USER GUIDE | UG:122
PFC MicroS
TM
Power Factor Corrected AC-DC Switcher
October 2012
Contents
Overview
of Product
Standard Features
Optional Features
Part Numbering
Mechanical
Considerations
Do's and Don'ts
Technical Description
"Quick Install"
Instructions
Mechanical Drawings
Output Connections
PFC Micro
Connector Kit
Power Connections
User Interface
Connections
Specificaitons
Output Power
Derating
Current Share Boards
Page
1
2
2
3
3
3
4
5
Overview
7
8
8
The PFC MicroS is an ultra low profile switching power supply that combines the
advantages of power factor correction (PFC) with high power density. This guide
covers both the standard and rugged COTS (MI) versions of the supply. The PFC MicroS
provides up to three isolated outputs (from one slot) and accommodates the following
Vicor DC - DC Converters:
VI-200/VI-J00:
1 full brick or 2 half brick
Maxi/Mini/Micro:
1 full brick, 2 half bricks or 3 quarter bricks
The use of these converters give the PFC MicroS the inherent power flexibility typical of
all Vicor products. Accepting input voltages of 85 Vac to 264 Vac, and 100 to 300 Vdc, the
PFC MicroS can provide up to 600 Watts in a package size of 1.86" H (47mm) x 5.06" W
(128,5 mm) x 7.95" L (201,9 mm). The PFC MicroS is factory configured to meet output
requirements of the user. Using the VSPOC configurator tool available on vicorpower.
com, anybody can now configure a PFC MicroS (and other Vicor power supplies) online.
9
10
16
18
20
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Page 1
Standard Features
n
Power Factor Correction: Typically 0.98 (>75% Load)
n
Universal Input: 85-264 Vac, 47-500 Hz, or 120-300 Vdc
n
Power Output: 600 W at 230 Vac (200 Vac minimum input) ; 500 W at 115 Vac
(100 Vac minimum input)
n
Up to three isolated outputs (one slot)
n
Fan cooled
n
Full power to 45°C; half power at 65°C
n
Soft start for limiting inrush current
n
Conducted EMI:
FCC Class A
EN 55022, Class A (consult factory)
n
Harmonic Distortion to EN61000-3-2
n
AC Power OK status signal;
n
Output Sequencing and General Shutdown
n
Autosense (Refer to Page 6 and 14 for more information on Autosense)
n
Output overcurrent protection on all outputs
n
Output overvoltage protection (not applicable when using VI-J00 DC-DC Converters)
n
Output overtemperature limiting
(not applicable when using VI-J00 DC-DC Converters )
n
Ride-through (holdup) time: >20 ms at 500 W load (nominal line)
n
Size: 1.86" H (47,3 mm) x 5.06" W (128,5 mm) x 7.95" L (201,9 mm)
n
Safety Agency Approvals: CE Marking, TUV CUE
(certain configurations may not have all listed approvals)
n
Uses 300 Vdc input VI-200/VI-J00 modules and/or 375 Vdc input
Maxi/Mini/Micro modules
n
Power good status signal when Maxi, Mini or Micro modules used
Optional Features
n
I/T/H-grade output converters
n
Current Share Board for unit to unit power sharing- See Pages 20 - 22
n
Connector kits (#19-130044)
n
MI Chassis specific options:
n
n
n
n
Mil-STD 810 for Shock and Vibration
Mil-STD 704 and 1399 for Overvoltage and Transients
-40°C operation
Conformal coating - contact factory
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Page 2
Part Numbering
PFC MicroS
PSx
1
-x
2
x
3
(x
4
)-xxxx-x
5
ex. PS2-20-6544-G
x
1
= number of outputs
x
2
= number of VI-200/VI-J00 modules
x
3
= number of Maxi/Mini/Micro modules
(x
4
)
= optional Factory assigned
xxxx
= sequential number assigned by Vicor
-x
5
= optional Factory assigned
Note:
x
5
= MI for rugged chassis, = MC for rugged chassis with conformal coating
Mechanical Considerations
The PFC MicroS can be mounted on one of three surfaces using standard 8 - 32 or 4 mm
screws. Maximum allowable torque is 5 in. lbs., and the maximum penetration of 0.25 (6
mm) on the sides and 0.125 in. (3 mm) on the bottom.
When selecting a mounting location and orientation, the unit should be positioned so
air flow is not restricted. Maintain a 2" (5,1 cm) minimum clearance at both ends of the
PFC MicroS, 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
10 CFM 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 10 in. lbs.
Avoid applications in which the unit is exposed to excessive shock or vibration levels as
the unit is designed primarily for office type equipment. In such applications, a shock
absorbing mount design is required.
PFC MicroS Do’s and Don’ts
n
Do not restrict airflow to the unit. The cooling fan draws air into the unit and forces
it out at the output power terminals. A minimum of 2” in front and behind the supply
should be maintained in order to prevent air obstructions.
n
Run the output (+/–) power cables next to each other to minimize inductance.
Use twisted pairs if possible.
n
Do not attempt to repair or modify the power supply in any manner. In the event of
problems, contact Customer Service at 1-800-735-6200.
n
Insert proper fault protection at power supply input terminals (i.e., a fuse).
n
Use proper size wires to avoid overheating and excessive voltage drop.
n
Output voltages over 60 Vdc, whether from individual modules or series arrays, are
considered as hazardous secondary outputs under UL 60950. Appropriate care must
be taken in design implementation of the supply.
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Applications Engineering: 800 927.9474
Page 3
Technical Description
The PFC MicroS consists of an off-line single phase, power-factor-corrected front end,
EMI filter, cooling fan, customer interface, power supply control circuitry, associated
housekeeping circuits, and a selection of Vicor’s VI-200/VI-J00 and/or Maxi/Mini/Micro
DC-DC converters.
Input AC mains voltage is applied to input connector MBJI. The input current is passed
through an EMI filter designed to meet conducted noise limit "A" specifications of FCC
Part 15.
At start-up, inrush current is limited by a PTC thermistor. The PTC is shunted out
shortly after initial power-up by a DC bus voltage sense circuit driving a relay. After
rectification, the input voltage is put through a boost converter that keeps the AC input
current sinusoidal and synchronized with the input AC voltage (in compliance with
EN61000). The boost converter delivers a regulated input to the hold-up capacitors and
a high voltage backplane. The backplane supplies power to the DC-DC converters that
provide the desired low voltage regulated outputs.
Output voltage conversion is achieved by Vicor’s 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 MicroS outputs are disabled to limit the inrush current and
to allow the DC bus potential to settle out to the correct operating level. A low-power
flyback converter converts the high voltage DC bus into regulated low voltage to power
the internal housekeeping circuits and DC cooling fan.
The internal housekeeping Vcc comes up within 1 s after the application of input power.
Once the high voltage bus is within operating limits, the AC Power OK signal asserts to a
TTL "1," indicating the input power is OK, and the power outputs will come up
250 ms later.
An output Enable/Disable function is provided to control Vicor’s DC-DC converters.
If the Enable/Disable control pin is pulled low, the modules output is disabled. The
nominal delay associated for an output to come up when measured from release of the
Enable/Disable pin is 9 - 12 ms. The General Shutdown function controls all outputs
simultaneously and works in a similar manner.
Figure 1.
PFC MicroS Architecture
Input
Line Filter
Bridge
Rectifier
Soft Start
Circuit
Boost Converter
Output Card #1
Power
Output
PFC Control
Customer
Interface
Power Supply
Control
Enable/Disable -Power Good Read
Fan
Isolated
Housekeeping
Power Supply
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Page 4
PFC MicroS “Quick Install” Instructions
(For Mechanical Drawing, see Page 7)
Mounting the PFC MicroS
n
The PFC MicroS can be mounted on either of three sides.
n
Use #8 - 32 or 4 mm mounting screws. Maximum penetration should not exceed
0.25 in. (6 mm) on the side and 0.125 in. (3 mm) on the bottom.
n
Maintain 2" (5,1 cm) clearance at both ends of power supply for airflow.
Input Connections
Input Power MBJ1
MBJ1-5 PIN
L1
Not Connected
n
Apply input AC power connector MBJ1.
n
Maximum torque is 5 in. lbs.
n
A fuse or circuit breaker in the input line is necessary for safety
L2/N
Not Connected
GND
requirements (10 A).
n
Molex mating receptacle 39-01-4051, terminals 39-00-0089, crimp tool
Molex # 11-01-0199.
DUAL MINI
MODULES
MAXI
MODULE
Output Connections
Power Connections
Installing bus bars on
output studs
(when full size and half size modules used):
n
The right stud is Positive and the left stud is the Return on single output cards.
M1
S1J1
M1
-
+
-
+
10-32 STUDS
M2
S1J3
M2
M1
S1J2
M1
-
+
n
Remove the nut and place ring lug over output stud.
n
Replace and tighten the nut to a torque of
10 inch pounds.
Do Not Over-Tighten Nuts.
S1J1
Installing power connectors
with 16 pin Molex connectors
(when quarter size modules used):
n
S1J1-7 and S1J1-15 are Positive for output #1, while pins S1J1-8 and S1J1- 16 are the
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
Return. S1J1-4 and S1J1-12 are Positive for output #2, while pins S1J1-5 and S1J1- 13
are the Return. S1J1-1 and S1J1-9 are Positive for output # 3, while pins S1J1-2, and
S1J1-10 are the Returns.
n
For this 16 pin housing, use Molex mating receptacle #39-01-2160 with
S1J1 (16 Pin)
-
+ T -
+
N/C
- +
#39-00-0039 terminals.
n
Attach 18 - 24 AWG stranded wire using Molex tool #11-01-0197.
- + T
- + T - +
See Page 9 for diagrams of output connections.
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