VICOR MegaPAC 3-Phase User manual

UG:107 Page 1
Overview
The 3-Phase MegaPAC and 4kW MegaPAC are field configurable, single- or multiple-output switchers
providing up to 2,000W (3-Phase MegaPAC) to 4,000W (4kW MegaPAC) of output power. The chassis
has ten slots and can provide up to 40 regulated, fully-isolated outputs. It achieves power densities
of 4.4W per cubic inch (3-Phase MegaPAC) to 7.8W (4kW MegaPAC) per cubic inch. The dimensions
of the 3-Phase MegaPAC are 4.9 x 7.5 x 12.3in [124,5 x 190,5 x 312,4mm] and the dimensions of the
4kW MegaPAC are 4.9 x 7.5 x 14in [124,5 x 190,5 x 355,6mm]. The 4kW MegaPAC is longer than the
3-Phase MegaPAC to accommodate a second fan.
A complete power supply is configured at the factory by selecting and inserting up to ten same-length
slide-in output assemblies called ConverterPACs™. ConverterPACs incorporate one or two
VI-200™ / VI-J00™ and / or Maxi Vicor DC-DC converters and are available in a wide selection of
outputs and power levels. The net result is a power supply that offers the advantages of a custom
supply, but is assembled from standard and modular building blocks. For detailed information about
ConverterPACS, refer to the ConverterPAC information sheet. The 4kW MegaPAC uses VI-200 /
VI-J00 and Maxi Vicor DC-DC converters while the 3-Phase MegaPAC uses VI-200 / VI-J00 Vicor
DC-DC converters.
Manufactured at Vicor, the entire family of MegaPAC power supplies is completely user-configurable.
If output requirements change, i.e., more power or a different output voltage is needed, upgrading is
easy: simply unlock a single screw and replace the slide-in ConverterPAC with one of the same length
and has the desired voltage power rating. For additional flexibility, same-length ConverterPACs can
be connected in parallel to increase output power (booster ConverterPACs), or in series for higher
voltages (total output voltage should not exceed 400V). The driver is to the left of the boosters
when looking at the output end of the supply. A user-friendly interface provides control and output
sequencing capability, in addition to useful status indicators. Please consult our Applications Engineering
Department if you have other special requirements.
3-Phase MegaPAC
4kW MegaPAC
Overview 1
Standard Features 2
Optional Features 2
Mechanical Considerations 2
MegaPAC Dos and Don’ts 3
Technical Description 4
Configuring and
Reconfiguring MegaPACs 5
ConverterPAC Functional
Description 6
ConverterPAC Output
and Connector Pin
Identification for the 3-Phase /
4kW MegaPACs 8
Part Numbering 10
3-Phase and 4kW MegaPACs Quick
Install Instructions 12
3-Phase MegaPAC
Mechanical Drawings 15
4kW MegaPAC
Mechanical Drawings 16
Interface Connections 17
Specifications 25
Current Share Boards -
Optional Feature 26
Current Share Boards -
Optional Feature Diagram 28
Low-Leakage Version 29
3-Phase MegaPAC™ and
4kW MegaPAC™ AC-DC Switchers
USER GUIDE | UG:107
Contents Page
Note: This user guide contains references to parts and products that are no longer available for new designs.
They remain included for reference only.

UG:107 Page 2
Standard Features
 Input: 3-phase 208 / 240VAC Wye or Delta, 1-phase 180 – 264 (47 – 500Hz) or 260 – 352VDC
 Power Output: 3-Phase MegaPAC™: 2,000W with 3-phase input;
1,200W with 1-phase input; 1 – 20 outputs
4kW MegaPAC™: 4,000W with 3-phase input;
1,500W with 1-phase input; 1 – 20 outputs
 Ten slots (up to 20 outputs)
 Fan cooled (the 4kW MegaPAC has two fans)
 Full-power to 45°C; half power to 65°C
 Power factor correction (passive) 0.92PF (3-phase input)
 Conducted EMI meets EN 55022 Level A
 AC Power OK and AC Power Fail status signals
 Output Sequencing and General Shut Down
(Consult Applications Engineering for automatic sequencing circuitry)
 Autosense (Refer to pages 13 and 17 for more information on Autosense)
 Overcurrent protection on all outputs
 Overtemperature limiting (not applicable with VI-J00™ modules)
 Output overvoltage protection (not applicable with VI-J00 modules)
 Ride-through time: >20ms at nominal line (full load)
 Size: 4kW MegaPAC: 4.9 x 7.5 x 14in [124,5 x 190,5 x 355,6mm] Regular chassis
Size: 3-Phase MegaPAC: 4.9 x 7.5 x 12.3in [124,5 x 190,5 x 312,4mm] Regular chassis
 Safety Agency Approvals: CE Mark, UL, CSA, TÜV
Optional Features
 DC OK status signal
 Output voltage adjustment range with built-in potentiometer
 Reversed fan air-flow direction
 Industrial-grade screening of output converters
 Current Share Boards (see pages 26 – 28)
Mechanical Considerations
The 3-Phase MegaPAC and 4kW MegaPAC can be mounted on any of four surfaces using standard
8-32 or 4mm screws. The chassis comes with four mounting points on each surface; maximum
allowable torque is 20lb.in. The maximum penetration is 0.15in [3,8mm].
When selecting a mounting location and orientation, the unit should be positioned so air flow is not
restricted. Maintain a two inch minimum clearance at both ends of the 3-Phase MegaPAC and 4kW
MegaPAC and route all cables so air flow is not obstructed. The standard unit draws air in at the
fan side / AC input side and exhausts air out the load side. If air-flow ducting is used, use caution, as
sharp turns could present back pressure to the 3-Phase MegaPAC and 4kW MegaPAC. The fans move
approximately 50CFM of air for the 4kW MegaPAC and 30CFM for the 3-Phase MegaPAC. The 4kW
MegaPAC has a second fan for additional cooling capabilities.
Avoid excessive bending of output power cables after they are connected to the 4kW MegaPAC or
3-Phase MegaPAC. For high-current outputs, use cable ties to support heavy cables in order to minimize
mechanical stress on output studs. Be careful not to short-out to neighboring output studs. The
3-Phase MegaPAC and 4kW MegaPAC is supplied with serrated, flanged hex-nuts on all output studs,
so thread-locking compounds or lock washers are not required. The maximum torque recommended
on flanged nuts is 45lb.in. Never loosen the inner nut on a ConverterPAC™. This nut supports the
hardware inside the ConverterPAC and is factory torqued.
Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such
applications, a shock-absorption mounting design is required.

UG:107 Page 3
MegaPAC Dos and Don’ts
 For units without Autosense, do not leave ConverterPAC™ SENSE lines open. Always terminate
them at their respective outputs locally or at the load. Use twisted pair 22 – 24AWG wire. If
ConverterPAC has Autosense, no local-sense connection is required. See Pages 13 and 17 for
more information on Autosense.
 If needed, use Connector Kit #19-130041 for the 3-Phase / 4kW MegaPACs.
 Always fill all output slots of the MegaPAC™. If a slot is not filled with a ConverterPAC, it
should be filled with an airblock. Airblocks are plastic assemblies whose main function is to fill up
an empty slot. Any airflow escape from an empty slot, significantly degrade thermal performance can
result in overheating and damage to the power supply.
 Do not unplug ConverterPACs while input power is applied. They are not designed for
hot-plug applications.
 Do not restrict air flow to the unit. Leave a two-inch minimum space in front and behind the
supply. The cooling fan draws air into the unit and forces it out at the output power terminals.
 For power expansion, use booster ConverterPACs. Viewing the unit from the output terminal side,
always insert boosters to the right side of the driver.
 Do not use boosters as independent outputs. Disconnecting bus bars will damage
booster ConverterPACs.
 Always ensure that output hex-nuts are properly torqued before applying power to supply.
 For booster arrays, do not remove bus bars.
 Run the output (+/–) power cables next to each other to minimize inductance.
 Wait five minutes after shutting off power before inserting or removing ConverterPACs.
 The MegaPACs does not have user-serviceable components. They must be returned to the factory
for repairs. Contact Customer Service for a RMA number before returning the unit. Do not attempt
to repair or modify the power supply in any manner other than the exchange of ConverterPACs as
described in this user guide.
 Insert proper fault protection at power supply input terminals (i.e., a fuse).
 Use proper-size wires to avoid overheating and excessive voltage drop.
 Never loosen the inner nut on a ConverterPAC.
 Verify output nuts are tight before powering up.
 Only use the regular-length ConverterPACs in the 3-Phase / 4kW MegaPAC chassis. You cannot use
any of the extended-length ConverterPACs which are only used in the EL (low-noise) products.
 Keep in mind that currently, the UniPAC™ ConverterPAC can only be used in the 4kW MegaPAC.

UG:107 Page 4
Technical Description
The 3-Phase MegaPAC™ and 4kW MegaPAC are configured by installing same-length ConverterPAC™
assemblies into the chassis. The chassis takes AC input power and performs filtering and rectification
functions. The ConverterPACs plug into a high-voltage backplane and provide low-noise,
independently-regulated and fully-isolated outputs.
Input AC mains voltage (L1, L2, L3 and GND) is applied to an agency-approved mating plug. The input
current is passed through an EMI filter designed to meet EN 55022 Level A before it is passed to a
three-phase, full-wave bridge rectifier. The rectifier charges storage capacitors and delivers unregulated
300VDC to a backplane after passing through a large choke that improves input power factor. The
power factor typically exceeds 0.9 depending upon load, line voltage, frequency and line balance. Inrush
current is actively controlled with an IGBT and never exceeds 30A peak regardless of hot or cold starts.
A housekeeping supply, isolated from the AC input, powers the brushless DC cooling fan and other
input monitoring circuits, in addition to providing an auxiliary +5V power source for the user. The 4kW
MegaPAC has a second fan for extra cooling. Excessive input currents caused by loss of a phase
or excessive output loading in single-phase operation will safely shut down the unit until input power
is recycled. This occurs when the peak input current reaches 30A. An analog temperature monitor
is provided, as well as overtemperature shut down. An active-high TTL compatible Enable control is
included for each ConverterPAC assembly, as well as an active-low General Shut Down control; the
polarities, active-high or active-low, are factory set. The 3-Phase MegaPAC and 4kW MegaPAC can be
safely paralleled (with another of its own kind) with accurate current sharing for high-power systems. All
interface signals are safety isolated using a common floating return.
Upon power up, all outputs are first disabled to limit the inrush current and to allow the unregulated
bus to reach correct operating levels for ConverterPAC assemblies. The internal housekeeping supply
comes up within 500ms after input power is applied and the AC Power OK signal asserts to a TTL "1,"
indicating the input power is OK. The low-voltage power outputs come up within 10 – 20ms after the
AC Power OK asserts to a TTL "1." Output ramp-up time from Enable or General Shut Down is
10 – 20ms. Output-fall time from Disable is dependent on load, but is typically a few
hundred microseconds.
Fuse
Isolated
Housekeeping
Power Supply
DC Brushless
Cooling Fan
EN 55022
Level A
3-Phase
Full-Wave
Rectifier
PFC Choke
IGBT
Opto-isolated
Control / Status
J10
Customer
Interface
J1
Input
Power
+P, –P
Output
Power
Remote Sense,
Trim Interface
Power Good
Interface
3 Phase/4kW MegaPAC Chassis ConverterPAC (Up to ten)
DC/DC
Converter
Start-up Control
Circuits
Figure 1
3-Phase MegaPAC and
4kW MegaPAC Architectures

UG:107 Page 5
Configuring and Reconfiguring MegaPACs™
Most ConverterPACs™ of the same length can be easily added, replaced or moved by sliding the
assemblies in or out of a MegaPAC chassis. They are driver ConverterPACs and can be inserted into
any available slot. For outputs greater than 200W, a driver ConverterPAC and one or more booster
ConverterPACs will be used. For outputs greater than 500W (in the 4kW MegaPAC), a driver UniPAC™
and one or more booster UniPACs will be used. Arrays of drivers and boosters should be configured so
all boosters are placed in the slots to the immediate right of the driver when looking at the output end
of the MegaPAC.
Prior to removing or installing ConverterPACs, you must remove power from the MegaPAC
and wait five minutes. Failure to do so can result in personal injury or damage to the supply.
Take standard ESD precautions when handling ConverterPACs.
Removing ConverterPACs
ConverterPACs can be removed by loosening the captive screw at the base. Once this screw has
been loosened, the ConverterPAC will slide out of the chassis. Once a ConverterPAC has
been removed, the empty slot MUST be filled with either another ConverterPAC of the same
length or an airblock. If the slot is left empty, it will provide an airflow escape and cause failure to
the power supply.
Installing ConverterPACs as Drivers
ConverterPACs can be installed in empty slots by simply sliding in the new ConverterPAC and securing
the screw at the base. Torque the retaining screw to 0.23N.m (2lb.in); do not overtighten. Power and
interface connections can be made after the ConverterPAC has been installed.
Installing Booster ConverterPACs to Increase Output Power
ConverterPACs can be paralleled for more power. Additional power to an output is obtained by
connecting one or more boosters in parallel with a single driver. The driver can be placed in any open
slot. All boosters should be inserted in the slots to the immediate right of the driver, as viewed from the
output end of the MegaPAC. Figure 2 shows a driver placed in slot #1 and three boosters placed in slots
#2 – 4. After inserting the driver and boosters, they are paralleled using bus bars across the positive and
negative output studs. Drivers should not be paralleled with each other. Bus bars between a driver and
booster(s) should never be disconnected. For help in identifying boosters and drivers, refer to the Part
Numbering section on Page 10. Please note that total output voltage should not exceed the converter
baseplate-output isolation rating of 400V. For a detailed guideline on how outputs should be placed in
series, please refer to: AN:204 Creating High-Voltge Outputs.
Driver
Bus Bars for Paralleling
Loosen screw to
remove ConverterPAC
Boosters: Slots 2, 3, 4
12345678
L1 L2 L3
910
Figure 2
Paralleling ConverterPACs

UG:107 Page 6
ConverterPAC™ Functional Description
ConverterPACs are the family of slide-in output assemblies used in MegaPAC™ power supplies. Most
ConverterPACs of the same length are interchangeable within a MegaPAC or between different AC
input chassis. They can be added, moved or changed as necessary. The following ConverterPACs can be
used in the 3-Phase and 4kW MegaPACs.
ModuPAC™
The ModuPAC output assembly consists of a VI-200™ Vicor DC-DC converter that converts the
unregulated high-voltage bus to the desired regulated output voltage. Each ModuPAC can provide
up to 200W of power. Multiple ModuPACs can be paralleled in a driver-booster configuration to
provide more power.
JuniorPAC™
The JuniorPAC consists of a VI-J00™ Vicor DC-DC converter that converts the unregulated high-voltage
bus to the desired regulated-output voltage. JuniorPACs can provide up to 100W of output power.
DualPAC™
This output assembly consists of two VI-J00 Vicor DC-DC converters that convert the unregulated
high-voltage bus to the desired regulated-output voltages.
RamPAC™
This output assembly consists of a VI-J00 Vicor DC-DC converter with a Ripple Attenuator Module
(RAM) and is designed for applications requiring low-output ripple / noise.
BatPAC™
The BatPAC output assembly consists of a VI-200 BatMod current source that converts the unregulated
high-voltage bus to the desired regulated-output voltage. The BatPAC is a 200W programmable current
source that can be configured as a battery charger.
UniPAC™
The UniPAC output assembly consists of a Maxi Vicor DC-DC module that converts the unregulated
high-voltage bus to the desired regulated-output voltage. UniPACs can provide up to 500W of
power. Multiple UniPACs can be paralleled in a driver-booster configuration to provide more power.
The UniPAC can only be used in the 4kW MegaPAC (not in the 3-Phase MegaPAC or any
other MegaPACs).
+
_
Remote Sense
VI-200
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
+
_
VI-J00
Remote Sense
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
Remote Sense
Output #2 Adjust
Output #2
Output #1
Remote Sense
Output #1 Adjust
VI-J00 VI-J00
M2 M1
M1
M2
+
_
VI-J00 RAM
Remote Sense
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
+ Vout
VI-200/BatMOD
- Vout
Remote Interface
Voltage Limit Adjust
Current Limit Adjust
+
_
ModuPAC
JuniorPAC
DualPAC
RamPAC
BatPAC
+
_
Remote Sense
Maxi
Output Adjust
- Vout
+ Vout
DC OK (Power Good)
UniPAC

UG:107 Page 7
OVP Overvoltage Protection (latching) OCP Overcurrent Protection (auto-recovery)
OTL Overtemperature Limiting (latching) RS Remote Sense
PG Power Good (DC OK TTL Signal) LS Local Sense
AS Autosense
Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualPAC, JuniorPAC and RamPAC.
List of ConverterPACs™ used in the 3-Phase / 4kW MegaPACs™ and their features
ConverterPAC OVP OCP OTL RS/AS
[a] LS/AS [a] PG TrimPot
ModuPAC™ Std Std Std AS
[a] AS [a] Opt Opt
JuniorPAC™ N/A Std N/A AS
[a] AS [a] Opt Opt
DualPAC™ N/A Std N/A AS
[a] AS [a] N/A Opt
RamPAC™ N/A Std N/A AS
[a] AS [a] Opt Opt
BatPAC™ N/A Std N/A N/A N/A N/A Std
UniPAC™
[b] Std Std N/A AS [a] AS [a] Opt Opt
[a] See Pages 13 and 17 for more information on Autosense.
[b] Currently, the UniPAC (XU) can only be used in the 4kW MegaPAC.

UG:107 Page 8
ConverterPAC™ Output and Connector Pin Identification for the
3-Phase / 4kW MegaPACs™
J2-B-PIN1
OUTPUT ADJUST
J2-A-PIN1
J2
(REMOTE SENSE) MATING HDWR:
HOUSING- MOLEX P/N: 50-57-9403
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 63811-8700
3–SENSE
+SENSE
1TRIM PIN ACCESS
2
OUTPUT ADJUST
J1-B-PIN1
J1-A-PIN1
(OUTPUT CONNECTORS)
1 AND 4 +VOUT
33 +R/SENSE 6 –R/SENSE
1
2
J1
TERMINALS- MOLEX P/N: 39-00-0039
HOUSING- MOLEX P/N: 39-01-2060
CRIMP TOOL MOLEX P/N: 63819-0901
MATING HDWR:
6
5
4
2 AND 5 –VOUT
DUALPAC
VOLTAGE LIMIT ADJUST
J2 (BATPAC REMOTE INTERFACE)
CURRENT MONITOR
CURRENT LIMIT ADJUST
–VOUT
VOLTAGE LIMIT ADJUST
1
–VOUT
3
2
4
J2-PIN1
CURRENT LIMIT ADJUST
CRIMP TOOL MOLEX P/N: 63828-1900
TERMINALS- MOLEX P/N: 80-70-1040
HOUSING- MOLEX P/N: 50-37-5043
MATING HDWR:
BATPAC
+VOUT
DualPAC™
BatPAC™
20-130182-TAB
J1-B (M1)
J1-A (M2)
M2 M1
Output A
48V/2.1A
Output B
12V/8.3A
Example: D12V/8.3A-48V/2.1A
DUALPAC - COMPONENT SIDE VIEW

UG:107 Page 9
ConverterPAC™ Output and Connector Pin Identification for the
3-Phase / 4kW MegaPACs™ (Cont.)
POWER GOOD INVERTED
P2 REMOTE SENSE TRIM/SC & POWER GOOD
3
2
4
1
POWER GOOD
SIGNAL GROUND
VCC IN
TERMINALS- MOLEX P/N: 08-70-1040
HOUSING- MOLEX P/N: 50-37-5073
MATING HDWR:
OUTPUT ADJUST
–VOUT
+VOUT
P2-PIN1
7
6
5
+SENSE
–SENSE
TRIM
CRIMP TOOL MOLEX P/N: 63828-1900
UNIPAC
J2-PIN1
J3-PIN1
0UTPUT ADJUST
+VOUT
–VOUT
(REMOTE SENSE)
J2
2
1
3–SENSE
+SENSE
MATING HDWR:
TRIM PIN ACCESS
3POWER GOOD
2
1SIGNAL GROUND
POWER GOOD INVERTED
MATING HDWR:
4
J3 DC OK (POWER GOOD)
V
CC
IN
HOUSING- MOLEX P/N: 50-57-9403
TERMINALS- MOLEX P/N: 16-02-0103
CRIMP TOOL MOLEX P/N: 63811-8700
HOUSING- MOLEX P/N: 50-37-5043
TERMINALS- MOLEX P/N: 08-70-1040
CRIMP TOOL MOLEX P/N: 63828-1900
MODUPAC
UniPAC™
ModuPAC™
JuniorPAC™
RamPAC™
Note: The UniPAC can ONLY be used in the 4kW MegaPAC™.

UG:107 Page 10
Part Numbering
3-Phase MegaPAC™ mPx1-5x2xxxx
e.g. MP4-510108
m= M or W
P= P
x1= number of outputs
9= 3-Phase MegaPAC chassis
x2= number of modules
xxxx = assigned by Vicor
4kW MegaPAC™ mPx1-4x2xxxx-x3x4-x5-x6
With VI-200™ / VI-J00™ e.g. MP10-410008-23
With Maxi e.g. MX10-410008-23
m= M or W
P= P
x1= number of outputs
4= 4kW MegaPAC chassis
x2= number of modules
xxxx = assigned by Vicor
x3= Optional Code 2 = VI-J00 or VI-200 module in slot #1; 3 = Maxi in Slot 1
x4= Optional Code 2 = VI-J00 or VI-200 module in slot #10; 3 = Maxi in Slot 10
x5= Optional Code
x6= Optional Code
ConverterPAC™ XxDV/xEAxF
e.g. M15V/10A
e.g. M15V/10ADF
e.g. D15V/6.7A-12V/8.3AT
X= ConverterPAC type - If RoHS precede with a “G”
M= ModuPAC™ D= DualPAC™ R= RamPAC™ J= JuniorPAC™ B= BatPAC™
XU = UniPAC™ (currently only used in the 4kW MegaPAC)
xD= Voltage out
xE= Current out (rounded to one decimal point)
xF= Can be multiple options (see next page)

UG:107 Page 11
ConverterPAC™ options
BBooster module (SI for FasTrak) MM-Grade module
DDC OK or Power Good
[c] PPreload
FFull 50 – 110% output adjustment
[d] RRAM external [e]
F1 50 – 107.5% output adjustment STrimpot removed for external BatPAC adjustment
F2 50 – 105% output adjustment T90 – 110% output adjustment
[f]
F3 50 – 102.5% output adjustment T1 90 – 107.5% output adjustment
F4 50 – 100% output adjustment T2 90 – 105% output adjustment
F5 60 – 110% output adjustment T3 90 – 102.5% output adjustment
F6 70 – 110% output adjustment T4 90 – 100% output adjustment
F7 80 – 110% output adjustment T5 98 – 105% output adjustment
F8 90 – 110% output adjustment T6 100 – 110% output adjustment
F9 100 – 110% output adjustment V1 "VXI" low noise (150mV) 15V < VOUT ≤ 24V outputs
[g]
I/H I-/H-Grade module V2 "VXI" low noise (50mV) VOUT ≤ 15VDC
KCustom SRF module used V3 1% ripple for outputs > 24V
[c] D option: Optional for all ConverterPACs EXCEPT the DualPAC™, BatPAC™.
[d] F option: Optional for all ConverterPACs EXCEPT the BatPAC™ and DualQPAC™.
[e] R option: When using an external RAM, components such as autosense resistors and local sense jumpers must
be removed before turning on the supply. In addition, in order to insure proper operation, sense pins must be
connected either locally or remotely after the RAM's output.
For further information, contact Applications Engineering.
[f] T options: Optional for all ConverterPACs EXCEPT the BatPAC and DualQPAC.
[g] V options: Optional ONLY on the ModuPAC™, DualPAC and JuniorPAC™. N/A on all other ConverterPACs.

UG:107 Page 12
3-Phase and 4kW MegaPACs™ Quick Install Instructions
(For Mechanical Drawing, see Page 15 – 16.)
Mounting the 3-Phase MegaPAC and 4kW MegaPAC
 The 3-Phase MegaPAC and 4kW MegaPAC can be mounted on any of four sides.
 Use #8-32 or 4mm mounting screws. Maximum penetration should not exceed 0.15in [3,8mm].
 A minimum of 2in [5,1cm] clearance must be maintained at either end of the supply in order to insure
proper air flow and cooling.
 Maximum allowable torque is 20lb.in.
Input Connections
Input Power J1
 Input AC power is applied to terminal block J1 using mating receptacle AMP
#54483-4 with #53892-4 crimp or #54329-1 solder terminals provided.
 Use size 12AWG wire with soldered terminals.
 A fuse or circuit breaker in the input line is required for safety reasons.
Output Connections
Power Connections
Installing ring lugs and / or bus bars on output studs:
 The upper stud is Positive and the lower stud is the Return.
 Remove outer nut. Do not remove or loosen inner nut.
 Place ring lug over output stud.
 Replace and tighten outer nut to a maximum torque of 45lb.in. Do not over-tighten nuts.
 Verify all output nuts are properly installed before turning on supply.
Installing power connectors on DualPACs™ (J1A and J1B):
 Use Molex mating receptacle #39-01-2060 with #39-00-0039 terminals provided.
 Pins 1 and 4 are Positive, while pins 2 and 5 are the Return.
 Attach terminals to 18 – 24AWG stranded wire using Molex tool #63819-0901.
J2-PIN1
J3-PIN1
0UTPUT ADJUS
T
+VOUT
–VOUT
MODUPAC
6 –REMOTE SENSE
3 +REMOTE SENSE
2 & 5 –VOUT
1 & 4 +VOUT
PIN
J1B
+
46
-
5
+
+RS
-
–RS
321
J1A
321
46
+RS
–RS
+
+
-
5
-
Input Panel Connectors
Single-Output ModuPAC™
DualPAC Output Connector
J1-4 Earth Ground
J1-1 Line 3
J1-2 Line 2
J1-3 Line 1
J1

UG:107 Page 13
3-Phase and 4kW MegaPACs™ Quick Install Instructions (Cont.)
Sense Connections
Note: Newer power supplies may have a new feature installed called Autosense. For units with Autosense, if
remote-sense connections are not made or needed, no local-sense selection is necessary - simply connect the output
to the load and the unit will automatically operate in local sense. If remote-sense connections are made, the unit will
operate in a remote-sense mode. Remote-sense terminals should be terminated to their respective output i.e., –RS to
–Output and +RS to +Output. See Page 17 for more information on Autosense.
For units without Autosense, sense connections must always be made. Not connecting sense lines to their
respective outputs can cause failure to the unit.
Sense Connector J2 (P2 for the UniPAC™):
 Sense connections do not have to be made if the local-sense option has been ordered.
(An “L” in the ConverterPAC™ part number means the local-sense option has been installed;
e.g., M5V/40AL. Only applies to units without Autosense.)
 Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided.
 J2-2 is the +SENSE and J2-3 is the –SENSE.
 Attach terminals to 22 – 24AWG twisted pair wire using Molex tool #63811-8700.
 Attach opposite ends of Sense lines to point where regulation is desired.
 Verify that Sense lines are not cross-connected before applying input power.
 For the UniPAC, P2-7 is the +SENSE and P2-6 is the –SENSE.
 Use Molex mating receptacle #50-37-5073 with #08-70-1040 terminals provided
 Attach terminals to 22 – 28AWG stranded wire using Molex tool #63828-1900.
Sense Connectors on DualPACs™:
 Sense connections do not have to be made if the local-sense option has been ordered.
(An “L” in the ConverterPAC part number means the local-sense option has been installed;
e.g., D5V/20AL-12V/4.2AL. Only applies to units without Autosense.)
 Sense connections are available on the J2, P2 or the J1A and J1B connectors.
 If using J2 or P2 connectors, see Page 17.
 For J1A and J1B, Pin 3 is the +SENSE and Pin 6 is the –SENSE.
 Use Molex mating receptacle #39-01-2060 with #39-00-0039 terminals provided.
 Attach terminals to 18 – 24AWG twisted pair wire using Molex tool #63819-0901.
 Verify that Sense lines are not cross-connected before applying input power.
6 –REMOTE SENSE
3 +REMOTE SENSE
2 & 5 –VOUT
1 & 4 +VOUT
PIN
J1B
+
46
-
5
+
+RS
-
–RS
321
J1A
321
46
+RS
–RS
+
+
-
5
-
DualPAC Output Connectors
J2 Sense Connectors
1
2
3
Sense Connector
J2-1 Trim Pin Access
J2-2 +SENSE
J2-3 –SENSE
Pin
J2
POWER GOOD INVERTED
P2 REMOTE SENSE,
TRIM/SC & POWER GOOD
3
2
4
1
POWER GOOD
SIGNAL GROUND
VCC IN
7
6
5
+SENSE
–SENSE
TRIM

UG:107 Page 14
3-Phase and 4kW MegaPACs™ Quick Install Instructions (Cont.)
J2 Trim Connection (and P2 for UniPACs™)
 The J2 remote Trim connection should only be used if the local Trim option has not been installed.
(A “T” or an “F” in the ConverterPAC™ part number means the Trim option is installed;
e.g., M5V/40AT.)
 Use Molex mating receptacle #50-57-9403 with #16-02-0103 terminals provided and 22 – 24AWG
stranded wire using Molex tool 63811-8700.
 J2-1 provides Trim access.
 For the UniPAC, refer to P2 Connector. P2-5 provides Trim Access.
 Use Molex mating receptacle #50-37-5073 with #08-70-1040 terminals provided.
 Attach terminals to 22 – 28AWG stranded wire using Molex tool #63828-1900.
DC OK (Power Good)
 DC OK is only available as an option and is only present when requested.
 Use Molex mating receptacle #50-37-5043 with #08-70-1040 terminals provided.
 Attach terminals to 22 – 28AWG stranded wire using Molex tool #63828-1900.
 For the UniPAC, refer to the P2 Connector. P2-3 is Power Good.
 Use Molex mating receptacle #50-37-5073 with #08-70-1040 terminals provided.
 Attach terminals to 22 – 28AWG stranded wire using Molex tool #63828-1900.
Interface Connections J10
 J10-7 to 11 and J10-20 to 24 are Enable / Disable for slots 1-10.
 J10-16, 17 are VCC, J10-12 and 15 are Signal Ground, J10-18 is AC Power OK,
and J10-5 is General Shut Down.
Gate #1 Input (isolated)
25
J10 INTERFACE CONNECTOR IDENTIFICATION
Analog Temperature
Overtemperature Warning
14
1
1615
234
191817
56
222120
78 9
2423
1110 12
Signal Ground1
Enable/Disable #8
Enable/Disable #10
No Connection
General Shutdown
Signal Ground
Signal Ground
Enable/Disable #2
Enable/Disable #4
Enable/Disable #6
7
13
12
11
10
9
8
4
6
5
3
2
13
A.C. Power Fail
A.C. Power OK
V
CC
+5V, 300mA
V
CC
+5V, 300mA
Signal Ground
Enable/Disable #7
Enable/Disable #9
Phase Fail
Gate #10 (Output (Isolated)
Enable/Disable #1
Enable/Disable #3
Enable/Disable #5
14
19
18
17
16
15
21
25
24
23
22
20
J2 Connectors
1
2
3
Sense Connector
J2-1 Trim Pin Access
J2-2 +SENSE
J2-3 –SENSE
Pin
J2
4
3
2
1
J3
4 V
CC
3 Power Good
2 Power Good Inverted
1 Signal Ground
Pin
DC OK (Power Good)
J3 Connectors
Power Good Inverted
6
Signal Ground
7
Power Good
V
CC
IN
–SENSE
+SENSE
Trim
5
4
2
3
1
PIN
P2
J3 Connectors

UG:107 Page 15
3-Phase MegaPAC™ Mechanical Drawings
1/4 - 20 ZINC PLATED STEEL,
SERRATED FLANGED NUTS
#4-40 CAPTIVE SCREWS
TO SECURE CONVERTERPACS
10 PLACES
CONVERTERPAC REMOVAL
LABEL LOCATED
APPROXIMATELY
AS SHOWN
LABEL LOCATED
APPROXIMATELY
AS SHOWN (TYP)
(CONVERTERPAC MODEL NO.)
MegaPAC
WESTCOR
45INLBS ±5
3O
STANDARD AIR FLOW
(OUTER NUT ONLY)
DO NOT LOOSEN OR
TIGHTEN INNER NUTS
1.40
.60 [15.2mm]
.150 [3.8mm] 12.28 [311.2mm]
11.95 [303.5mm]
.15 MAX. PENETRATION
(16X) M4/#8-32 TAPPED HOLE
[35.6mm]
7.50
[190.5mm]
4.00
[101.6mm]
2.25 6.75 [171.5mm]
[57.2mm]
6.75 [171.5mm]
2.25
[57.2mm]
1.20 [30.5mm]
.65 [16.5mm]
5.10 [129.5mm]
V
COR
I
BOTTOM VIEW
.50 [12.7mm] 2.25
6.50 [165.1mm]
6.75
[57.2mm] [171.5mm]
4.90 (124.5 MM)
-P8 TYP.
+P8
+P1 -P1
BUS BARS - FOR
PARALLEL OUTPUTS
BUS BAR - FOR
SERIES OUTPUTS
DUAL CONVERTERPAC
(NO "POWER GOOD"
OPTION AVAILABLE)
AIR BLOCK
(EXAMPLE)
J2-PIN1
J3-PIN1
R4 "TRIMPOT" PRESENT
WHEN ADJUSTABLE OUTPUT
OPTION IS SPECIFIED
R12
R4
C
LL
C
J2A-PIN1
(SAME AS J2)
(SAME AS J2)
J2B-PIN1
1
J1A-PIN1
(DUALPAC)
J1B-PIN1
(DUALPAC)
TYP.
TYP.
TYP.
NO. 54489-4 HOUSING FOR 3-PHASE INPUT W/GROUND.
.31 X 1.25AMP
MATES WITH HSG AMP NO.
747547-2 PLUS SLIDE
2
FOR FLAT RIBBON CABLE
AMP NO. 746862-2 PLUG
LATCH OR SIMILAR.
MATING HSG IS AMP NO. 54483-4 AND CONTACTS
ARE AMP 53892-5 CRIMP OR AMP NO. 54329-1
SOLDER.
9=SP. @ .7285
6.56 [166.6mm]
[18.5mm]
L3
1.15 [29.2mm]
.54 [13.7mm]
L2L1
2.068
1.852
.240 [6.1mm]
(12X) 1/8 X 1/2 SLOTS
1.852
.40
.560 [14.2mm]
.46 [11.7mm]
[10.2mm]
[47.0mm]
[47.0mm]
[52.5mm]
1.20 [30.5mm]
208/240 VAC 3ÿ 15A 47-440 HZ

UG:107 Page 16
4kW MegaPAC™ Mechanical Drawings
1/4 - 20 ZINC PLATED STEEL, SERRATED FLANGED NUTS
-P8 TYP.
+P8
+P1 -P1
BUS BARS - FOR PARALLEL OUTPUTS
BUS BAR - FOR SERIES OUTPUTS
DUAL MODUPAC (NO "POWER GOOD" OPTION AVAILABLE)
AIR BLOCK (EXAMPLE)
J2-PIN1
GOOD
LABEL LOCATED APPROXIMATELY AS SHOWN
LABEL LOCATED APPROXIMATELY AS SHOWN (TYP) (MODUPAC MODEL NO.)
R4 "TRIMPOT" PRESENT WHEN ADJUSTABLE OUTPUT OPTION IS SPECIFIED
R12
R4
C
LL
C
J2A-PIN1
(SAME AS J2)
(SAME AS J2)
J2B-PIN1
1
J1A-PIN1
(DUAL MOD)
J1B-PIN1
(DUAL MOD)
45 INLBS ±5
TYP.
TYP.
TYP.
NO. 54489-4 HOUSING
FOR 3Ø INPUT W/GROUND.
.31 X 1.25 AMP
MATES WITH HSG AMP NO.
747547-2 PLUS SLIDE
2
(OUTER NUT ONLY)
FOR FLAT RIBBON CABLE
AMP NO. 746862-2 PLUG
LATCH OR SIMILAR.
MATING HSG IS AMP NO. 54483-4 AND CONTACTS ARE AMP 53892-5 CRIMP OR AMP NO. 54329-1 SOLDER.
DO NOT LOOSEN OR
TIGHTEN INNER NUTS
J3-PIN1 POWER
3
AIR FLOW
STANDARD
9=SP. @ .7285
6.56 [166.6mm]
[18.5mm]
1.40
.25 [6.35mm]
L3
1.15 [29.2mm]
.54 [13.7mm]
L2L1
2.068
1.852
.240 [6.1mm]
(12X) 1/8 X 1/2 SLOTS
1.852
.40
.560 [14.2mm]
.46 [11.7mm]
BOTTOM VIEW
.50 [12.7mm] 2.25
6.50 [165.1mm]
6.75
.15 MAX. PENETRATION (16X) M4/#8-32 TAPPED HOLE
[57.2mm] [171.5mm]
[35.6mm]
[10.2mm]
[47.0mm]
[47.0mm]
[52.5mm]
1.20 [30.5mm]
7.50
[190.5mm]
4.90 [124.5mm]
4.00
[101.6m]
2.25 6.75 [171.5mm]
[57.2mm]
6.75 [171.5mm]
2.25
[57.2mm]
1.20 [30.5mm]
.65 [16.5mm]
5.10 [129.5mm]
1.64
[41.8mm]
11.95 [303.5mm]
12.28 [311.9mm]
V
COR
I
208/240 VAC 3Ø
15A 47-440 HZ

UG:107 Page 17
Interface Connections
Chassis Input Power Terminals (J1)
Input AC power is applied to a plug-in connector, J1, that accepts soldered terminals with a wire size of
12AWG. For operation on high-voltage DC input, input power can be connected to any two input lines.
A fault-clearing device should be installed at the input of the unit. A user-accessible input fuse is not
present within the unit. For an output of 2,000 – 4,000W with operation on 208VAC, three-phase input,
a 20A fuse in each input line is acceptable. Input power cables should be shielded to minimize radiated
noise effects.
Output Power Connections (+P, –P for Single Output, or J1A/J1B for Dual Outputs)
For single output ConverterPACs™, these terminals are two 1/4-20 plated steel studs. The upper stud
is positive with respect to the lower stud. For dual output ConverterPACs, there is a six-pin Molex
connector for each output. J1A pins 1 and 4 are the +Output, and J1A pins 2 and 5 are the –Output.
Pins 3 and 6 are duplicates of the Remote Sense terminals present on J1B. Use appropriate wire size
rated to handle the full output current, including short circuit levels. Avoid large current loops in output
cables; run power and return cables next to one another to minimize inductive effects. All outputs are
isolated and can provide positive or negative outputs.
Output +/–SENSE Connections (J2 for Single Output, or J1A/J1B for Dual Outputs)
Newer power supplies may have some outputs configured with the Autosense feature that automatically
locally senses the output if remote sense is not used. To check if an output has the Autosense feature,
measure the impedance from the +OUT to +SENSE and –OUT to –SENSE pins. If the impedance is 5Ω,
then the output has Autosense and does not require local-sense jumpers.
For units without Autosense, sense connections must be made. When making sense connections,
keep in mind that although all outputs are open-sense protected, the +/–SENSE terminals MUST be
connected to their respective outputs before the 3-Phase MegaPAC™ or 4kW MegaPAC is powered
up. Regardless of the output polarity configured, the +SENSE should always connect to the +Power
output. The –SENSE connects to the –Power output. Sense connections are not required on booster
ConverterPACs, BatPACs™ or if the local-sense option is specified.
J1-4 Earth Ground
J1-1 Line 3
J1-2 Line 2
J1-3 Line 1
J1
Figure 3
Input panel connector

UG:107 Page 18
Signal Ground (J10-1, J10-2, J10-12, J10-15)
Signal Ground (see Figure 4) is an isolated ground reference for all J10 interface signals and can be used
for ConverterPAC™ output status signals such as Power Good. This is not the same as Earth Ground on
input power connector J1.
Figure 4
Interface connector (J10)
Gate #1 Input (isolated)
25
J10 INTERFACE CONNECTOR IDENTIFICATION
Analog Temperature
Overtemperature Warning
14
1
1615
234
191817
56
222120
78 9
2423
1110 12
Signal Ground1
Enable/Disable #8
Enable/Disable #10
No Connection
General Shutdown
Signal Ground
Signal Ground
Enable/Disable #2
Enable/Disable #4
Enable/Disable #6
7
13
12
11
10
9
8
4
6
5
3
2
13
A.C. Power Fail
A.C. Power OK
V
CC
+5V, 300mA
V
CC
+5V, 300mA
Signal Ground
Enable/Disable #7
Enable/Disable #9
Phase Fail
Gate #10 (Output (Isolated)
Enable/Disable #1
Enable/Disable #3
Enable/Disable #5
14
19
18
17
16
15
21
25
24
23
22
20
Figure 5
Enable / Disable and
General Shut Down
10kΩ
Signal Ground 1, 2, 12, 15
J10
General Shut Down 5
Enable/Disable Output #1 24
+5 Volt VCC 16
10kΩ
499Ω
499Ω
JP1 JP2
1 2
3
1 2 3
Enable/Disable and General Shut Down (GSD)
The Enable / Disable control lines allow ConverterPAC outputs to be sequenced either on or off. For
DualPACs™, both outputs are sequenced. In parallel arrays, only the driver ConverterPAC needs to be
sequenced. The GSD control line on J10-5 allows simultaneous shut down of all ConverterPAC outputs.
An internal factory-configured jumper selects polarity, either active-high or active-low. Another jumper
selects a pull-up or pull-down source for the HCMOS control inputs.
The standard Enable / Disable controls are configured as active-low with internal pull up; outputs are
enabled when these pins are open-circuited or allowed to exceed 4.5V with respect to Signal Ground.
Outputs are disabled when the Enable / Disable control lines are pulled low to less than 0.7V. The GSD
control line is configured to be active-low with internal pull up; all outputs are simultaneously inhibited
when the GSD control line is pulled low to less than 0.7V. All outputs are enabled when GSD is open
circuited or allowed to exceed 4.5V. Do not apply more than 5V to these inputs at any time. The E/D
and GSD circuits will sink up to 0.6mA. If driven from an electromechanical switch or relay, a small
capacitor should be connected between the control line and Signal Ground to eliminate latch-up due to
the effects of switch bounce (1mF, typical). As noted, active polarity and pull up / down can be altered
in the factory.

UG:107 Page 19
Enable / Disable Control of Maxi Module Arrays
When using the Enable / Disable function on an output that consists of two or more Maxi modules, it
is necessary to connect the E/D pins of the corresponding module locations together such that both
modules are commanded to turn ON or OFF simultaneously.
Example:
Slots 1 through 6 have been configured as a single output parallel array (see Figure 6).
In order to disable this array, E/Ds 1 through 6 should be shorted together as shown in
Figure 6. With the E/Ds connected together, a single switch can then be used to remotely enable and
disable the output.
Note: For single output power supply configurations, the simplest method of remotely enabling and disabling the
output is to use the General Shut Down (GSD) function.
Figure 6
Enable / Disable control
of Maxi arrays
L1 L2 L3
14
12
15 16
34
17 18
56
19 20
78
21 22
910
23 24
11 12
25
13
12345678 109
Figure 7
AC OK / Power Fail
10kΩ
1, 2, 12,15 Signal Ground
19 AC Power Fail
+5V J10
2.49kΩ
2N2222
2.49kΩ
2N2222
2N2222
14 Phase Fail
18 AC Power OK
4.99kΩ
AC Power OK (J10-18)
This signal on J10-18 provides a status indication of the AC input power (see Figure 7). It is active high,
TTL compatible and capable of sourcing 10mA maximum. This signal switches to a TTL “1” when the
high-voltage bus exceeds low-line condition during turn on and switches to a TTL “0” 3ms (minimum)
before loss of output regulation due to the loss of input AC power. This signal can be used to warn
external control circuits of an impending loss of power.

UG:107 Page 20
AC Power Fail (J10-19)
J10-19 is the inverse of AC Power OK, and goes to a TTL “1” when the input AC power is not OK. It is
capable of sourcing 10mA maximum. The fan out is 20.
Phase Fail (Input Overcurrent) (J10-14)
J10-14 is a TTL level active-high signal that is asserted when the peak input current reaches 30A due
to the loss of an input phase or severe line imbalance. This occurs when one input phase is lost with
approximately 1400W output loading. Maximum current that can be sourced is 10mA.
Overtemperature Warning (J10-3)
J10-3 is a signal that asserts a TTL level "1" if the air temperature exceeds the following factory set
levels. The warning trip point is 65 – 76°C, typically, and recovery point is 60 – 71°C, typically.
Overtemperature Shut Down
If the inlet ambient air temperature exceeds the following factory-set levels, the outputs are disabled.
The shut-down trip point is 70 – 81°C, typically, and recovery point is 40 – 48°C, typically.
Analog Temperature Monitor (J10-4)
This signal on J10-4, referenced to Signal Ground, provides an analog DC voltage output between
0V and 10V that represents the air temperature of 0 – 100°C inside the power supply. The inlet air
temperature is monitored close to the fan.
Gate IN/Gate OUT (J10-13, 25)
The 3-Phase MegaPAC™ and 4kW MegaPAC can be paralleled with other 3-Phase MegaPACs and
4kW MegaPACs respectively to increase output power. The Gate OUT (or PC) pin of the ConverterPAC™
in slot #10 is available on J10-25 and can be used to provide input to the Gate In (or PC) pin of the
ConverterPAC in slot #1 of a different 3-Phase MegaPAC or 4kW MegaPAC. The ConverterPAC in slot
#1 of the second chassis must be a booster and additional boosters can be connected in parallel to it.
The ConverterPAC in slot #10 of the first 3-Phase MegaPAC or the 4kW MegaPAC must be either a
driver or a booster in a parallel array. ConverterPACs paralleled from chassis to chassis must be of the
same type, voltage and power.
The 3-Phase MegaPAC and 4kW MegaPAC are configured at the factory to allow box-to-box paralleling
using the ConverterPACs originally shipped in the chassis. Since the MegaPAC is a field-configurable
supply, the proper configuration must be verified before paralleling from chassis to chassis. The last two
digits of the 4kW MegaPAC part number will identify whether slot #1 and slot #10 were configured for
use with VI-200™ / VI-J00™ or Maxi ConverterPACs.
Using the example of MX7-410108-32, the last two digits, "–32," identify the type of module in slot
#1 and slot #10, respectively. A "3" indicates the chassis is configured to parallel box-to-box using a
Maxi converter. A "2" indicates the chassis is configured to parallel box-to-box using a VI-200 converter.
The above example shows the chassis is configured for a Maxi converter in slot #1 and a VI-200
converter in slot #10.
When connecting multiple chassis in parallel, the signal ground on J10 of each chassis should be
tied together. Chassis outputs should be tied together near the power supply and then cabled to
the load. Using separate cables to provide power to the load will limit the supplies' ability to current
share properly.