VIPAC Data Sheet Design Guide · Overview Vicor’s VIPAC offers the choice of 115/230Vac autoranging or 48Vdc input. The front end section utilizes Vicor’s FARM or FIAM input module

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


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


Efficiency (typ) 71 72 75 78 82 86 87 88 88 89 %







Maxi

Parameter 1.8V1

2V 2.5V2


Efficiency (typ) 73 74 76 80 83 85 87 88 89 90 %







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


*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

–


+

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


FARM

6 PinConnector

+ V BUS

Strap

- V BUS

L1

L2/N

HUBHold-up Box

+PC

PR

–

+PC

PR

–

+PC

PR

–

+

SC

–


+

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


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.


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


J2 1 V Bus+ P/N 224992 Strap 3 V Bus–4 L2/N5 L16 GND


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


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


*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


14

1

5

1

5

Micro LugMate

Ring LugsLugMate (Factory Installed Option)


J4

1

5

1

5

Mini/Maxi LugMate


*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.


*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*


15

1

234

5

1

234

5

123

123

123

*Use of CableMate requires compatible module pins, specified with VCAD Design Tool.


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


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


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)



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


0.5" Fin Option

Coldplate

Note 2: (1 location)




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


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)


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

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In UK: 0800-980-8427In Denmark: 80 88 11 41In Norway: 800 11083In Sweden: 020 798236

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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.

Documents

VIPAC Data Sheet Design Guide · Overview Vicor’s VIPAC offers the choice of 115/230Vac autoranging or 48Vdc input. The front end section utilizes Vicor’s FARM or FIAM input module