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rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 flatpac-en design guide design guide and ?quick install? instructions www.vicorpower.com flatpac-en? en compliant autoranging switcher
table of content overview of product............................................................................................................ ...............3 part numbering................................................................................................................. ..................3 mechanical considerations...................................................................................................... ...........4 flatpac-en do?s and don?ts..................................................................................................... ........4 technical description.......................................................................................................... ...............5 configuration layout drawing................................................................................................... ........6 quick install instructions..................................................................................................... ...............7 mechanical drawings............................................................................................................ .............10 interface connections.......................................................................................................... ...............11 rs 232 microcontroller......................................................................................................... .............12 batmod current source.......................................................................................................... ............16 in-line filter................................................................................................................. .......................16 specifications................................................................................................................. ......... ..........17 output vs. ac & dc voltage graphs . ........................................................................................... ..19 thermal curves................................................................................................................. .................21 current share boards........................................................................................................... ..............23 pg. 2 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide
flatpac-en? en compliant autoranging switcher overview the flatpac-en is an ultra low profile switching power supply that provides up to 500 watts from up to 4 isolated outputs. it operates on either 115 or 230 vac nominal (47-63 hz), or 250-380 vdc. the two-output version con- tains 1 full brick and 1 half brick. the three-output version contains 3 half bricks. and the four-output version con- tains 1 half brick and 3 quarter bricks. the use of these converters gives the flatpac-en the inherent power flexibility typical of all vicor products. with dimensions of 1.4" h (35,6mm) x 5.0" w (127mm) x 9.2" l (233,7mm), the flatpac-en provides a power density greater than 7w/in 3 . it is factory configured to meet user output requirements. note: the flatpac-en does not have an internal fan. standard features ? power factor correction (passive): power factor (typical) 0.70 (>75% load) ? input voltage: 90-132/180-264 vac 1 , 47-63 hz, or 250-380 vdc ? maximum power output: 500w (105/190vac min.) 425w for en61000-3-2 compliance ? up to 4 isolated user specifiable outputs ? conducted emi: fcc class a en 55022 class a fcc class b en 55022 class b *(may require optional in-line filter. contact factory.) ? harmonic attenuation to en61000-3-2/a14 2 ? compliant to en61000-4-4 (electrical fast transient/burst) and en61000-4-5 (surge immunity) ? rugged: meets mil-std-810e, category 10 for vibration ? efficiency (typical) > 70% ? autosense 3 ? rs-232 microcontroller interface ? output overcurrent protection on all outputs ? size: 1.4" h (35,6mm) x 5.0" w (127,0mm) x 9.2" l (233,7mm) ? safety agency approvals: ce marking, c tv us , c ul us 1 derates to 260w@90vac, 400w @ 180 vac. 2 for output power 425w, not to exceed an input current of 3.33 a rms at 230 vac, 50 hz. 3 this feature is implemented in all converter slots. autosense allows automatic local sensing when remote sense connec- tions are not made. the flatpac-en will operate in remote sense mode when remote sense connections are made. refer to page 14 for more information on autosense. optional features ? extended temperature range version ? current share board for unit to unit power sharing - see page 23 and page 24 ? connector kits (# 19-130044) ? in-line filter - see page 16 ? low leakage version part numbering flatpac-en flx 1 - x 2 x 3 -xxx (-x 4 )x 1 number of outputs e.g. fl4-13-501 x 2 number of 1st gen vi-200 & vi-j00 modules x 3 number of 2nd gen maxi, mini and micro modules xxx sequential number assigned by westcor ( x 4 ) optional versions e - extended temperature range version ll - low leakage version rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 3 flatpac-en design guide
mechanical considerations the flatpac-en is mounted on the bottom surface using standard 8-32 or 4 mm screws (cannot be mounted from the front.) maximum allowable torque is 5 in. lbs.,. the maximum penetration for mounting holes a1, a2, a3 and a4 is 0.125 in. (3mm) and for mounting holes b1, b2, c1 and c2 is 0.250 in. (6mm). the minimum recommended mounting holes are as follows: 1. for standard mounting (forced air cooling), use a1, a2, a3, a4 mounting holes. 2. for standard mounting (conduction cooling), use a1, a2, a3, a4, b1 and b2 mounting holes. 3. for a vicor 2 up flatpac retrofit replacement, use c1 and c2 as these two are identical to the recommended mounting holes on the flatpac. for increased ruggedness, additional mounting holes can be used to secure the power supply. the flatpac-en does not have an internal fan. it can be conduction or convection cooled (same model). 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. for applications that require vibration levels above mil-std-810e, a shock absorbing mount design is required. flatpac-en do?s and don?ts ? do not exceed an operating case temperature of 90 o c. to prevent an overtemperature condition, an external fan may be required. ? run the output (+/?) power cables next to each other to minimize inductance. ? do not attempt to repair or modify the power supply in any manner as this action will void the warranty. in the event of problems, contact westcor?s customer service department at 1-800-797-5678 or (408) 522-5280. ? insert proper fault protection at power supply input terminals (i.e., a fuse). ? use proper size wires to avoid overheating and excessive voltage drop. pg. 4 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide identical mounting holes (c1 & c2) to vicor's 2 up flatpac c1 c2 a1 a2 b1 b2 a3 a4
technical description the flatpac-en consists of an off-line single phase autoranging front end, emi filter, customer interface, power supply control circuit, associated housekeeping circuits, a miniham module and a selection of vicor?s 1st generation (vi-200 and vi-j00) and/or 2nd generation (maxi, mini and micro) dc-dc converters. the miniham was specifically designed for en compliance using passive filtering. unlike active pfc solutions, the miniham generates no emi, greatly simplifying and reducing system noise filtering requirements. it is also considerably smaller and more efficient than active alternatives and improves the unit?s mtbf. it will provide har- monic current compliance at 230vac input up to 425w of output power. input ac mains voltage is applied to input connector mbj1 (see page 6) and the input current is passed through an emi filter designed to meet conducted noise limit of en 55022, classes a and b specifications. certain configurations may require westcor?s optional external in-line filter to meet en 55022 class b. at start-up, the microcontroller verifies that the input voltage is within the specified operating range. once this occurs, the microcontroller closes the safety relay and puts the autoranging front-end in the correct mode (closing or opening the doubler relay). the autoranging front-end has two modes, the doubler mode (90vac - 132vac) or bridge rectifier mode (180vac-264vac, 250vdc-380vdc). inrush current is limited by a ptc thermistor. the ptc is shunted out (by closing the inrush relay) when the output voltage has charged up the bus capacitors within the specified range (205vdc-390vdc). approximately 1 second after the application of the input voltage, the bus volt- age is within operating limits and the ac ok signal asserts to a ttl "1", indicating the input power is ok. after ac ok is asserted high, the user can now control the power outputs. output voltage conversion is achieved by vicor?s 300vin family of zero-current-switching (zcs) dc-dc con- verters. 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, all outputs are disabled to limit the inrush current and to allow the dc bus potential to settle to the correct operating level. a low-power transformer flyback circuit converts the high voltage dc bus into regu- lated low voltage to power the internal housekeeping circuits as well as the auxiliary +5vs located in the interface connector. 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. rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 5 flatpac-en design guide figure 1. flatpac-en architecture 1000uf 1000uf miniham 100k 100k 1 2 3 4 5 microcontroller safety inrush strap gnd n/c line n/c neutral mbj1 vbus to dc/dc modules 50 ohm ptc emi filter
flatpac-en configuration layout pg. 6 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide cbj1 interface conn. m2 vi-200, maxi or batmod m1 vi-j00 or mini mbj1 input conn. miniham cbj1 interface conn. mbj1 input conn. m2 micro m1 micro m3 micro miniham m4 vi-j00 or mini cbj1 interface conn. m1 vi-j00 or mini mbj1 input conn. miniham m2 vi-j00 or mini m3 vi-j00 or mini single or dual outputs (stud connectors) triple outputs (two 18 pin molex connectors) quadruple outputs (two 18 pin molex connectors) for a single output configuration, either m1or m2 is used
flatpac-en ?quick install? instructions (for mechanical drawings, see page 10) mounting the flatpac-en ? mount the flatpac-en on the bottom (cannot be mounted from the front). ? for standard mounting (forced air cooling), use a1, a2, a3, a4 mount- ing holes. for standard mounting (conduction cooling) , use a1, a2, a3, a4, b and b2 mounting holes. ? for a vicor 2 up flatpac retrofit replacement , use c1 and c2 as these two are identical to the mounting holes on the flatpac. ? for increased ruggedness, use additional mounting holes to secure the power supply. ? use #8-32 or 4mm mounting screws. for mounting holes a1, a2, a3 and a4, the maximum penetration should not exceed 0.125 in. (3mm). for mount- ing holes b1, b2, c1 and c2, do not exceed maximum penetration of 0.250 in. (6 mm). * the maximum allowable torque is 5 in. lbs., input connections input power mbj1 ? apply input ac power connector mbj1 using a maximum torque of 5 in. lbs ? place a fuse or circuit breaker in the input line for safety requirements (10a). ? use molex mating receptacle 39-01-4051, terminals 39-00-0090 and crimp tool molex # 11-01-0199. output connections power connections installing power connectors on single and dual output (uses 10-32 output studs) : ? install #10 ring lugs on output studs * the right stud is positive and the left stud is the return when viewed from the output end . ? remove the nut and place ring lug over output stud. ? replace and tighten the nut to a torque of 10 inch pounds. do not over- tighten nuts. installing power connectors on triple output (uses 18 pin housing) : ? the output m1 slot accepts either a mini or a junior module. j2-7, j2-8, j2- 16 are positive, while pins j2-9, j2-17 and j2-18 are the returns. ? j2-1, j2-2, j2-3, j2-4, j2-5, j2-10, j2-11, j2-12 and j2-14 are not connected. ? the output m2 slot accepts either a mini or a junior module. j3-7, j3-8, and j3-16 are positive while pins j3-9, j3-17 and j3-18 are the returns. ? the output m3 slot accepts either a mini or a junior module. j3-1, j3-10, j11 are positive while pins j3-2, j3-3, j3-12 are the returns. ? for this 18 pin housing, use molex mating receptacle #39-01-2180 with #39- 00-0039 terminals. ? attach 24-30 awg stranded wire using molex tool #11-01-0197. rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 7 flatpac-en design guide mbj1 n/c n/c l1 l2/n gnd output m1 output m2 10-32 studs + j2 - m1 - j1 + single and dual output identical mounting holes (ci & c2) to vicor's 2 up flatpac c1 c2 b1 b2 a3 a4 a1 a2 outputs m2 & m3 output m1 triple output j2 j3 1 18 9 10 1 9 10 18 pin description 1 n/c 2 n/c 3 n/c 4 n/c 5 n/c 6 trim m1 7 +v out m1 8 +v out m1 9 -v out m1 pin description 10 n/c 11 n/c 12 n/c 13 + sense m1 14 n/c 15 - sense m1 16 +v out m1 17 - v out m1 18 - v out m1 j2 pin description 1 +v out m3 2 -v out m3 3 -v out m3 4 + sense m3 5 - sense m3 6 trim m2 7 +v out m2 8 +v out m2 9 -v out m2 pin description 10 +v out m3 11 +v out m3 12 -v out m3 13 + sense m2 14 trim m3 15 - sense m2 16 +v out m2 17 - v out m2 18 - v out m2 j3
installing power connectors on quadruple output (uses 18 pin housing) : ? the output m1 slot only accepts a micro module. j2-7, j2-8, j2-13 and j2-16 are positive, while pins j2-9, j2-15, j2-17 and j2-18 are the returns. ? the output m2 slot only accepts a micro module. j2-1, j2-4, j2-10, j2-11 are positive, while pins j2-2, j2-3, j2-5 and j2-12 are the returns. ? the output m3 slot only accepts a micro module. j3-7, j3-8, j3-13 and j3- 16 are positive, while pins j3-9, j3-15, j3-17 and j3-18 are the returns. ? the output m4 slot only accepts either a mini or a junior module. j3-1, j3-10 and j3-11 are positive while pins j3-2, j3-3, and j3-12 are the returns. ? for this 18 pin housing, use molex mating receptacle #39-01-2180 with #39- 00-0039 terminals. ? attach 24-30 awg stranded wire using molex tool #11-01-0197 see page 10 for detailed diagrams of output connections. sense connections the flatpac-en is shipped with autosense installed (for more information on autosense, refer to page 14) sense connections for single and dual isolated output: ? for remote sense, connect remote sense wires to remote sense/trim pin access connector j1 or j2 for single output and j1/j2 for dual outputs. * connector pins j1-2 and j2-2 are the + senses and j1-3 and j2-3 are the -senses. ? use molex mating receptacle #50-57-9403 with #16-02-0103 terminals. ? attach terminals to 24-30 awg stranded twisted pair wire using molex tool # 11-01-0208. ? attach opposite end of sense lines to their respective outputs to point where regulation is desired. verify that sense lines are not cross-connected . sense connections on triple output: ? if remote sense is desired, connect remote sense wires to the sense lines of connector j2 for output 1 and j3 for outputs 2 and 3. * for output m1, j2-13 is the +sense and j2-15 is the -sense. * for output m2, j3-13 is the +sense and j3-15 is the -sense. * for output m3, j3-4 is the +sense and j3-5 is the -sense. ? use molex mating receptacle #39-01-2180 with #39-00-0039 terminals. ? attach 24-30 awg stranded twisted pair wire using molex tool #11-01-0197. sense connections on quadruple output: ? if remote sense is desired (available only on output m4), connect remote sense wires to sense lines of connector j3 * remote sense is not available for micro modules and hence is not available on outputs m1, m2 and m3. * on output m4, j3-4 is the +sense and j3-5 is the -sense. ? use molex mating receptacle #39-01-2180 with #39-00-0039 terminals. ? attach 24-30 awg stranded twisted pair wire using molex tool #11-01-0197 trim connections trim connections on single and dual output : ? for output m1, j1-1 provides trim access ? for output m2, j2-2 provides trim access ? use molex mating receptacle #50-57-9403 with #16-02-0103 terminals. ? attach 24-30 awg stranded wire using molex tool #11-01-0208. pg. 8 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide 1 2 3 1 trim pin 2 + remote sense 3 - remote sense pin output m1 output m2 10-32 studs + m2 j2 - m2 m1 - j1 + trim: single and dual output output m1 output m2 10-32 studs + m2 j2 - m1 - j1 + single and dual output 1 2 3 1 trim pin 2 + remote sense 3 - remote sense pin outputs m1 & m2 outputs m3 & m4 quadruple output j2 j3 pin description 1 +v out m2 2 -v out m2 3 -v out m2 4 +v out m2 5 - vout m2 6 trim m1 7 +v out m1 8 +v out m1 9 -v out m1 pin description 10 +v out m2 11 +v out m2 12 -v out m2 13 + vout m1 14 trim m2 15 - vout m1 16 +v out m1 17 - v out m1 18 - v out m1 pin description 1 +v out m4 2 -v out m4 3 -v out m4 4 + sense m4 5 - sense m4 6 trim m3 7 +v out m3 8 +v out m3 9 -v out m3 pin description 10 +v out m4 11 +v out m4 12 -v out m4 13 + vout m3 14 trim m4 15 - vout m3 16 +v out m3 17 - v out m3 18 - v out m3 1 9 10 18 1 9 10 18 outputs m2 & m3 output m1 triple output j2 j3 j2-13 + sense m1 j2-15 - sense m1 j3-4 + sense m3 j3-5 - sense m3 j3-13 + sense m2 j3-15 - sense m2 1 18 9 10 1 9 10 18 +s -s +s -s +s -s outputs m1 & m2 outputs m3 & m4 quadruple output j2 j3 m4 accepts 1 mini or 1 junior j3-4 + sense m4 j3-5 - sense m4 1 9 10 18 1 9 10 18 m1, m2, m3 accept micro modules no sense connections are available for micro modules +s -s
trim connections for triple output : ? for output m1, j2-6 provides trim access ? for output m2 and m3, j3-6 and j3-14 provides trim access respectively. ? use molex mating receptacle #39-01-2180 with #39-00-0039 terminals. ? attach 24-30 awg stranded wire using molex tool #11-01-0197. trim connections for quadruple output : ? for outputs m1 and m2, j2-6 and j2-14 provide trim access respectively. ? for outputs m3 and m4, j3-6 and j3-14 provide trim access respectively. ? use molex mating receptacle #39-01-2180 with #39-00-0039 terminals. ? attach 24-30 awg stranded wire using molex tool #11-01-0197. trim connections when using batmod: ? j2-1 provides current trim access. * for the flatpac-en, batmods can only be used in output slot m2 of a dual configuration. ? use molex mating receptacle #50-57-9403 with #16-02-0103 terminals. ? attach 24-30 awg stranded wire using molex tool #11-01-0208. interface connections ? cbj1-1 is signal ground and cbj1-3 is ac ok. ? cbj1-4 is the transmit and cbj1-5 is the receive functions for the rs-232 command protocol. + ? cbj1-4 thru 9 are enable/disable,cbj1-10 is general shutdown and cbj3- 12 is +5vs. ? for the flatpac-en, cbj1-2 and cbj1-11 are not connected. ? use molex mating receptacle #50-57-9412 with #16-02-0097 cinch pins. ? attach 24-30 awg stranded wire using molex tool #11-01-0209. + these functions are part of the rs-232 command protocols. see page 12 for detailed information . rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 9 flatpac-en design guide pin description cbj1-1 sgnd cbj1-2 n/c cbj1-3 acok cbj1-4 tx cbj1-5 rx cbj1-6 e/d-4 cbj1-7 e/d-3 cbj1-8 e/d-2 cbj1-9 e/d-1 cbj1-10 gsd cbj1-11 n/c cbj1-12 +5vs outputs m2 & m3 output m1 triple output j2 j3 j2-6 trim m1 j3-6 trim m2 j3-14 trim m3 1 18 9 10 1 9 10 18 t t t outputs m1 & m2 outputs m3 & m4 quadruple output j2 j3 j2-6 trim m1 j2-14 trim m2 j3-6 trim m3 j3-14 trim m4 1 9 10 18 1 9 10 18 t t t t 1 2 3 j2-1 i trim pin (current trim access) j1-3 i mon (current monitor) pin output m2 m2 j2 m2 batmod current source connections j2-2 v trim (voltage trim) j2
flatpac-en mechanical drawings pg. 10 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide mating connector: housing: molex (50-57-9412) socket crimp 24-30 awg: molex (16-02-0097) crimp tool: molex (11-01-0209) mating connector: housing: molex (39-01-4051) socket crimp 16 awg: molex (39-00-0090) crimp tool: molex (11-01-0199) mbj1 a/c input pin ref description cbj1-1 sgnd signal ground cbj1-2 n/c n/c cbj1-3 acok ac power ok cbj1-4 tx transmit cbj1- 5 rx receive cbj1-6 e/d-4 enable/disable cbj1-7 e/d-3 enable/disable cbj1- 8 e/d-2 enable/disable cbj1-9 e/d-1 enable/disable cbj1-10 gsd general shutdown cbj1-11 n/c n/c cbj1-12 +5vs +5v@300ma 1 2 3 cbj1 e/d interface connector cb j1 (12 pin) 2 3 mbj1 1 outputs m1 & m2 outputs m3 & m4 output m2 & m3 output m1 output m1 output m2 9.53 .38 215.90 8.500 12.70 .50 101.60 4.000 4x #8-32 x .125 or m4 x 3mm max lg from outside of power supply customer mounting holes 138.43 5.450 147.96 5.825 5.56 .219 115.89 4.563 air flow customer mounting holes 4x #8-32 x .250 or m4 x 6mm max lg from outside of power supply quad output j2 j3 10 n/c 11 n/c 12 n/c 13 + sense m1 14 n/c 15 - sense m1 16 +v out m1 17 -v out m1 18 -v out m1 pin description 1 n/c 2 n/c 3 n/c 4 n/c 5 n/c 6 trim m1 7 +v out m1 8 +v out m1 9 -v out m1 (18 pin, mini or junior pin description 1 +v out m2 2 -v out m2 3 -v out m2 4 +v out m2 5 -v out m2 6 trim m1 7 +v out m1 8 +v out m1 9 -v out m1 (18 pin, two micro modules) 10 +v out m2 11 +v out m2 12 -v out m2 13 +v out m1 14 trim m2 15 -v out m1 16 +v out m1 17 - v out m1 18 - v out m1 (18 pin, two mini or junior pin description 1 +v out m3 2 -v out m3 3 -v out m3 4 + sense m3 5 - sense m3 6 trim m2 7 +v out m2 8 +v out m2 9 -v out m2 10 +v out m3 11 +v out m3 12 -v out m3 13 + sense m2 14 trim m3 15 - sense m2 16 +v out m2 17 -v out m2 18 -v out m2 2 3 j2 & j3 remote sense/output connectors mating connectors: 18 pin housing: molex (39-01-2180) socket crimp 24-30 awg: molex (39-00-2180) crimp tool: molex (11-01-0197) triple output j2 j3 pin description 1 +v out m4 2 -v out m4 3 -v out m4 4 +sense m4 5 -sense m4 6 trim m3 7 +v out m3 8 +v out m3 9 -v out m3 (18 pin, micro and mini 10 +v out m4 11 +v out m4 12 -v out m4 13 +v out m3 14 trim m4 15 -v out m3 16 +v out m3 17 - v out m3 18 - v out m3 10-32 studs + remote sense + m2 j2 - m2 m1 m1 - j1 + j1 & j2 remote sense/trim pin access connector mating connector: housing: molex (50-57-9403) socket crimp 24-30 awg: molex (16-02-0103) crimp tool: molex (11-01-0208) 3 2 single* or dual output pin 1 n/c n/c l1 l2/n gnd 0.77 .03 35.59 1.40 233.69 9.20 j2 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 1 2 3 - remote sense trim pin 3 2 1 reference designation notes: unless otherwise specified mb mother board cb control board connector part numbers specified are molex or equivalent a complete set of mating connectors can be purchased from westcor by specifying connector kit p/n 19-130044 j2 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 j3 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 j3 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 * for single output configurations, either j1 or j2 is used. see page 6 for flatpac-en configuration layout. c1 c2 4 cbj4 and cbj5 are part of the rs-232 microcontroller functions. see page 12 information. 4 5 for a vicor 2 up flatpac retrofit, use mounting holes c1 and c2. see page 4 or 7 for mounting details. 5 5 measurement tolerances are fractions +/- 1/32 decimals .xx +/- .01 .xxx +/- .005 angles +/- 1/2 o
interface connections chassis input power terminals (mbj1) input ac power is applied through connector mbj1 using molex mating connector 39-01-4051. use 16 awg wire with molex socket pin 39-00-0090 and crimp tool 11-01-0199. a fault clearing device, such as a fuse or circuit breaker, with a maximum 10a rating at the power supply input is required for safety agency compliance. it should be sized to handle the start-up inrush current of 14a pk rms at 115 vac or 230 vac. output power connections there are two types of output power terminals available in the flatpac-en. each slot has one of the following configurations: 10-32 plated steel bolts for single and dual output configurations and an 18 pin molex connector for triple and quadruple output configurations. the positive polarity of the single and dual output termination is the right bolt when viewed from the output end. each power output is isolated, so outputs of positive or negative polarity can be configured through proper selection of the output reference terminal. in order to minimize parasitic cable inductance and reduce emi, the output power cables should be routed in close proximity to one another, and large current loops should be avoided. to avoid excessive voltage drop, do not undersize power cables, especially for high current outputs. do not bulk input ac wires with the output wires because this can couple output noise into the input wires which can increase emi. excessive cable inductance coupled with large capacitive loading can introduce instability in switching power supplies. this problem can be avoided with proper system design. consult vicor?s applications engineering department for assistance with applications that use long cable lengths and excessive load capacitance. user interface connections signal ground (cbj1-1) signal ground on cbj1-1 is an isolated secondary ground reference for all cbj1 interfacing signals. this is not the same as earth ground on input power connector mbj1. rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 11 flatpac-en design guide mating connector: housing: molex (39-01-4051) socket crimp 16 awg: molex (39-00-0090) crimp tool: molex (11-01-0199) mbj1 a/c input mbj1 n/c n/c l1 l2/n gnd figure 2: input power terminal mbj1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 1 10 9 18 1 n/c 2 n/c 3 n/c 4 n/c 5 n/c 6 trim m1 7 +v out m1 8 +v out m1 9 -v out m1 10 n/c 11 n/c 12 n/c 13 + sense m1 14 n/c 15 - sense m1 16 +v out m1 17 - v out m1 18 - v out m1 pin description pin description 10-32 output studs trim 1 j1/j2 sense/trim pin connector 3 2 - sense + sense b. triple output a. single or dual output j2 (18 pin output, sense and trim pin connector) -v out +v out outputs m2 and m3 (using 2 minis or 2 juniors) 1 +v out m3 2 -v out m3 3 -v out m3 4 + sense m3 5 - sense m3 6 trim m2 7 +v out m2 8 +v out m2 9 -v out m2 10 +v out m3 11 +v out m3 12 -v out m3 13 + sense m2 14 trim m3 15 - sense m2 16 +v out m2 17 - v out m2 18 - v out m2 pin description pin description j3 (18 pin output, sense and trim pin connector) j2/j3 2 3 4 5 6 7 8 11 12 13 14 15 16 17 1 10 9 18 c. quadruple output outputs m3 and m4 (using 1 micro and 1 mini or 1 junior) 1 +v out m4 2 -v out m4 3 -v out m4 4 + sense m4 5 - sense m4 6 trim m3 7 +v out m3 8 +v out m3 9 -v out m3 10 +v out m4 11 +v out m4 12 -v out m4 13 + vout m3 14 trim m4 15 - vout m3 16 +v out m3 17 - v out m3 18 - v out m3 pin description pin description j3 (18 pin output, sense and trim pin connector) 1 +v out m2 2 -v out m2 3 -v out m2 4 +v out m2 5 - vout m2 6 trim m1 7 +v out m1 8 +v out m1 9 -v out m1 10 +v out m2 11 +v out m2 12 -v out m2 13 + vout m1 14 trim m2 15 - vout m1 16 +v out m1 17 - v out m1 18 - v out m1 pin description pin description j2 (18 pin output, sense and trim pin connector) j2/j3 output m1 (using 1 mini or 1 junior) outputs m1 and m2 (using 2 micros) figure 3: output power connections
ac ok (cbj1-3) ac ok is an active high ttl compatible signal and provides a status indication of the ac input power. it is on pin cbj1-3 and is capable of sinking 16 ma maximum. this signal switches to a ttl "1" when the high voltage bus exceeds low-line condition during turn-on. upon loss of input power, the bus voltage will drop, causing the ac ok signal to go low. typically, a 2.5ms holdup time is provided for a 500w load following the loss of the ac ok sig- nal. transmit/receive rs-232 command protocol (cbj1-4 and cbj1-5) the flatpac-en incorporates a microprocessor for communicating status and allowing user control. operation in the remote mode requires commanding the power supply to be a slave via the rs-232 interface. operating modes the flatpac-en has two operating modes, remote and manual, which can be set using the rs-232 interface fea- ture. the operating mode setting is stored in a non-volatile eeprom and requires an reon or reoff command in order to switch modes. the default mode setting from the factory is in manual mode. the flatpac-en has an operating mode indicator led, which is viewable through the left side vent hole nearest the cbj1 e/d interface connector. when this led is on, the power supply is operating in remote mode. communications protocol the protocol is an ascii character stream that will be sent back and forth between the power supply and the user. the flatpac-en in the remote mode will be considered a slave in that it will only respond to commands and requests and will not initiate conversations. communications are half-duplex in that only the flatpac-en receiver or transmitter may be active at one time. the unit will reply to all commands or requests with a defined response followed by a carriage return and line feed character pair (cr/lf). the user must wait for the reply from the flatpac-en 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. commands, status requests and module replies all commands and requests will have a reply. the reply will be one of the following character strings followed by a cr/lf character pair. "ok"- issued when a command has been received and acted upon and the command has no return data associated with it. "inv command"- issued when an unrecognized command has been received or a command cannot be executed at this time. "inv range"- issued when a command argument is not within a valid range. the following is the list of commands and their definitions. all commands must be followed with a cr/lf charac- ter pair. pup - power up this command starts the automatic turn on timed sequence for the modules. if a power down sequence is active at the time this command is received, a reply of "inv command" is returned; otherwise "ok" is returned. pdn - power down this command starts the automatic turn off timed sequence for the modules. this command can be given at any time and will cancel any uncompleted automatic power up sequences. "ok" is returned. emo - emergency off this command turns all modules off. if either a power up or power down sequence is active at the time, it will be terminated immediately. a response of "ok" is returned. pg. 12 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide led indicator inside cbj1 interface connector output connections figure 4: led indicator
ton1, ton2, ton3, ton4 - turn on commands for modules 1, 2, 3, or 4. these commands turn on the module identified by the trailing digit. 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. toff1, toff2, toff3, toff4 - turn off commands for modules 1, 2, 3, or 4. these commands turn off the module identified by the trailing digit. 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, sdon4 - set delay on time for modules 1, 2, 3 or 4. these commands set the associated time delays for the dc-dc converters to be activated via "pc" pin release. there is an additional delay of up to 7ms inherent in the dc-dc converters. these commands are entered with a trailing argument. the valid range of the argument is from 1 to 255 and is in 10 millisecond increments. the effec- tive range of delay then becomes 10 to 2550 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 concur- rent from either power up of the unit or from receipt of the power up command. if these commands are entered without an argument then the unit will report the present settings of these variables. sdoff1, sdoff2, sdoff3, sdoff4 - set delay off time for modules 1, 2, 3, or 4. these commands set the associated time delays for the dc-dc converters to be deactivated via "pc"pin release. these commands are entered with a trailing argument. the valid range of the argument 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 sec- onds. out of range arguments are 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 condition with the unit. if these commands are entered without an argument then the unit will report the present settings of these variables. bv - bus voltage readback this command returns the current bus voltage reading. ms - module status this command returns the module status as shown: ms=x1 x2 x3 x4 x5 x1 indicates the status of module output 1. x2 indicates the status of module output 2. x3 indicates the status of module output 3. x4 indicates the status of module output 4. a "1" indicates the output is up/on and ok and a "0" indicates the output is down/off. x5 indicates the status of the power supply bus. a "1" indicates bus ok and a "0" indicates bus not ok. sn - serial number this command returns the serial number as set by factory (available only on request.) reon - remote mode on this command put the power supply into the slave mode. in this mode the power supply will only respond when commanded. reoff - remote mode off this command put the power supply into the manual mode. in this mode the power supply will only respond to the following commands via the rs-232 interface: reon, sn, sdon1, sdon2, sdon3, sdon4, bv, ms, hst. hst - heat sink temperature this command returns temperature of the heat sink in degrees celsius. heat sink temperature is measured fre- quently and stored into eeprom memory. upon loss of power last measured value in stored in eeprom. rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 13 flatpac-en design guide
enable/disable mode (cbj1-8 and cbj1-9) the enable/disable control pins allow outputs to be sequenced either on or off. cbj1-4 through cbj1-9 are the control pins for outputs 1 through 4. the enable/disable pins should be pulled low to less than 0.7v with respect to signal ground to disable the outputs. they will source 9ma maximum. these pins should be open circuited or allowed to exceed 4.5v when enabled. do not apply more than 5v to these inputs. the correspondence between a module and its e/d line as seen from the output end of the power supply goes from left to right. general shutdown /gsd (cbj1-10) the gsd control pin on cbj1-10 allows simultaneous shutdown of all outputs. this pin must be pulled down to less than 0.7v, and will source 9ma maximum to shut down all outputs. the gsd pin should be open circuited or allowed to exceed 4.5v when not in use, or when the outputs are to be enabled. do not apply more than 5v to this input at any time. normal open circuit voltage is 1.5 to 4v with respect to signal ground. auxiliary vcc +5v/300ma (cbj1-12) the vcc on cbj1-12 is an auxiliary 5v regulated power source. it is +5 vdc +/?5% with respect to signal ground and can supply 300 ma maximum. it is capable of withstanding a short, but shorted user interface functionality will be lost. +sense/?sense ( j2) (not applicable when using batmod current source.) the sense lines for the outputs are shipped from the factory with autosense. autosense provides the user with automatic sensing of the outputs. with autosense, the flatpac-en will automatically operate in a remote sense mode when the remote sense connections are made. but in the event that the remote sense is not connected or needed, no local sense selection is necessary - simply hook up the outputs and the flatpac-en will automatically operate in local sense mode. in the local sense mode (remote sense lines not connected), 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 nec- essary 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 24-30 awg wire for the remote sense lines. remote sense can com- pensate for a voltage drop of up to 0.5v, or 0.25v on each leg. the sense connector for a single or dual output board is a 3 pin connector providing the +sense connection on j1/ j2-2 and the - sense connection on j1/j2-3. the sense connector for a triple and quadruple output board is provid- ed on the 18 pin output connector that also provides the output and trim connections. for a triple output board, the sense connectors are as follows: ? for output m1, j2-13 is the + sense and j2-15 is the - sense. ? for output m2, j3-13 is the + sense and j3-15 is the - sense. ? for output m3, j3-4 is the + sense and j3-5 is the - sense. for a quadruple output board, j3-4 is the +sense and j3-5 is the - sense on output m4 only. pg. 14 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide 78m05 auxiliary vcc cbj1-12 0.1 f signal ground cbj1 cbj1-1 +5v/300 ma figure 6: auxiliary vcc flatpac-en 4 7 signal ground general shutdown enable/disable output 1 j1 1 0 ttl "1" (off) ttl "0" (on) a ttl "1" applied to the base of the transistor turns output off. pin 1 (or pin 7 for gsd) is pulled low with respect to signal ground. 5 vcc 1 enable/disable control figure 5: enable/disable mode
note: remote sense is not available for output configurations using the micro modules. external trim (not applicable when using batmod current source) the trim pin can be used for external control of the output voltage. trim connections on single and dual output connector for output m1 is j1-1 while for output m2 is j2-2. trim connections on triple output connectors for out- put m1 is j2-6, for output m2 is j3-6, and for output m3 is j3-14. trim connections for quadruple output connec- tors on outputs m1 and m2 is j2-6 and j2-14 respectively, and for outputs m3 and m4 is j3-6 and j3-14 respec- tively. a 10% increase to the trim pin voltage will result in a 10% increase in output voltage. reducing the trim pin voltage by 10% will result in a 10% decrease in output voltage. output module v ref r th vi-200/vi-j00 3.3v 2.5v 10k ? vi-200/vi-j00 <3.3v 0.97v 3.88k ? 2 nd generation (predefined) 1.23v 1k ? 2 nd generation (userdefined) 1.23v consult factory table 1. module internal reference voltages and thevenin resistances . example: 10% trim adjust on a 12v nominal output. figure 7 shows a typical variable trim circuit. using a 10k trimpot (r7), the resistor values for r6 and r8 can be calculated as follows: v 1 = v ref + 10% = 2.75v given: v ref = 2.5v (see table 1) i r5 = (2.75v - v ref )/r th = (2.75v - 2.5v)/10k ? = 25 a given: r th = 10k ? (see table 1) setting the bottom limit: v r6 = 2.5v - 10% = 2.25v and since i r5 = i r6 = 25 a, r6 = v r6 /i r6 = 2.25v/25 a = 90k ? v 2 = v 1 + v r6 = 2.75v + 2.25v = 5v i r7 = v 2 /r7 = 5v/10k ? = 500 a i r8 = i r7 + i r6 = 525 a v r8 = (v nom +10%) - v 2 = 13.2v - 5v = 8.2v given: v nom = 12v r8 = v r8 /i r8 = 8.2v/525 a = 15.62k ? consult applications engineering when trimming outputs below 5v. rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 15 flatpac-en design guide load +out +sense -sense -out use 24-30 awg twisted pair wire s figure 7: remote sense (remote sense) load +out +sense -sense -out use 24-30 awg twisted pair wires r5 v ref trim r6 r8 r7 to error amplifier r4 r3 r2 r1 + + v 2 v 1 - - rth use 24-30 awg twisted pair wires figure 7: external trim
using a batmod current source in the flatpac-en the batmod is a programmable current source that can also be used as a con- stant voltage converter. it has three control signals that can be found on j2. all three are referenced to the - out pin. current trim j2-1 is an input sig- nal with an analog voltage of one to five volts that can adjust the sourced cur- rent rating from 0 to 100%. voltage must be applied to the current trim input for the module to provide power. the voltage trim j2-2 is an input signal that can be set for a maximum voltage with a fixed resistor, or adjusted by using an external voltage source. a source voltage referenced to the - out of 1.25 to 2.5v for a 50% to 100% of rated voltage adjustment. leaving the voltage trim open will set the trim limit to maximum. the current monitor j2-3 is an output signal that indicates the amount of current being sourced. it is a linear voltage/current relationship in which one volt corresponds to 0% of sourced current, and five volts corresponds to 100% of sourced current. in-line filter (preliminary data. available q4 2003) the in-line filter (part # if1232) provides emi filtering and suppresses transients and surges. these functions allow any westcor power supply to comply with en 55022 class b. it connects to the input side of the flatpac- en as well as other westcor products with input currents lower than 15a rms. the preliminary specifications for the in-line filter are as follows: general dimensions 5.5? x 2.7? x 1.3? (120 x 69 x 33 mm) weight 0.5 lb (0.2 kg.) safety approvals tbd vibration mil-std-810e, category 10 input voltage 85 - 264 vac current 15a rms max. frequency 47-500 hz emi fcc class a and en 55022 class a fcc class b and en 55022 class b eft/burst en 61000-4-4 class 4 performance criteria a surge immunity en 61000-4-5 class 4 performance criteria a envir onmental operating temperature -20 o c to 70 o c storage temperature -40 o c to 90 o c altitude 15,000 ft (4,572m) max. relative humidity non-condensing notes: ? these specifications only apply to if1232 when used in conjunction with a westcor power supply. ? this unit does not have an internal fan. ? specifications subject to change. pg. 16 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide 1 2 3 j2-1 i trim pin (current trim access) j1-3 i mon (current monitor) pin output m2 m2 j2 m2 batmod current source connections j2-2 v trim (voltage trim) j2
specifications (typical at 25c, nominal line and 75% load, unless otherwise specified) g eneral number of outputs 1-4 modules 1st generation: vi-200 or vi-j00 2nd generation: maxi, mini or micro efficiency typically > 70% safety agency approvals ce m arking , c tv us , c ul us vibration meets mil-std-810e, category 10 maximum output power up to 500 watts; 425 watts for en 61000-3-2/a14 compliance (105/190 vac minimum input) i nput input 90-132/180-264 vac (derates to 260w @ 90 vac, 400w @ 180 vac) 47-63hz 250-380 vdc inrush current 14 a pk @ 115 vac 14 a pk @ 230 vac line/load regulation* 0.5 (see module datasheets for exact specifications) ride through time 500w 400w @ 115vac (typical) 12ms 15ms @ 230vac (typical) 16ms 18ms harmonic distortion en61000-3-2 a/14 (for output power 425w or input current not in excess of 3.33 a rms at 230 vac, 50 hz.) conducted emi fcc and en 55022 class a fcc and en 55022 class b (en 55022 class b may require optional in-line filter) power factor >.70 transient burst immunity en61000-4-4 surge immunity en61000-4-5 voltage dips en61000-4-11 dielectric withstand primary to chassis gnd = 1,500 v rms primary to secondary = 3,000 v rms secondary to chassis gnd = 500 v rms * see vicor module specifications. a preload may be necessary for modules trimmed down below 90% of normal output voltage. o utput vi-200/vi-j00 modules (1st generation) parameter min. typ . max. units notes setpoint accuracy* 0.5 1 % of vnom load/line regulation 0.05 0.5 % ll to hl, 10% to full load load/line regulation 0.2 0.5 % ll to hl, no load to 10% temperature regulation 0.01 0.02 %/c over rated temp. long term drift 0.02 %/k hours output ripple & noise: vi-200 100 mv p-p see module design guide vi-j00 100 mv p-p for exact specifications voltage trim range 1st gen slots 50-110 % v out 10% on 10-15 vout total remote sense compensation 0.5 volts autosense. see pg.14 ovp set point 1 115 125 135 %vout recycle power current limit 105 115 125 % of i max auto recovery short circuit current 20 (105 2 ) 130 % overtemperature limiting not available on vi-j00 * for special and adjustable voltages, maximum setpoint accuracy is 2% of vnom. 1 131% nominal for booster modules. no ovp for vi-j00 2 vi-j00 modules only. rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 17 flatpac-en design guide
o utput ( cont ? d .) 2nd generation modules (maxi, mini and micro modules) parameter min. typ . max. units notes setpoint accuracy* 0.5 1 % of v nom load/line regulation 0.05 % of v nom see module design guide for e exact specifications. temperature regulation 0.002 0.005 %/c -20 to 100c long term drift 0.02 %/k hours output ripple and noise: maxi 75 mv p-p see module design guide mini 100 mv p-p for exact output ripple micro 125 mv p-p specifications. voltage trim range 2nd gen slots 10-110 % vout preload may be required. total remote sense compensation 0.5 volts autosense. see pg 14 ovp set point 112 135 % of v out recycle power current limit 102 115 135 % of i max auto recovery overtemperature limiting not available * for special, adjustable voltages and 48vdc outputs, maximum setpoint accuracy is 2% of vnom. note: see individual module datasheets for specific module specifications. e nvironmental storage temperature -20c to +100c (standard range) -40c to +100c (extended temperature range) (extended temperature range option includes module burn-in and temperature cycling) operating temperature ambient air (see derating curves) -20c to +70c case temperature -20c to +90c (75 for full size vi-200 module) specific temperature data on all module configurations can be obtained by contacting applications engineering. altitude derate 2.6% total output power for each 1,000 ft to a maximum operating altitude of 15,000 ft. non-operating storage maximum altitude is 40k. humidity 0 to 95% non condensing product weight 3.4 lbs. (1,5 kg) dimensions 1.4" h (35,6mm) x 5.0" w (127,0mm) x 9.20" l (233,7mm) warranty* 2 years limited warranty. see vicorpower.com for complete warranty statement. * opening, repairing or modifying the unit will void the warranty. if you have any problem with the power supply, please conta ct customer service at 1-800-797-5678. if the unit needs to be returned for inspection/analysis, an rma number will be issued. all units mu st have a rma number prior to return. pg. 18 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide
output power derating rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 19 flatpac-en design guide flatpac-en output power vs. input voltage input voltage (vac) 250 300 350 400 450 500 output power (w atts) 90 95 100 105 115 125 132 132 145 155 165 175 180 185 190 195 200 200 205 215 225 235 245 255 265 safe operating range safe operating range 260 flatpac-en output power vs. dc input voltage 0 50 100 150 200 250 300 350 400 450 500 550 600 250 260 270 280 290 300 310 320 330 340 350 360 370 380 input voltage (vdc) output powe r (w atts ) safe operating range
pg. 20 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide vicor dc to dc converters - 300vin family available power in watts 1 st gen 2 nd gen output voltage vi-200 vi-j00 maxi mini micro 2vdc 80 40 160 100 50 3.3vdc 132 66 264 150 75 5vdc 200 100 400 200 100 12vdc 15vdc 24vdc 28vdc 48vdc 200 100 500 250 150 1. for all module configurations: the flatpac-en or an individual output may be limited by module power limitations. one cannot exceed the output power rating of the flatpac-en regardless of the module capability. 2. also see output power vs. input voltage charts on page 19.
thermal curves for flatpac-en - 5v output (preliminary) rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 21 flatpac-en design guide output power vs. operating temperature low line (90vac-132vac) 5v m odules 0 50 100 150 200 250 300 350 400 450 500 0 102030405060708090 ambient temperature (deg c) output power (watts) lfm=1000 lfm=750 lfm=500 free air 9/12/2002 preliminary output power vs. operating temperature high line (180vac-264vac) 5v m odules 0 50 100 150 200 250 300 350 400 450 500 0 102030405060708090 ambient temperature (deg c) output power (watts) lfm=1000 lfm=750 lfm=500 free air 9/12/2002 preliminary
pg. 22 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide output power vs. operating temperature low line (90vac-132vac) 12v-48v m odules 0 50 100 150 200 250 300 350 400 450 500 0 102030405060708090 ambient temperature (deg c) output power (watts) lfm=1000 lfm=750 lfm=500 free air 9/17/2002 preliminary output power vs. operating temperature high line (180v-264vac) 12v-48v m odules 0 50 100 150 200 250 300 350 400 450 500 0 102030405060708090 ambient temperature (deg c) output power (watts) lfm=1000 lfm=750 lfm=500 free air 9/23/2002 preliminary thermal curves for flatpac-en - 12v-48v output (preliminary)
current share board - optional feature rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 23 flatpac-en design guide " 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 sup- ply and allows them to run cooler, resulting in higher reliability. standard "current sharing" tech- niques typically utilize shunt resis- tors or hall effect devices to meas- ure the current from each power supply. power shunt resistors con- tinually dissipate power and require cooling especially when dealing with high output currents of >100amps. hall effect devices measure magnetic fields generated by current flowing through a con- ductor and, although they dissipate no power, they tend to be large and expensive. first developed by westcor 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 uni- directional and can only trim an output voltage up. the ben- efit 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 hotswap applications. 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 prop- er operation. 50mv to 100mv of drop will provide from 5% to 1% accuracy. 3. -v1 and -v2 for all box-to-box circuits must be connect- ed 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 connec- tions. 5. when using d*, the power input should be connected on the cathode side of the paralleling diodes as shown above. 6. terminate sense leads either locally or remotely as shown in figure 1. 7. for paralleling more than 2 supplies consult factory for assistance. figure 1. csb interconnect example supply # 1 5v @ 120a +out +s -out -s trim supply # 2 5v@120a +out +s -out -s trim t1 -v1 t2 -v2 power +vout -vout d* d* csb02 black white brown yellow red
current share board - optional feature (continued) specifications: 1. power: 2-50vdc at 5ma maximum. 2. accuracy: +/- 1mv between -vout connections. 3. output current when not trimming up: +/- 1ua (vi-200/j00), +/-5ua (2nd generation). 4. use 4 non-plated through holes with standoffs for mounting. 5. csb01 must be used for current sharing 1st generation converters (vi-200/j00). 6. csb02 must be used for current sharing 2nd generation converters (maxi, mini and micros). ***please note, the csb is not intended for hotswap applications*** contact your regional applications engineer at 1-800-927-9474 for additional information. pg. 24 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 rev. 4/2003 flatpac-en design guide figure 3. cable drawing p1 24.0" +/- 1.0" power t1 -v1 t2 -v2 red, 22 awg yellow, 22 awg brown, 22 awg white, 22 awg black, 22 awg 1 2 3 4 5 6 1.74" (44.2mm) 0.12" (3.0mm) 1.500" (38.1mm) 0.12" (3.0mm) 0.900" (22.9mm) 1.14" (29.0mm) 0.13" (3.3mm) dia non plated thru hole 4 places molex ct43045f surface mountable connector. .390" height above board. pin description 1 power 2t1 3 -v1 4t2 5 -v2 6 no connection j1 pinout figure 2. mechanical drawing
notes rev. 4/2003 vicor 800-735-6200 westcor division 408-522-5280 applications engineering 800-927-9474 pg. 25 flatpac-en design guide
flatpac-en design guide vicor global offices 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's comprehensive line of power solutions includes modular, high-density dc- dc converters and accessory components, configurable power supplies, and custom power systems. westcor, a division of vicor, designs and builds, configurable power supplies incorporating vicor?s high density dc-dc converters and accessory components. westcor?s product line includes: lopac family: ? pfc micros ? pfc micro ? pfc mini megapac family: ? pfc megapac ? pfc megapac-el (low noise) ? pfc megapac (high power) ? pfc megapac (low noise/high power) ? mini megapac ? autoranging megapac ? 4kw megapac ? 4kw megapac-el (low noise) ? converterpacs others: ? flatpac-en information furnished by vicor is believed to be accurate and reliable. however, no responsibility is assumed by vicor for its use. no license is grant- ed by implication or otherwise under any patent or patent rights of vicor. vicor components are not designed to be used in appl ications, such as life sup- port systems, wherein a failure or malfunction could result in injury or death. all sales are subject to vicor's terms and cond itions of sale, which are available upon request. specifications are subject to change without notice. the latest data is available on the vicor website at vicorpower.com _________________________________________________________________________________________________ www.vicorpower.com usa vicor corporation, corporate headquarters 25 frontage road andover, ma 01810 tel: 800-735-6200, tel: 978-470-2900 fax: 978-475-6715 vicor corporation 377 e. butterfield road suite 201 lombard, il 60148 tel: 630-769-8780 fax: 630-769-8782 vicor, westcor division 560 oakmead parkway sunnyvale, ca 94085 tel: 408-522-5280 fax: 408-774-5555 europe vicor france vicor germany tel: 33-1-3452-1830 tel: +49-89-962439-0 free phone free phone france only : germany only : 0800 419 419 0800 018 29 18 fax: 33-1-3452-2830 fax: +49-89-962439-39 email: vicorfr@vicr.com email: vicorde@vicr.com vicor italy vicor u.k. tel: +39-02-2247-2326 tel: +44-1276-678-222 free phone italy only: free phone uk only: 800-899-677 0800-980-8427 fax: +39-02-2247-3166 fax: +44-1276-681-269 email: vicorit@vicr.com email: vicoruk@vicr.com asia-pacific vicor hong kong tel: +852-2956-1782 fax: +852-2956-0782 vicor japan co., ltd. tel: 81-3-5487-3880 fax: 81-3-5487-3885 ? vicor corporation 2003

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