F, POLA 3rd Bldg.8-9-5, Nishi-gotanda Shinagawa-kuTokyo 141-0031 Japan Tel: +81-3-5487-3880Fax: +81-3-5487-3885www.vicr.co.jp
Vicor Hong Kong Rm 511, Tower 1, Silvercord30 Canton RoadTsim Sha TsuiHong Kongwww.vicr.com.cnTel: +852-2956-1782Fax: +852-2956-0782
Vicor’s Technical support team is staffed with Applications
Engineers to provide the product and application
information and technical assistance customers need
concerning Vicor products and power solutions.
Our facilities house electronics laboratories where Vicor
Applications Engineers can evaluate specific customer
design issues and offer a wide range of component-based
power solutions that include distributed power, current
sharing, N + 1 redundancy, thermal management, and
compliance with safety and performance standards.
Applications engineers ...
• Answer technical questions (by phone, fax, E-mail,
or the Vicor web site).
• Assist with component-based power system design.
• Support user needs through visits to Vicor and customer
facilities.
• Help select the most appropriate product for your
application.
If you have a specific technical question, you may call ore-mail an Applications Engineer located at one of ourglobal offices.
Component Solutions For Your Power System
Vicor Corporation
Tel: 978-470-2900
Fax: 978-475-6715
vicorpower.com
Rev.1.1 P/N 24662 01/02/50M
Information furnished by Vicor is believed to be
accurate and reliable. However, no responsibility is
assumed by Vicor for its use. No license is granted by
implication or otherwise under any patent or patent
rights of Vicor. Vicor components are not designed to
be used in applications, such as life support systems,
wherein a failure or malfunction could result in injury
or death. All sales are subject to Vicor’s Terms and
Conditions of Sale, which are available upon request.
No user serviceable components, contact Vicor to
arrange for repair or replacement. Specifications are
subject to change without notice.