VICOR PFC MegaPAC-EL User manual

UG:119 Page 1
PFC MegaPAC-ELTM
PFC MegaPAC-HPELTM
Power Factor Corrected AC-DC Switchers
USER GUIDE | UG:119
Overview
The PFC MegaPAC-EL and PFC MegaPAC High Power Low Noise (HPEL) combine power factor
correction (PFC) with the configurability of the MegaPAC family of power supplies. The
PFC MegaPAC-EL and PFC MegaPAC-HPEL provide up to 1,600W and 2,400W of output power
respectively and have power densities of 4.3W/in3and 6.5W/in3respectively. The chassis has eight slots
and can provide as many as 16 outputs. The PFC MegaPAC-EL and PFC MegaPAC-HPEL have the same
input and output connections, mounting points and the same dimensions: 3.4 x 6.0 x 15.6in
[85,6 x 152,4 x 396,2mm]. Note that length of older units were 15.5in [393,6mm].
A complete power supply is configured at the factory by selecting and inserting up to eight (four – six
for the PFC MegaPAC-HPEL depending on ConverterPACs used) 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 output voltage 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.
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 assembly with one that is
of the same length and has the desired voltage power rating. For additional flexibility, 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 (see Page 16 for more information about this capability), in addition to
useful status indicators. Please consult our Applications Engineering Department if you have other
special requirements.
Note: This user guide contains references to parts and products that are no longer available for new designs.
They remain included for reference only.
Contents Page
Overview 1
Standard Features 2
Optional Features 2
Mechanical Considerations 3
MegaPAC Dos and Don’ts 3
Technical Description 4
Configuring and
Reconfiguring MegaPACs 5
ConverterPAC Functional
Description 7
Part Numbering 8
ConverterPAC Output and
Connector Pin Identification 10
PFC MegaPAC-EL and -HPEL
Quick Install Instructions 11
PFC MegaPAC-EL and PFC
MegaPAC-HPEL
Mechanical Drawing 14
Interface Connections 15
Specifications 22
Output Studs 23
Output Power Derating 24
PFC MegaPAC-EL/HPEL
Connector Kit (19-130040)
Listing 24
Connector Kit for
Dual Outputs only -
MegaPAC Family 19-130042 24
Current Share Boards -
Optional Feature 25
Current Share Boards -
Optional Feature Diagram 27
Output Sequencing 28

UG:119 Page 2
Standard Features
 Power Factor Correction; 0.99 at 115VAC, 0.95 at 230VAC
 Universal Input: 85 – 264VAC, 47 – 500Hz, or 100 – 380VDC
 Power Outputs:
PFC MegaPAC-EL™: 1,600W at 230VAC PFC MegaPAC-HPEL™: 2,400W at 230VAC
1,200W at 115VAC 1,200W at 115VAC
 Outputs:
PFC MegaPAC-EL and HPEL: Up to 16 outputs
 Output ripple: 10mVP-P or 0.15% whichever is greater
 Fan Cooled
 Full-power to 40°C; half power to 60°C
 Soft start for limiting inrush current
 Conducted EMI meets FCC Class A and EN55022 A specifications
(some configurations meet Class B. Contact factory)
 Harmonic Distortion to EN61000-3-2
 RoHS compliant available
 Output Sequencing and General Shutdown
(General Shutdown refer to Page 17. Output sequencing refer to Page 28.
Consult Applications Engineering for automatic sequencing circuitry.)
 Overcurrent protection on all outputs
 Overvoltage protection on all ConverterPAC outputs
(not applicable with VI-J00 modules)
 Overtemperature limiting on all ConverterPAC outputs
(not applicable with VI-J00 modules)
 Size: 3.4 x 6.0 x 15.6in [85,6 x 152,4 x 396,2mm]
 Safety Agency Approvals: CE Mark, cTÜVus, UL
Optional Features
 DC OK status signal
 Current Share Boards - see Pages 25 – 27
 Output voltage adjustment range with built-in potentiometer

UG:119 Page 3
Mechanical Considerations
The PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ 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 [3.8 mm].
When selecting a mounting location and orientation, the unit should be positioned so air flow is
not restricted. Maintain a 2in minimum clearance at both ends of the PFC MegaPAC-EL and PFC
MegaPAC-HPEL and route all cables so airflow is not obstructed. The standard unit draws air in at the
fan side / AC input side and exhausts air out the load side. If airflow ducting is used, use caution, as
sharp turns could present back pressure to the PFC MegaPAC-EL and PFC MegaPAC-HPEL. The fan
moves approximately 30CFM of air.
Avoid excessive bending of output power cables after they are connected to the PFC MegaPAC-EL
and PFC MegaPAC-HPEL. 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 PFC MegaPAC-EL and PFC MegaPAC-HPEL units are supplied with serrated, flanged hex-nuts on all
output studs. Therefore, 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.
MegaPAC™ Dos and Don’ts
 For units without Autosense, do not leave ConverterPAC Sense lines open. Always terminate them to
their respective output locally or at the load. Use twisted pair 22-24AWG wire. If ConverterPAC has
Autosense, no local-sense connection is required. See Pages 11 and 12 for more information
on Autosense.
 If needed, use Connector Kit # 19-130040 for the PFC MegaPAC-EL and PFC MegaPAC-HPEL.
 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 degrades thermal performance and can result in
overheating and damage to the power supply.
 Always turn the power supply off before disconnecting input or output wires.
 NEVER disconnect the +Out and –Out load wires while the supply is operating, as disconnecting WILL
cause 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 airflow to the unit. The cooling fan draws air into the unit and forces it out at the
output power terminals.

UG:119 Page 4
 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.
 For booster arrays, do not remove bus bars.
 Always ensure that output hex-nuts are properly torqued before applying power to supply.
 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 Design 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.
 FinQPACs™ require two slots each because of the larger heat sink attached to dissipate the extra
heat generated by the higher-power Maxi module. Refer to Page 8 for more information on which
ConverterPACs can be used.
Technical Description
The PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ chassis consists of an offline single phase,
power-factor-corrected front end, EMI filter, cooling fan, low-noise filters, customer interface and
associated housekeeping circuits. Input AC mains voltage (L1, L2 and GND) is applied to a terminal
block. The input current is passed through an EMI filter designed to meet conducted noise limit A
specifications of FCC Part 15, VDE 0871 and EN55022 Class A. At start up, inrush current is limited by a
PTC thermistor. The PTC is shunted out shortly after initial power up by a DC bus voltage Sense circuit
driving a relay. After rectification, the input voltage is put through a boost converter that keeps the AC
input current sinusoidal and synchronized with the AC input voltage (in compliance with EN61000).
The boost converter delivers regulated high voltage DC to the hold-up capacitors and backplane.
The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired
regulated outputs.
Voltage conversion in the output assemblies is achieved by the Vicor family of Zero-Current Switching
(ZCS) DC-DC converters. These are forward converters in which the main switching element switches
at zero current. This patented topology has a number of unique attributes: low-switching losses;
high-frequency operation resulting in reduced size for magnetics and capacitors; excellent line- and
load- regulation; wide-adjustment range for output; low EMI / RFI emissions and high efficiencies.
At initial power up, the PFC MegaPAC-EL and PFC MegaPAC-HPEL outputs are disabled to limit the
inrush current and to allow the DC bus potential to settle out to the correct operating level.
A low-power flyback converter operating with PWM current-mode control converts the high-voltage
DC bus into regulated low voltage to power the internal housekeeping circuits and DC cooling fan. The
internal housekeeping VCC comes up within two seconds after the application of input power. Once the
high-voltage bus is within its limits, the AC OK signal asserts to a TTL “1” indicating the input power is
OK and enables the power outputs. An auxiliary VCC output of 5VDC sourcing up to 0.3A is provided for
peripheral use.

UG:119 Page 5
An output Enable / Disable function is provided by using an optocoupler to control the Gate In pins
of the ConverterPAC™ assemblies. If the Enable / Disable control pin is pulled low, the optocoupler
turns on, pulling the Gate In pin low and disabling the ConverterPAC output. The nominal delay for an
output to come up when measured from release of the Enable / Disable pin is 10 – 15ms. The General
Shutdown function controls all outputs simultaneously and works in a similar manner.
The ride-through (hold-up) time is the amount of time the load can be supported before loss of output
regulation after the loss of input power. Detecting the loss of input power takes a finite time period
after which the AC Power OK signal goes from a TTL “1” to “0." This signal is available for use within
1.2s after initial power up and can be used to indicate an impending loss of power. At least 3ms of
warning time is given. Following the loss of input power, the outputs are disabled when the bus voltage
drops below its operating threshold.
Configuring and Reconfiguring MegaPACs
Most ConverterPACs of the same length can be inserted into any available slot of a MegaPAC chassis.
They can also be easily added, replaced or moved by sliding the assemblies in or out of a MegaPAC
chassis. For outputs greater than 200W, a driver QPAC™ and one or more booster ConverterPACs will
be used. For outputs greater than 600W, a driver FinQPAC™ and one or more booster ConverterPACs
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 or an airblock. If the slot is left
empty, it will provide an airflow escape and cause failure to the power supply.
Line Filter Rectifier Soft Start
Circuit Boost Converter
PFC Control
E/D Control
QPAC #1
QPAC #2
QPAC #3
QPAC #8
Fan
Housekeeping
Power
Current
Monitor
Customer
Interface
Power
Output
Power
Output
Power
Output
Power
Output
Input
High Voltage
DC Bus
Enable/Disable Control
Current
Sample
Waveform
Sample
Figure 1
PFC MegaPAC-EL™ and
PFC MegaPAC-HPEL™
low-noise architecture

UG:119 Page 6
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 slots #1 and 3, 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 8. 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.
Figure 2
Paralleling ConverterPACs
Driver
Bus Bars for Paralleling
Loosen screw to
remove ConverterPAC
Boosters
12345678

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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 MegaPAC chassis. They can be added, moved or changed as necessary. A key feature of
the Extended Length ConverterPAC is the low ripple and noise output to 10mVP-P or 0.15%,
whichever is greater. The following Extended-Length ConverterPACs can be used in the
PFC MegaPAC/EL - Low Noise.
QPAC™ (L)
The QPAC output assembly consists of a VI-200™ DC-DC converter that converts the unregulated
high-voltage bus to the desired regulated output voltage. Each QPAC (L) can provide up to 200W of
output power, and booster QPACs can be added in parallel for more power. Power and slave QPACs
can be added in parallel for more power. QPACs are fused with a PC-Tron, DC-rated, fast-acting fuse.
An active preload ensures the DC-DC converter operates in its highest-noise performance range.
As the load on the module increases, the preload removes itself from the circuit. QPACs, using the
VI-200 module, have an optional DC OK TTL signal. All QPACs have overcurrent protection with
automatic recovery when the overcurrent condition is removed. Overvoltage Protection (OVP) and
Overtemperature Limiting (OTL) are available. Please note that for the QPAC (L), the output voltage
from either output terminal to chassis should not exceed 400VDC, or peak.
DualQPAC™ (LD)
The DualQPAC output assembly consists of two VI-J00 DC-DC converters that provide two isolated
output voltages. DualQPACs can provide up to 100W of output power from each output. The
DualQPACs are fused with a PC-Tron, DC-rated, fast-acting fuse. An active preload ensures the DC-DC
converter operates in its highest noise performance range. OVP and OTL is not available. Please note
that for the QPAC (L) the output voltage from either output terminal to chassis should not
exceed 400VDC, or peak. For detailed pinout description, refer to Page 10.
JuniorQPAC™ (LJ)
The JuniorQPAC output assembly consists of a VI-J00 Vicor DC-DC converter that converts the
unregulated high-voltage bus to the desired regulated output voltage. OVP and OTL is not available.
Please note that for the QPAC (L) the output voltage from either output terminal to chassis
should not exceed 400VDC, or peak.
FinQPAC™ (PZL)
The FinQPAC output assembly consists of a Maxi DC-DC converter that converts the unregulated
high-voltage bus to the desired regulated output voltage. Each Maxi module can provide up to 600W
of output power. Each FinQPAC occupies two slots because it has an extra large heat sink attached
to dissipate the heat generated by this more powerful Maxi converter. It cannot be used in any other
member of the MegaPAC Family. FinQPACs have overcurrent protection with automatic recovery when
the overcurrent condition is removed. Overvoltage Protection (OVP) and Overtemperature Limiting (OTL)
are available. Please note that for the FinQPAC (PZL) the output voltage from either output
terminal to chassis should not exceed 400VDC, or peak.
+
_
VI-200
VI-J00 VI-J00
M2 M1
M1
M2
VI-J00
+
_
Maxi
QPAC
DualPAC
JuniorQPAC
FinQPAC

UG:119 Page 8
List of ConverterPACs™ used in the PFC MegaPAC-EL™ and
PFC MegaPAC-HPEL™ Low Noise and their features
ConverterPAC OVP OCP OTL RS/AS* LS/AS* PG TrimPot
QPAC (L) Std Std Std AS
[a] AS [a] Opt Opt
DualQPAC (LD) N/A Std N/A AS
[a] AS [a] Opt N/A
JuniorQPAC(LJ) N/A Std N/A AS
[a] AS [a] Opt Opt
FinQPAC(PZL)+ Std Std Std AS
[a] AS [a] Opt Opt
OVP Overvoltage Protection (latching) RS Remote Sense
OCP Overcurrent Protection (auto-recovery) LS Local Sense
OTL Overtemperature Limiting AS Autosense
PG Power Good (DC OK TTL Signal) + Maxi OTL is non-latching
[a] See Pages 11 and 12 for more information on Autosense.
Note: All ConverterPACs mentioned above can be paralleled EXCEPT the DualQPAC and JuniorQPAC.
Part Numbering
PFC MegaPAC-EL MPxA-7xBxxxx-xC-xD
eg. MP5-782560-G-EL
PFC MegaPAC-HPEL MXxA-7xBxxxx-xC-xD
eg. MX4-742543-2-EL
MP = MegaPAC™ prefix
xA= number of outputs
7= power factor corrected
xC= optional code ex. G = RoHS
MX = PFC MegaPAC-HPEL prefix
X= PFC chassis that can use Maxi
xB= Number of modules
xxxx = assigned by Vicor
xD= optional code e.g., EL = Extended Length
ConverterPAC XxDV/xEAxF
eg. L15V/10A
X= ConverterPAC type (For RoHS, add G to current prefix)
xD= Voltage out
xE= Current out (rounded to one decimal point)
xF= Can be multiple options (see Page 9)

UG:119 Page 9
ConverterPAC™ options
BBooster module MMilitary Grade module
DDC OK or Power Good
[b] RRAM external [d]
FFull 50 – 110% output adjustment
[c] STrimpot removed for external
BatPAC™ adjustment
F1 50 – 107.5% output adjustment T90 – 110% output adjustment
[e]
F2 50 – 105% output adjustment T1 90 – 107.5% output adjustment
F3 50 – 102.5% output adjustment T2 90 – 105% output adjustment
F4 50 – 100% output adjustment T3 90 – 102.5% output adjustment
F5 60 – 110% output adjustment T4 90 – 100% output adjustment
F6 70 – 110% output adjustment T5 98 – 105% output adjustment
F7 80 – 110% output adjustment T6 100 – 110% output adjustment
F8 90 – 110% output adjustment V1 "VXI" low noise (150mV) 15V < VOUT ≤24V outputs
[e]
F9 100 – 110% output adjustment V2 "VXI" low noise (50mV) VOUT ≤15VDC
IIndustrial Grade module V3 “VXI” low noise (1% ripple) VOUT > 24V
KCustom SRF module used
PPreload
[b] D option: Optional for all ConverterPACs used in this power supply.
[c] T & F options: Optional for all ConverterPACs used in this power supply EXCEPT the DualQPAC™.
[d] R option: N/A to any ConverterPACs used in the PFC MegaPAC-EL™ / PFC MegaPAC-HPEL™.
[e] V options: N/A to any ConverterPACs used in the PFC MegaPAC-EL / PFC MegaPAC-HPEL.

UG:119 Page 10
ConverterPAC™ Output and Connector Pin Identification
+VOUT J2 REMOTE SENSE TRIM/SC & POWER GOOD
OUTPUT ADJUST
POWER GOOD INVERTED
SIGNAL GROUND
POWER GOOD
J2-PIN1
1
2
VCC IN
4
3
6–SENSE
TRIM
5
+SENSE
7
–VOUT
CRIMP TOOL MOLEX P/N: 57005-5000
HOUSING- MOLEX P/N: 39-01-0073
TERMINALS- MOLEX P/N: 39-00-0031
MATING HDWR:
QPAC VI-200 MODULE
DualQPAC™
Notes:
1. All ConverterPACs except the FinPAC™ occupy one slot. The FinPAC occupies two slots.
2. New output studs were installed on the ConverterPACs and are 1/8th inch longer.
Refer to Pages 14 and 23 for more information.
FinQPAC™
DUAL QPAC
1SIGNAL GROUND
TRIM BOT
TRIM TOP
POWER GOOD
POWER GOOD INVERTED
N/C
VCC IN
5
3
2
4
6
7
J2-PIN1
(OUTPUT CONNECTORS)
J1-B
J1-B-PIN1(M1)
3 +R/SENSE 6 –R/SENSE
3 +R/SENSE 6 –R/SENSE
J1-A
5
6
J1-A-PIN1
(M2)
4
2 AND 5 –VOUT
2
3
1 AND 4 +VOUT
(OUTPUT CONNECTORS)
1
6
4
5
3
1 AND 4 +VOUT
2 AND 5 –VOUT
1
2
CRIMP TOOL MOLEX P/N: 11-01-0197
HOUSING- MOLEX P/N: 39-01-2060
TERMINALS- MOLEX P/N: 39-00-0039
MATING HDWR:
HOUSING- MOLEX P/N: 39-01-2060
CRIMP TOOL MOLEX P/N: 11-01-0197
TERMINALS- MOLEX P/N: 39-00-0039
MATING HDWR:
M2 M1 J1-B (M1)
J1-A (M2)
Output A
48V/2.1A
Output B
12V/8.3A
Example: LD12V/8.3A-48V/2.1A
DUALQPAC - COMPONENT SIDE VIEW
(J1-B)
(J1-A)
P2-PIN1
1
2
4
3
VCC IN
6
5
7
TRIM
+OUT
–OUT
FinQPAC
SIGNAL GROUND
CRIMP TOOL MOLEX P/N: 57005-5000
HOUSING- MOLEX P/N: 39-01-0073
TERMINALS- MOLEX P/N: 39-00-0031
MATING HDWR:
POWER GOOD INVERTED
POWER GOOD
–SENSE
+SENSE
OUTPUT ADJUST
P2 REMOTE SENSE TRIM/SC & POWER GOOD
QPAC™
JuniorQPAC™

UG:119 Page 11
PFC MegaPAC-EL™ and -HPEL Quick Install Instructions
(For Mechanical Drawing, see Page 14)
Mounting the PFC MegaPAC-EL and PFC MegaPAC-HPEL™
 Mount the power supply on any of its four sides.
 Use #8-32 or 4mm mounting screws. Do not exceed a maximum penetration of 0.15in [3,8 mm].
The maximum allowable torque is 20lb.in.
 Maintain 2in [5,1cm] clearance at either end for airflow.
Input Connections
Input Power J9
 Apply input AC power to terminal block J9 using a pressure screw terminal.
 Strip length of AC power conductors to be 0.35in.
 Maximum torque is 4.4lb.in.
 Place a fuse or circuit breaker in the input line for safety reasons.
 Use a maximum wire size of 14AWG with soldered terminals.
 The connector manufacturer recommends the wires not be tinned.
A ferrule (Phoenix P/N 32-00-58-0, purchased from other sources) can be used to prevent fraying.
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.
 Newer outputs studs are 1/8th inch longer. See Pages 14 and 23 for more information.
 Remove 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 DualQPACs - J1A (M2) and J1B (M1):
 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 #11-01-0197.
Sense Connections
Newer power supplies have the Autosense feature. For these units, 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 12 for more information on Autosense. For
units without Autosense, sense connections must ALWAYS be made. Not connecting sense
lines to their respective output can cause failure to the unit. WARNING: NEVER disconnect
the +Out and –Out load wires while the supply is operating as disconnecting WILL cause damage to
the power supply.
INPUTS DO NOT
WITHOUT
EARTH
GROUND
L2
115/230 VAC
300VDC
INPUT CONNECTIONS
J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1
L1
47 TO 500 Hz
OPERATE
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4 INCH POUNDS
LABEL NO: 94-00046 REV B
QPAC (L)
J2-PIN1
OUTPUT ADJUST
–VOUT
+VOUT
J1B (M1)
+
46
–
5
+
+RS
–
–RS
321
J1A (M2)
321
46
+RS
–RS
+
+
–
5
–
Input Panel Connectors
Single Output QPAC™
DualQPAC™ Output Con-
nector

UG:119 Page 12
Sense Connector J2 (and P2 for the FinQPAC™):
 Sense connections do not have to be made if either the Local Sense option was ordered (older units)
or if Autosense is present (see previous note on Autosense).
 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 QPAC™, J2-7 is the +Sense and J2-6 is the –Sense.
 For the FinQPAC, P2-7 is the +Sense and P2-6 is the –Sense.
 Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG stranded wire using Molex tool #57005-5000.
Sense Connections on DualQPACs™:
 Sense connections do not have to be made either if the Local Sense option has been ordered or
Autosense is present (refer to note on Autosense).
 Sense connections are available on the J2 connector (P2 for the FinQPAC) or the J1A (M2)
and J1B (M1) connectors.
 If using J2 or P2 connector, see pin description on Page 10.
 On 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 #11-01-0197.
 Verify that Sense lines are not cross connected before applying input power.
Trim Pin Connection J2 for QPACs (and P2 for FinQPAC)
 The Trim J2 connection should only be made if the Trim option has not been installed.
(A “T” or an “F” in the ConverterPAC™ part number means the Trim option is installed; eg. M5V/40AT).
 For the QPAC™, refer to J2 Connector. J2-5 provides Trim Access.
 For the FinQPAC, refer to P2 Connector. P2-5 provides Trim Access.
 Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG stranded wire using Molex tool #57005-5000.
Trim Pin Connection J2 for DualQPACs
 The Trim J2 connection should only be made if the Trim option has not been installed.
 J2-7 is Trim B and J2-6 is Trim A.
 Use Molex mating receptacle #39-01-0073 and #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG twisted pair wire using Molex tool #57005-5000.
POWER GOOD INVERTED
N/C
5
3
2
4
1SIGNAL GROUND
POWER GOOD
VCC IN
7
6
TRIM TOP
J2-PIN1
TRIM BOT
J2/P2 Sense Connectors
1 AND 4 +VOUT
33 +R/SENSE 6 –R/SENSE
1
2
J1-A (M2)
6
5
4
2 AND 5 –VOUT
3 +R/SENSE 6 –R/SENSE
6
5
4
J1-B (M1)
2 AND 5 –VOUT
3
2
(OUTPUT CONNECTORS)
1 AND 4 +VOUT
1
DualQPAC Sense Connector
Trim Pin Connection on the
J2 /P2 Connector
POWER GOOD INVERTED
N/C
5
3
2
4
1SIGNAL GROUND
POWER GOOD
VCC IN
7
6
TRIM TOP
J2-PIN1
TRIM BOT
POWER GOOD INVERTED
N/C
5
3
2
4
1SIGNAL GROUND
POWER GOOD
VCC IN
7
6
TRIM TOP B
J2-PIN1
TRIM BOT A

UG:119 Page 13
DC OK (Power Good) Connection J2 (and P2 for FinQPAC™)
 DC OK is only available as an option and is not present unless requested.
 For the QPAC™, refer to the J2 connector. J2-3 is Power Good.
 For the FinQPAC, refer to the P2 connector. P2-3 is Power Good.
 Use Molex mating receptacle #39-01-0073 with #39-00-0031 terminals provided.
 Attach terminals to 22-28AWG stranded wire using Molex tool #57005-5000.
Interface Connections J10
 Use Molex mating receptacle #39-01-2120 with #39-00-0039 terminals.
 J10-1 through 8 are Enable / Disable for slots 1 – 8.
 J10-9 is VCC, J10-10 is Signal Ground, J10-11 is AC Power OK and J10-12 is General Shutdown.
 Attach terminals to 18-24AWG stranded wire using Molex tool #11-01-0122.
+SENSE
POWER GOOD
SIGNAL GROUND
POWER GOOD INVERTED
VCC IN
2
1
3
TRIM
4
5
–SENSE
7
6
DC OK/Power Good
Connection on
the J2 /P2 Connector
J10-9
J10-10
J10-11
J10-12
VCC +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
J10 INTERFACE
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
J10-7
J10-8
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
E/D-7
E/D-8
12
1110
9
8
7
65
43
2
1
J10
Interface Connections J10

UG:119 Page 14
PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ Mechanical Drawing
14AWG WIRE
J10-9
J10-1O J10-11 J10-12
VCC +5V, 0.3A SIGNAL GROUND AC POWER OK GEN SHUTDOWN
J10 INTERFACE
J10-1 J10-2 J10-3 J10-4 J10-5 J10-6 J10-7 J10-8
E/D-1 E/D-2 E/D-3 E/D-4 E/D-5 E/D-6 E/D-7 E/D-8
INPUTS DO NOT
WITHOUT
EARTH
GROUND
L2
115/230 V
AC
300V
DC
INPUT CONNECTIONS
J9-1 EARTH GROUND J9-2 L2-NEUTRAL J9-3 L1
HOUSING-MOLEX P/N: 39-01-2120.
L1
47 – 500Hz
OPERATE
CLAMPING SCREWS
47TO 500 Hz
300VDC
115/230 VAC
L2
INPUTS
L1
OPERATE
GROUND
EARTH
WITHOUT
DO NOT
MATING HDWR: TERMINALS-MOLEX P/N: 39-00-0039 CRIMP TOOL-MOLEX P/N: 11-01-0122
(T0P AND BOTH SIDES)
(RE-DESIGNED LENGTH)
(ORIGINAL LENGTH)
RE-DESIGNED STUD AND PANEL
ORIGINAL STUD AND PANEL
FAN
(DIRECTION OF AIR
FLOW OPTIONAL)
6.04 [153.42]
3.37 [85.60]
5.100 [129.54]
.470 [11.94]
.21 [5.33]
2.92 [74.17]
10.01 [254.25]
.21 [5.33]
2.92 [74.17]
.25 [6.35]
10.01 [254.25]
15.62 [396.81]
15.50 [393.63]
2.75 [69.85] 10.01 [254.25]
15.18 [385.69]
.53 [13.39]
.41 [10.35]
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4INLBS
TORQUE = 4.4 INCH POUNDS
NOTE: SET SCREW MAXIMUM
LABEL NO: 94-00046 REV B
LABEL NO: 94-00046 REV B
3.28 [83.19]
1.40 [35.56]
2.77 [70.23]
.73 [18.52]
.47 [11.94]
1.46 [37.03]
[18.5mm]
5.10 [129.5mm]
7 SP. @ .7285
1/4 - 20 SERRATED FLANGED NUT ZINC PLATED STEEL
WITH OPTIONAL BUSS BARS
CUSTOMER MOUNTING HOLES (16X) M4 OR #8-32 THREAD MAXIMUM SCREW PENETRATION .150 [4.00mm] FROM OUTSIDE SURFACE.
12
1110
9
8
7
65
43
2
1
J10
RE-DESIGNEDORIGINAL
NUT FLANGED INSERT
BRASS
STUD IS 1/8 INCH LONGER.
MAY BE PRESENT. THE NEW OUTPUT PANEL HAS A BRASS INSERT AND THE
NOTE: EITHER THE ORIGINAL OR RE-DESIGNED OUTPUT STUD AND PANEL COMBINATION
OUTPUT PANEL AND STUDS

UG:119 Page 15
Interface Connections
Chassis Input Power Terminals (J9)
Input AC power is applied to terminal block J9 using a pressure screw terminal that accepts a maximum
wire size of 14AWG. The insulation should be stripped 0.35in and the maximum torque applied to the
screws should not exceed 4.4lb.in.
The connector manufacturer recommends the wires not be tinned. A ferrule (Phoenix P/N 32-00-58-0,
purchased from other sources) can be used to prevent fraying. J9-1 (GND) is Earth Ground for safety;
J9-2 (L2) and J9-3 (L1) are the other Hot connections. For Input DC power, L2 is (+) and L1 is (–).
A fault clearing device, such as a fuse or circuit breaker with a maximum 15A rating at the power supply
input is required for safety agency compliance. It should be sized to handle the start-up inrush current of
25APK at 115V RMS and 230VRMS.
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 (M2) 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 J2A and J2B. 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.
If units do not have 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 PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™
are powered up. (NEVER disconnect the +Out and –Out load wires while the supply is operating as
disconnecting WILL cause damage to the power supply). 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™ or if the Local Sense option is specified
(old units). Local Sense mode means that the Remote Sense lines are not connected. Sense pins can be
accessed on J1A/J1B or J2A/J2B on dual output units.
INPUTS DO NOT
WITHOUT
EARTH
GROUND
L2
115/230V
AC
300V
DC
INPUT CONNECTIONS
J9-1 EARTH GROUND
J9-2 L2-NEUTRAL
J9-3 L1
L1
47 – 500 Hz
OPERATE
47 – 500Hz
300V
DC
115/230V
AC
L2
INPUTS
L1
OPERATE
GROUND
EARTH
WITHOUT
DO NOT
NOTE: SET SCREW MAXIMUM
TORQUE = 4.4IN.LBS
TORQUE = 4.4IN.LBS
NOTE: SET SCREW MAXIMUM
LABEL NO: 94-00046 REV B
LABEL NO: 94-00046 REV B
J10
Figure 3
Input panel connectors

UG:119 Page 16
Signal Ground (J10-10)
Signal Ground (see Figure 4 and Connector Pin Identification) is an isolated ground reference for all J10
interfacing 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 J9.
Enable/Disable (J10-1 to J10-8)
The Enable / Disable control pins allow ConverterPAC outputs to be set either on or off. J10-1 through
J10-8 are the control pins for output positions 1 – 8, respectively (see Figure 5 and Connector Pin
Identification above). For DualQPACs™, both outputs are set on or off by the same control pin. In
parallel arrays, only the driver ConverterPAC need be controlled. The Enable / Disable pins must be
pulled low to less than 0.7V with respect to Signal Ground to disable the outputs. They will sink 10mA
maximum. These pins should be open circuited or allowed to exceed 4.5V when enabled. Do not
apply more than 6V to these inputs at any time. If driven from an electromechanical switch or relay, a
capacitor should be connected to eliminate the effects of switch bounce.
Figure 4
Interface connector
J10-9
J10-10
J10-11
J10-12
VCC +5V, 0.3A
SIGNAL GROUND
AC POWER OK
GEN SHUTDOWN
J10 INTERFACE
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
J10-7
J10-8
E/D-1
E/D-2
E/D-3
E/D-4
E/D-5
E/D-6
E/D-7
E/D-8
12
1110
9
8
7
65
43
2
1
J10
Figure 5
Enable / disable and
general shutdown PFC MegaPAC-EL™
1
10
12
Signal Ground
General Shutdown
Enable/Disable Output 1
J10
1
0
TTL "1" (OFF)
TTL "0" (ON)
9VCC
Using external transistors to
drive enable/diable logic

UG:119 Page 17
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 2, 4 and 6 have been configured as a single-output parallel array (see Figure 6).
In order to disable the 48V output, E/D 2, E/D 4 and E/D 6 should be shorted together as shown in
Figure 6. With 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 Shutdown (GSD) function.
General Shutdown / GSD (J10-12)
The GSD control pin on J10-12 allows simultaneous shutdown of all ConverterPAC™ outputs (see
Connector Pin Identification on Page 16, Figure 4). This pin must be pulled down to less than 0.7V and
will sink 13mA 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 6V to
this input at any time. Normal open circuit voltage is 1.5 – 3V with respect to Signal Ground. If driven
from an electromechanical switch or relay, a capacitor should be connected to eliminate the effects
of switch bounce.
AC OK / Power Fail (J10-11)
This is an active high TTL compatible signal and provides a status indication of the AC input power
(see Figure 7 and Connector Pin Identification on Page 16, Figure 4). It is capable of sourcing 0.5mA at
>3.2V and sink 16mA at <0.5V. 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.
Figure 6
Enable / disable control
of Maxi Arrays
PZL48V/12.5AN
PZL48V/12.5AJS1
PZL48V/12.5AJS1
Slot# 1
Slot# 2
Slot# 3
Slot# 4
Slot# 5
Slot# 6
Slot# 7
Slot# 8
J1
J10
2
4
6
10
123
Power Factor Corrected
MegaPAC
L5V/40A
L3.3V/40A

UG:119 Page 18
Figure 7
AC OK Power Fail
Auxiliary VCC +5V / 0.3A (J10-9)
The VCC on J10-9 is an auxiliary 5V regulated power source (see Figure 8 and Connector Pin
Identification on Page 16). It is +5VDC ±5% with respect to Signal Ground and can supply 300mA
maximum. It is short-circuit-proof, but if shorted all outputs will shut down through the Enable / Disable
circuitry. The Auxiliary VCC typically powers user circuitry or is used with the Power Good circuitry to
provide a pull-up reference for the outputs of the DC Power Good circuit on a ConverterPAC™. If used
for this purpose, the Signal Ground on J10-10 must also be connected to the J3-1 Signal Ground pin of
the ConverterPAC.
Power Good (J2-3 / P2-3)
The optional Power Good signal on J2-3 / P2-3 is referenced to Signal Ground on J2-1 / P2-1 and
indicates the status of the output voltage. This signal is asserted a TTL “1” when the output voltage
is above 95% of nominal. It is a TTL “0” when the output voltage is below 85% of nominal. If the
Trim option is also used, the Power Good trip points DO NOT track with the trimmed voltage. It is
possible to trim the output below the fixed set points of the Power Good circuit and cause a negative
Power Good signal.
10kΩ
Signal Ground
AC Power OK
11
+5V
10
J10
2.49K
PN2222
Figure 8
Auxiliary VCC
78M05 Auxiliary VCC
9
0.1µF
Signal Ground
J10
10
+5V/300mA
Figure 9
Power Good and VCC
Signal Ground
2
VCC IN
4
J2/P2
10kΩ
2.49kΩ
2N2222
2.49kΩ
1
Power Good
3
Power Good Inverted

UG:119 Page 19
Power Good Inverted (J2-2 / P2-2)
This is the inverse of the Power Good signal and is referenced to Signal Ground on J2-1 / P2-1.
Signal Ground (J1-1 / P2-1)
Signal Ground on J2-1/P2-1 is an isolated secondary ground reference for J2/P2 status signals. It is used
to provide a reference point for the Power Good circuitry and is not the same as Earth Ground on input
power connector J9.
VCC IN (J2-4 / P2-4)
The VCC IN on J2-4/P2-4 is an input that requires +5V either from the J10 Auxiliary VCC, or from
another source. Input current to this pin is limited by an internal resistor to 3mA. If the J10 Auxiliary
VCC is connected to VCC IN on J2-4/P2-4, then the J10 Signal Ground must be connected to Signal
Ground on J2-1/P2-1.
+Sense / –Sense - J2-6 and J2-7 (See Pages 11 and 12 for information on Autosense)
The +Sense on J2-7 should be connected to the +Power Out, and the –Sense on J2-7 to the
–Power Out terminal. Do not reverse or leave the Sense pins open. Sense pins can be terminated locally
at the output of the power supply, in which case the power supply will provide regulation at the output
terminals. The voltage appearing at the load may drop slightly due to voltage drop in the power cables.
If it is necessary to compensate for voltage drop along the output power cables, this termination should
be made close to the output load. Compensation of up to 0.5V (0.25V per lead) can be obtained. Use
twisted pair 22-24AWG wire for this purpose.
For DualQPACs™, the +Sense pins are available on connectors designated as J2A-2 and J2B-2 for
outputs A and B, respectively. –Sense pins are on J1A-3 and J1B-3, respectively. These pins are also
duplicated on the power connectors J1A and J1B.
Reminder: Only units with Autosense will automatically operate in Local Sense mode if no Sense
connections are made. It will operate in Remote Sense mode if Remote Sense connections are made.
Units without Autosense MUST have sense connections (Local or Remote) terminated to their respective
output for the unit to operate properly. Further, NEVER disconnect the +Out and –Out load wires while
the supply is operating as disconnecting WILL cause damage to the power supply.
Figure 10
Sense Leads
(Remote Sense)
Load
(Local Sense)
+P +Out
P2-7 +Sense
P2-6 –Sense
-P –Out
Use 22-24AWG
Twisted Pair Wires

UG:119 Page 20
External Trim (J2-5/P2-5)
Output voltage can be trimmed using an optional factory-installed Trim potentiometer or with the Trim
pin (see Figure 11). The Trim potentiometer is located on the ConverterPAC™. If the Trim potentiometer
has not been ordered, the Trim pin must be used. When using the Trim pin, the Trim limits are
determined by the DC-DC converter used on the ConverterPAC. Maximum Trim ranges are 10% above
the nominal converter voltage and 50% below the nominal converter voltage (except 10, 12 and 15V
outputs which are 10% below nominal) as measured from the output studs or output connector of
the power supply.
Note: The combined effects of module trim up, remote sense and dynamic-load step may cause the module to trip
OVP. (Tripping OVP will require cycling input power to the supply off, then on).
The Trim pin on J2/P2 can be used to control the output voltage. It is referenced to the –Sense pin on J2
and can be controlled by either a resistor network or an external voltage source. To increase an output
voltage above its nominal, it is necessary to increase the voltage at the Trim pin above the internal
reference voltage (VREF). The reverse is true to decrease an output voltage.
Note: Converters are sometimes pretrimmed at the factory if a nonstandard output voltage is requested. If using a
nonstandard voltage or if a ConverterPAC is ordered with a Trim option, the resistor calculations will differ from those
on Page 21. Please consult the factory for assistance.
Output Module VREF RTH
VI-200™ / VI-J00™ ≥3.3V 2.50V 10.0kW
VI-200 / VI-J00 < 3.3V 0.97V 3.88kW
Maxi (Pre-Defined) 1.23V 1.0kW
Maxi (User-Defined) 1.23V Consult Factory
Figure 11
External trim
(Remote Sense)
Load
+P +Out
P2-7 +Sense
P2-6 –Sense
–P –Out
Use 22-24AWG Twisted Pair Wires
R5
V
REF
P2-5
R6
R8
R7
To Error
Amplifier
R4
R3
R2
R1
+
+
V2
V1
–
–
R
TH
Use 22-24AWG
Twisted Pair Wires
Table 1
Module internal
reference voltages and
Thevenin resistances