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/in3.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 Vac1, 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/A142
• 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%
• Autosense3
• 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, CTÜVUS, CULUS
1Derates to 260W@90Vac, 400W @ 180 Vac.
2For 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 FLx1-x2 x3 -xxx (-x4)x
1Number of outputs
e.g. FL4-13-501 x2Number of 1st Gen VI-200 & VI-J00 modules
x3Number of 2nd Gen Maxi, Mini and Micro modules
xxx Sequential number assigned by Westcor
(x4) 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 90oC. 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
TT
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
23
CBJ1 E/D INTERFACE CONNECTOR
CB J1 (12 PIN)
23
MBJ1
1
OUTPUTS M1 & M2 OUTPUTS M3 & M4
OUTPUT M2 & M3
OUTPUT M1
OUTPUT M1 OUTPUT M2
9.53.38 215.908.500
12.70.50
101.604.000
4X #8-32 x .125 OR M4 x 3mm MAX LG
FROM OUTSIDE OF POWER SUPPLY
CUSTOMER MOUNTING HOLES
138.435.450
147.965.825
5.56.219
115.894.563
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
23
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
35.591.40
233.699.20
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
4CBJ4 AND CBJ5 ARE PART OF THE RS-232 MICROCONTROLLER FUNCTIONS. SEE PAGE 12 INFORMATION.
4
5FOR 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 +/- 1/2o
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 14Apk 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
110
918
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
110
918
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 µF
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.
5Vcc
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 Vref RTH
VI-200/VI-J00 ≥3.3V 2.5V 10kΩ
VI-200/VI-J00 <3.3V 0.97V 3.88kΩ
2nd Generation (Predefined) 1.23V 1kΩ
2nd 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:
V1= Vref + 10% = 2.75V Given: Vref = 2.5V (see Table 1)
IR5 = (2.75V - Vref)/RTH = (2.75V - 2.5V)/10kΩ= 25µA Given: RTH = 10kΩ(see Table 1)
Setting the bottom limit:
VR6 = 2.5V - 10% = 2.25V
And since IR5 = IR6 = 25µA,
R6 = VR6/IR6= 2.25V/25µA = 90kΩ
V2= V1+ VR6 = 2.75V + 2.25V = 5V
IR7 = V2/R7 = 5V/10kΩ= 500µA
IR8 = IR7 + IR6 = 525µA
VR8 = (Vnom +10%) - V2= 13.2V - 5V = 8.2V Given: Vnom = 12V
R8 = VR8/IR8 = 8.2V/525µA = 15.62kΩ
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
+
+
V2
V1
-
-
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
Environmental
Operating Temperature -20oC to 70oC
Storage Temperature -40oC to 90oC
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 25°C, nominal line and 75% load, unless otherwise specified)
GENERAL
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 MARKING, CTÜVUS, CULUS
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)
INPUT
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 VRMS
Primary to Secondary = 3,000 VRMS
Secondary to Chassis GND = 500 VRMS
* See Vicor module specifications. A preload may be necessary for modules trimmed down below 90% of normal output voltage.
OUTPUT
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 Point1115 125 135 %Vout Recycle Power
Current Limit 105 115 125 % of I max Auto Recovery
Short Circuit Current 20 (1052) 130 %
Overtemperature Limiting Not available on VI-J00
*For special and adjustable voltages, maximum setpoint accuracy is 2% of Vnom.
1131% 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
OUTPUT (CONT’D.)
2nd Generation Modules (Maxi, Mini and Micro modules)
Parameter MIN. TYP. MAX. UNITS NOTES
Setpoint Accuracy* ±0.5 ±1 % of VNOM
Load/line Regulation ±0.05 % of VNOM See module design guide for e
exact specifications.
Temperature Regulation 0.002 0.005 %/°C -20 to 100°C
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 Vout 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.
ENVIRONMENTAL
Storage Temperature -20°C to +100°C (Standard Range)
-40°C to +100°C (Extended Temperature Range)
(Extended temperature range option includes module burn-in and
temperature cycling)
Operating Temperature
Ambient air (see derating curves) -20°C to +70°C
Case Temperature -20°C to +90°C
(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 contact 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 must 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
O utput P ow er
(Watts)
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)
Outpu t Power
(Watts)
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
1st Gen
2nd 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 Modules
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 Modules
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 Modules
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 Modules
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
12
34
56
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 applications, 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 Conditions 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
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