NN VICOR VIR ARE fanmone Attenuator Afeeiude Unity Power Factor Safety Agency Approvals: UL, CSA, TUV Meets IEC 6100-3-2 for Line Current Harmonic Content Reduces Peak and RMS Line Currents Universal Input: 85-264 Vac: 50/60 Hz Up to 600 Watts of Power Power Density Up to 100 W/in3 Adaptive Output Voltage Control Short-Circuit Protection Input Surge Current Limiting Module Enable Power OK Output Size: 4.6" x 2.4" x 0.5" (116,8mm x 61,0mm x 12,7mm) Efficiency: 90-94% Typical CE Marked Figure fa. Figure 16. Above: Oscilloscope pholos showing input vallage and current without power facior correction (A) and with power factor correc- tion as provided by the VI-HAM (8). 4. 98 Unky Power Factor Conventional capacitive-input front ends draw energy from the AC line in short bursts of current at the peaks of the line voltage waveform. These current bursts are character- ized by high peak currents and high harmonic content. The effect of the distorted line current can be appreciated by measuring the rms line current drawn by a conventional front end: the product of the measured rms current and the rms line voltage the apparent powet" being delivered by the line will be signifi- cantly greater (typically 1.6X) than the DC power delivered by the front end. The extra rms current at the input is circulating harmon- ic currents which deliver no power to the load but which flow in the delivery system and contribute to losses. Only the fundamental component of the line current contributes to real" power flow. Power factor the ratio of real" to "apparent" power is a measure of the effectiveness with which an AC load can extract usable power from an AC source. The VI-HAM (see Figure 2) consists of a full- wave rectifier, a proprietary high-frequency zero-current switching (ZCS) boost regulator (patents applied for), active inrush, short-cir- cuit protection, control and housekeeping cir- cuitry. The incoming AC line is rectified and fed to the ZCS boost converter. The control circuitry varies the operating frequency of the ZCS boost converter so as to simultaneously maintain the output voltage of the HAM ata DC voltage value above the peak of the incoming line, while forcing the input current to the ZCS converter to follow the waveshape of the rectified line. By this means, the AC input current follows the AC voltage wave- form and a power factor better than 0.99 is achieved. Operating efficiency of the ZCS boost converter is optimized at any incoming line voltage by a patented adaptive output voltage control scheme. The HAM also includes active circuitry which controls inrush currents when power is applied and active short circuit protection cir- cuitry features not normally found in con- ventional power factor correctors. Housekeeping circuitry provides two signals of use to the system designer (see Figure 2): Module Enable and Power OK. Referencing the timing diagram (Figure 3), the Module Enable signal, which is connected to the Gate In inputs of the Vicor DC-DC converters pow- ered by the HAM, will come high and enable the DC-DC converters when the HAM output voltage exceeds 240 Vdc. The DC-DC convert- er voltage outputs will be up approximately 10 ms after Module Enable goes high. Typical- ly, 20 ms after Module Enable goes high the HAM Power OK signal, which can be used by the system designer to enable circuitry pow- ered by the DC-DC converter modules, goes low. On loss of power or brownout, the Power OK signal will go high when the HAM DC output voltage drops below 230 volts, signal- ing an impending loss of input power to the converter modules. When the DC output dips below 195 volts, the Module Enable signal will toggle low, disabling the converter mod- ules and unloading the HAM. The HAM will provide at least 16 ms of ride-through or holdup time, and at least 5 ms of AC fail warming time with a 1000 pF output capacitor. - Inrush te + AC Recti- avs & Short DC Line fier C oost Circuit Out > onverter Protection L Current TM. bn High Frequency Note: Voltage Control Isolated Waveform ly! Control Output Voltage & House- Module Enable keeping Power OK Circuitry Gate In a | Gate Out Aux. Supply > NOTE: No input to output isolation. Figure 2 VI-HAM Block DiagramAG Mains 120V AMS cc Output of HAM Module Enable Power OK < a 5 Outputs Vi-200 Gonverter(s) Figure 3 Functional Timing Diagram Active power factor correctors incorporate a boost regulator which must operate over a range of incoming AC line voltages. Conven- tionally, the output voltage of the boost regu- lator is set to a value greater than the maximum anticipated peak value of the incoming AC line. Vicor varies the output voltage of the HAM as a function of incoming AC line voltage (Fig- ure 4, patent applied for). On a nominal 120 Vac line the output voltage of the HAM is 260 Vdc well within the input operating voltage range of standard Vicor converters. As input line increases, so does the HAM output voltage; at 220 Vac the delivered volt- age will be about 350 volts. For any given input line voltage, the HAM maintains enough headroom between the output voltage and peak input voltage to ensure high quality active power factor correction without unnecessarily sacrificing operating efficiency. 400 DC 350 VDC 300 DC 250 VDC 200 DC Output Voltage asa Function of Input Voltage 150 VDOC 100 OC 50 VDC Figure 4 + input Voltage vs. Quiput Voliage HAM Prolecton Features Overtemperature Shutdown The HAM incorporates overtemperature shut-down, and is designed to shut down when the temperature of the baseplate exceeds 90-100C. It is not safe to run the HAM for extended periods above its maximum operating temperature of 85C. Short Circuit Protection The HAM contains a short circuit shutdown function. Operation of this function does not clear the input fuse and the output will resume normal operation after removal of the short. A small period of time may be required to allow for cooling of an internal PTC. Overcurrent protection is provided by the Vicor DC to DC converters. Output Overvoltage Protection The HAM contains output overvoltage protection. In the event the output voltage exceeds approximately 420 Vdc, the boost will decrease to maintain 420 Vdc on the output. When the peak of the AC line exceeds 420 volts (approximately 293 Vac) the boost will have been reduced to zero. Beyond this the protection circuit will be enabled and the output voltage will decrease. Fin Function Description * Li and L2/N (VI-HAM): These pins are to be connected to the AC mains output of a suitable EMI/RH filter (Vicor P/N 07818 or equivalent). Do not connect an X capacitor across these pins as power factor carrection will be slightly degraded. +IN, -IN (VI-EHAMD, VI-BAMD): These pins are connected to the output of the external bridge rectifier. * Gate Input (VI-HAM): This pin disables the boost converter only. Rectified line current may still be present on the outout. This pin does not provide ihe same function as the gate input pin of Vi-200/VI-J00 modules. The user should not make any connection to this pin. * Gate Input (VI-HAMD): This pin serves as a rectified AC fallawing pin for power factor correction synchronization to line. This connection must be made through the synchronization diodes between the line filter and bridge rectifier shown in Figure 10, page 62. * Gate Input (VI-BAMD): The Gate Input pin is an interface pin to the Gate Out pin of a VI-HAM, VI-HAMD or VI-BAMD depending on configuration. The user should not make any other connection to this pin. * Gate Output The Gate Output pin is an interface pin to BAMDs; the user should not make any ather connection to this pin. * +Output and -Output and Holdup Capacitor: These outputs should be connected to the respective inputs af Vicor DC/DC converters. In addition, an external holdup capacitor of 1000 UF with a minimum voltage rating of 450 Vac, is required across the outout for 16 ms ride through time at 600 Watts (500 LF far 300W, etc). Do not exceed 3000 |/Faf total output capacitance. Lower values of capacitance may be used for reduced holdup requirements, but not less than 330 UF. Lower capacitance values may degrade power factor specifications. * Auxiliary Supply (A/S): The VI-HAM and VI-BAMD contain an internal low voltage outout (A/S) that may be used to power pri- mary side logic. This output is 19-23 Valts DC, referenced to -OUT, at 3 mA max. Do not overload or short this output as the HAM will fail. A typical use for A/S is to power an optical coupler that isolates the Power OK signal. Power OK" Status Low = OK sone] ED PIOK, S191, v4w Figure 5+ Auxiliary Supply (A/S} * Power OK (P/OK) P/OK is a moniter signal that indicates the status of the AC mains and the DC outout voltage of the HAM. P/OK, during normal operation, is an active low (Figure 6). In the event AC mains or DC output fails, this pin goes to an open circuit state. P/OK is asserted when the output bus voltage is within normal operating range and 20-25 ms after DC-DC converters are enabled by the Module Enable output of the HAM. This provides sufficient time for the converters to turn on and their outputs ta stabilize prior ta P/OK being asserted. When the AC mains is removed and the output of the HAM drops below 230 Volts, P/OK goes to an open circuit state. When the output voltage drops below 195 Valts the converters are disabled via Module Enable. P/OK will provide power fail warning at least 1 ms prior to converter shutdown. PIOK | | : o Loaic s a Figure 6 Power OK (P/OK} * Module Enable (E/O) The Module Enable output is used to disable the BC-DC converters until there is sufficient energy in the holdup capacitor (240 Volts} to support narmal operation, while limiting inrush current. Module Enable must be connected to the Gate Input of all driver DC-DG converters. Itis not necessary to connect this pin to boosters as they are contralled by their respective driver. If the AC mains fail, Module Enable goes low when the DC output of the HAM drops below 195 Volts. Failure to connect Module Enable may result in the output of the HAM latching low during turn-on. Figure 7 Enable/Quiput (E/Q} 4-98LHAM Protection Features fgomtinisedi? Inrush Current Limit The HAM contains inrush current protection in the form of a PTC and a shunt device. The same PTC is used for overcurrent protection on the output. Input Transient Overvoltage Surge Protec- tion This function is included in all HAM compatible filters. If any other filter is used this function must be provided externally, typically by a transient suppressor. * Safety Note * All VI-HAM configurations must be preceded by an appropriately rated fast-blow 3AG fuse ahead of the line filter. This fuse would be a 10A for a single VL-HAM connected to line. For fusing information on other VI-HAM configurations, please contact Vicors Appli- cation Engineering Department. Sompeiibie Mocules Over the full range of input voltages (85 to 264 Vac), the output varies from 260 to 415 Vdc. Therefore the modules used with the HAM are from the VI-260 and VL-J60 families. When ordering add the prefix VI- to the part number below; i.e., VE260-CU. VI-200 Family 5V 12V 15v24 48V Output 260-CU 261-CU 262-CU 263-CU 264-CU 200W 260-CV 261-CV 262-CV 263-CV 264-CV 150W 260-CW 261-CW 262-CW 263-CW 264-CW 100W 260-CX 261-CX 262-CX 263-CX 264-CX 75W 260-CY 261-CY 262-CY 263-C 264-CY SOW Framed area available as boosters. Change VI-2 XX-XX to VI-BXX-XX. I-JO0 Family 5V 12V 15V 0 24V0C 48V Output Jeo-CW J61-CW J62-CW J63-CW J64-CW 100W J60-CX J61-CX J62-CX J63-CX J64-CX 75W J60-CY J61-CY J62-CY J63-CY J64-CY SOW J60-0Z J61-CZ J62-CZ J63-CZ J64-CZ 25W Pred. Baseplate Storage Model Grade Temp. Temp. E -1oCto+85C = -20C to+100C =VI-HAM-EM CG -25Cto+85C = -40C to +100C = VI-HAM-CM | -40C to +85C 55C to +100C = VI-HAM-IM M -55Cto+85C )=-65C to +100C }=VI-HAM-MM Fitter Requirarmentie for the VI-HAR The VI-HAM requires an external filter to meet international standards for conducted EMI/RA emissions. P/N 07818 (for use up to GOOW) incorporates transient protection for compliance with IEC 61000-4-5 Level 3 and meets conducted emissions standards EN55022 and VFG243 Level A. VIHANM Configurations VI-HAM-CM Driver HAM: Fully configured power factor correcting front end. VI-HAMD-CM Driver HAM: No internal bridge rectifier or synchronization diodes. VI-BAMD-CM Booster HAM: Companion module to VI-HAMD-CM used for additional output power. No internal bridge rectifier. Use the VI-HAM-CM for applications requiring up to 600 Watts from the front end. For applications in excess of 600 Watts, it is not possible to simply parallel two driver HAMs due to conflicting control loops. Gate Out to Gate In connections on respective driver/boosters are used to ensure that the power train of the HAMs current-share. However, this does not ensure that the diodes in the lower half of the bridge rectifier will current-share. A solution for this situation is illustrated in Figure 8. VI-HAMD Vac Line Filter Figure 8 VEHAMD with Boosier HAMs (BAMDs} No Iniernal Bridge Rectifier A solution te bridge rectifier current sharing issues is to remove the bridge rectifier from each HAM and use one diode bridge sized to handle the entire load. Approxi- mately 25% of the heat is removed from the HAM in this approach; use a VI-HAMD-CM with one or more VI-BAMD-CMs. Note: Synchronization diodes are required when using this approach (see Agure 10, page 62).Sracifications V-HAM and VI-HAMD With External Bridge and Synchronization Diodes, 1000 PF Output Capacitor and Vicor Line Filter P/N 07818. VI-BAMD When Operated with VI-HAM and VI-HAMD, Respectively. (Unless otherwise indicated, specifications apply over operating input voltage and temperature range) Parameter I-HAM I-HAMD i-BAMD Remarks Line Input 85V to 264V 85V to 264 85V to 264V Unit will operate from 400 Hz, but 47-63 Hz (Volts AC) (Rectitied AC} (Rectified AC) may not meet PF or THD specs Output Power Up to 600 Watts Up to 600 Watts Up to 600 Watts Derate trom 110 Vac to 85 Vac @ 8WiVolt Efficiency 90-91% 90-91% (With ext. rectifier loss) 90-91% (With ext. rectifier loss) 120 Vac, full load Efficiency 93-94% 93-94% (With ext. rectifier loss} 93-94% (With ext. rectifier loss} 240 Vac, full load Power Factor 0.99 0.99 0.99 120/240 Vac, 50-100% of tull load Total Har. Distortion (line current}* <7.5% <7. 5% <7,.5% Sinusoidal, 120 Vac, full load Total Har. Distortion (line current)* <8.5% <8.5% <8.5% Sinusoidal, 240 Vac, full load Output Ripple 7V p-p TV p-p 7 p-p 120 Vac, full load Output Ripple 5V p-p 5V p-p 5V p-p 240 Vac, tull load Inrush Current <13 Amps peak <13 Amps peak <13 Amps peak 120 Vac, full load Inrush Current <20 Amps peak <20 Amps peak <20 Amps peak 240 Vac, full load Output Capacitance 500-3000 LF 500-3000 LF 500-3000 UF External to HAM (tor 6O0W load) (1000 UF Nom.) Ride Through/Holdup Time 16 ms 16 ms 16ms 600W output with a 1600 UF hold- up capacitor (300W = 500 UF, etc.) Transient Surge Withstand, Included in the Included in the Included in the Normal Mode external filter external filter external filter Isolation Voltage Input to Output None None None Isolation provided Input to Baseplate 1,500 VRMS 1,500 VRMS 1,500 VRMS by DG-DG converters Output to Baseplate 1,500 VRMS 1,500 VRMS 1,500 VRMS Auxiliary Output 19-23 Vde 19-23 Vde 19-23 Vde Note Not short circuit protected @<3ama @<amA @<10mA Thermal Shutdown 90C- 100C baseplate 90C-100C baseplate NA Baseplate Temperature -10C to +85C (E Grade) -25C to +85'C (C Grade} -40C to +85C (I-Grade) -55C to +85C (M-Grade) Storage Temperature -40C to +100C (C Grade) -55C to +100C (I-Grade) -65C to +100C (M-Grade} Short Circuit Protection Yes Yes Yes MTBF (GB, 25C) >420,000 hours >424,000 hours 818,000 hours Size 46'x2.4"x 05" (116,8 x 61,0 x 12,7) 4.6" x 2.4"x 0.5" (116,8 x 61,0. 12,7) 4,6"x2.4"x0.5" {116,8 x61,0 x 12,7) Weight 6 (170) Ounces (Grams) 6 (170) Cunces (Grams) 6 (170) Gunces (Grams) "Hp = HAM THD ~ THD Line current total harmonic distortion = input voltage distortion plus 8.5% max &uplicaiion of the Vi-PMAN The HAM must be used in conjunction with a suitable line filter, such as Vicors P/N 07818, output holdup capacitor and Vicor DC-DC converters (Figure 9). Con- nect single phase AC mains to the input of the line filter via a standard 10 amp AC fuse. Connect the output of the filter to L1 and L2/N of the HAM. Do not put an X capacitor across the input of the HAM or use a line filter with an X capacitor on its output as power factor correction may be impacted. Connect the +Output of the HAM to the tInput of the converters via a3 amp PC Tron DC fuse. Connect the -Output of the HAM to the -Input of the converters. Connect a 1000 pF electrolytic capacitor rated at a minimum of 450 Vde across the + and - Output of the HAM (or 500 pF for 300W, etc). This capacitor must be in close proximity to the HAM. Connect the Enable Output of the HAM to the Gate Input of each driver converter to disable the converters until the output of the HAM is within normal operating range. Please refer to Vicor's Applications Manu- al for information on the proper connec- tion of the DC-DC converters. The aforementioned connections are the minimum required. In addition, there are other features available. * The Auxiliary Supply output is approximately 21 volts at 3 mA max. This output is usually used in conjunction with the Power OK signal. Power OK provides an indication of the status of the DC output and the AC mains. * The Enable Output of the HAM must be connected to the Gate Input of all driver modules. The HAM will then disable the module output until the input exceeds 85 Vac and the output has been boosted to 260 Vde. If an external load is connected directly to the output of the HAM, do not apply the load until the output of the HAM is in boost mode. Although the efficiency of the HAM is quite high, it still dissipates significantly more power than a VI-200 DC-DC converter. Care should be taken to cool it. Thermal compound should be used between the heatsink and baseplate of the VLHAM, VI-HAMD and VI-BAMD. * When making any connections to the VLHAM for measurement purposes, remember that it is not isolated from the line either input or output. A line isolation transformer must be used when making scope measurements. * The input voltage range of the V-HAM is 85 to 264 Vac; however it may not start boosting until the AC mains has exceeded 87 Vac. Once the VI-HAM has started, it will operate down to 85 Vac. The VLHAM contains 2.5 to 6 Volts of input hysteresis, therefore if the AC line impedance is high, i.e., when using a variable autotransformer, the V-HAM may start, but the AC line may then fall enough to drop below undervoltage lockout. When this happens the AC line will go up, the HAM starts and the cycle repeats. Therefore avoid soft AC lines at or near low line. 4-98Gannecton figgrant, Vi-AM/ESC-IMG Gorivertars 10A 260-400 Vdc Vicor 26x or JX cor or MOV Up to BOOW Family Converters PIN cando f 1 J U 4 J ] Po Tron f 1 J 1 J 1 J HO 11 Li @ 11 + OUT | Ne +IN +OUT @& - et @ GATE P/OK @ [1000 ly oak SOF cau ine Filter IN | FO = H@ GATE IN i one a @ GND PN 07818 ecaTte = VIHA Se rl Driver T@|| Output 6.3A OUT -@ GATE OUT set Voltage te Lain L2N @4+-L-@ Lain ~ OUT | [] iN ourelll n - - LOAD 3oM ener (1N4709) Y-Capacitor : Vv Holdup Box (HUB) available as accessory product through Vicor Express pote, P +IN +OUT @ 2704F HUB270-P 3A Lh GATE IN 470aF HUB470-P Booster (n) e @ GATE OUT & 870uF HUBB70-P -IN -OUT 1100,F HUB1100-P f S S S t Y-Capacitor Figure 9 - VI-HAM Connection Diagram Gannection Diagram, VEK-HAMD/VE-R AMD iow Oe IN +OUT @ 1000 wF @ @GATE IN em o _L: 450 Vdc To Modules HAMD a Input Bridge @GATE OUT AS @ | -te 11 Lie@ L Rectifier -IN -OUT @ 204 na iN4oga + fi fi n Line Filter Ti [@ GND 12.64" ~ oa iN4o08 104 U U VU Te LN P/N TBD Lan & he IN +OUT @ 1000 wF @ @ GATE IN NC _[t 450 Vide BAMD NC @GATE OUT NS @ a a @-IN -OUT@ * Please consuli Vicor's Application Engineering Depariment for specific VI-HAMD/VI-BAMD filtering information. 4-98 Figure 10 * VEHAMD/BAMD Cennection DiagramMechanical Diagram 4.60 (116.8) _____+ Pin#] HAM [HAMD | BAMD 50 8 BD (91,4) ; i ui +IN +IN C1 2,7) 1.80 2) p (2.0) Dia. 2 Gate In Gate In Gate In 45,7 2) places 3 | Gate Out | Gate Out| Gate Out +018 thi) TI a ( Solder plate 4 L2iN IN IN over copper alloy 5 | +Out +Out +0ut TT -4 6 | POK PIOK NG v U / 7_| BO EO We 4 ad. 3 [As AS AS 9 Out Out Out 2.10 8 Be (53,3) Fes #2 Bed 1 \ 50 A. , al mA r= 15 | | FULL R \ 040 (1,0) Dia (7) places (3.8) Product ID Solder plate this surface over copper alloy 2.40 (61,0) 4.20 (106,7) 30 (7,6) | | 22 (5,6) MIN Min 1.75 (44,5) _i l - | | 1 0 (12,7) 7929 0.78) l LI LI Lt J t ZI. 12 (3,0 8.9) Aluminum Base Andover, MA, USA Sunnyvale, CA, USA France Italy Tel +33-13452-1830 Fax:+33-134522830 U.K. Tel +44-1276-078222 Fax: +44-1276-681269 Tel 4085225280 Fax: 408-774-5555 Tel: 800-735-6200 Fax: 978-475-6715 Lombard, IL, USA Tel 630-/69-8780 Fax: 630-/69-8782 Germany Tel: +49-89-962439-0 Fax: +49-89-962439-39 Tek +3922247-2326 Fax: +3922247-3166 Nip VICOR Hong Kong 4/98 Tel +8522956-41782 Fax: + 85229560782