4. Installation¶
4.1. Inspection¶
Carefully unpack the BDx Module and accessories saving all packing materials and included enclosures. Inspect product for possible shipping damage. Check that there are no broken knobs or connectors, the external surface is not scratched or dented, the meter faces are not damaged, and all controls move freely. Any external damage may be an indication of internal damage. If there is any damage, notify the shipping carrier and Magna-Power immediately: magna-power.com/support.
The following parts are included with all Accessory models:
BDx Module
DC input/output metal protective cover
BDx Module interface cable
Qty (2) rear support brackets for rack installation
Qty (16) 10-32 screws
Qty (8) 10-32 flat washers and lock washers
Qty (2) handles with mating hardware
USB drive with software, drivers, and digital documentation
4.2. Rack Installation¶
The BDx Module is intended for rack mount installations only and is designed to fit in standard 19-inch EIA equipment racks. The BDx Module product is designed to fit in one rack-unit (1U). Additional support, other than that provided by the front panel, is required. Fixed rear support rails are provided, which can be adjusted at time of installation to fit a variety of equipment rack depths. These included rails are designed to mate to inserts on the BDx Module side panels using included hardware. Alternatively, angle slides or cross beam supports can be used to securely fasten the product to the rack and support the rear weight. The unit should be horizontally mounted.
Fig. 4.1 Included rear support rails for BDx Module (inches). Click for a larger view.¶
4.2.1. Cooling Requirements¶
Each BDx Module is cooled by suitable fans exhausting warm air to the rear of the cabinet. Fresh air intake is from the sides of the cabinet allowing two or more BDx Module to be stacked without any clearance required. Equipment racks should be equipped with fans or blowers to remove heat generated by the power supplies. Magna-Power recommends fresh air intake at the bottom of the cabinet and exhaust fans at the top pulling air out of the cabinet.
The BDx Module features integrated fans that pull in cool air from sides and exhausts warm air from the rear. Air intake from only the sides of the product allow two or more BDx Module to be stacked with zero clearance between units. Equipment racks housing the BDx Module should be equipped with either an open back, back with grills, or closed back with cabinet fans to remove heat generated by the BDx Module. For fully enclosed cabinets, Magna-Power recommends fresh air intake from the bottom of the cabinet and exhaust at the top.
For cabinet fans to be effective, the ambient intake air temperature outside the rack must be less than the air temperature inside the rack. The BDx Module is rated for 50°C ambient operating temperature. In the case of rack installation, this corresponds to the temperature inside the rack and adequate cooling measures must be taken to ensure the rack’s internal temperature stays below 50°C.
The following table provides Magna-Power’s recommended per unit cabinet air flow when installing the BDx Module in a fully enclosed cabinet:
Note
The table above accounts for only a single Accessory. When sizing cabinet fans, it is necessary to account for the heat produced by all the products in the cabinet.
Caution
Do not block the air intake on the front or sides of the instrument, nor the exhaust at the rear of the instrument. Blocking these vents could cause the product to overheat. The recommended minimum clearances are 2 inches (5.1 cm) along the sides and back.
4.3. Interface Cable¶
The BDx Module includes a 15-pin D-Sub male to 37-pin D-Sub male interface cable to integrate the BDx Module with a MagnaDC programmable DC power supply. Connecting the Interface Cable ensures safe operation, allowing the BDx Module to shut down the power supply in the event of BDx Module thermal alarm.
Fig. 4.2 Interface Cable connection from BDx Module (top) to MagnaDC programmable DC power supply (bottom)¶
The Interface Cable’s 15-pin connector is attached to the BDx Module and the 37-pin connector is attached to the MagnaDC programmable DC power supply.
The power supply’s interlock feature must be enabled to allow the BDx Module to perform a shutdown. Refer to the power supply documentation for instructions on how to enable this interlock feature.
Warning
FIRE HAZARD. Failure to connect the Interface Cable or enable interlock on the MagnaDC power supply could result in overheating and catastrophic failure of the BDx Module.
4.4. AC Input Connection¶
A single-phase AC input connection is used to provide a ground reference and power for the Accessory fans and control circuits. The AC input power requirements are defined on the BDx Module product rating label. The AC input requirements are further defined in this section.
To provide AC power to the BDx Module, connect the provided power cord to the IEC 60320 C13 AC power receptacle, as shown in BDx Module IEC 60320 C13 AC power receptacle.
Fig. 4.3 BDx Module IEC 60320 C13 AC power receptacle¶
Warning
The power cord provides a chassis ground through the third conductor. Be certain that your power outlet is of the three-conductor type with the correct pin connected to earth ground.
4.4.1. Fuse Rating¶
The BDx Module is fused on its auxiliary power supply assembly, which is a printed circuit board (PCB) assembly located inside the product. The fuse can be accessed by removing the BDx Module top cover and locating the only PCB assembly inside.
The fuse is a through-hole component designated by F3 on the PCB. This fuse carries a 3.15 Aac rating, Bussmann / Eaton manufacturer part number SS-5H-3.15A-APH, Magna-Power Item 32060.
Failure of this fuse typically indicates a failure of this auxiliary power supply assembly and it’s recommended to contact Magna-Power support in the event this fuse has cleared.
4.5. DC Connections¶
Warning
SHOCK HAZARD. The DC input and output connections may still be live despite AC power being off or disconnected. Always measure both the DC input terminal and DC output terminal with respect to ground to ensure zero voltage before making any connections.
The BDx Module DC input and DC output consist of independent heavy-duty copper bus bars with a 3/8” threaded insert. Magna-Power recommends DC power cables be crimped to ring terminals and securely fastened to bus bars using the included 3/8” bolts, washers, and lock washers. The recommended torque for the DC connection is 240 in-lbf (27.1 N-m).
Select a wire size sufficient to handle the maximum output current of the unit, no matter what the intended load current or current limit setting. Connections can be made on top and bottom of the bus bars. Beyond two wire connections, a mating bus bar will need to be added to provide additional mounting holes.
The recommended wire size for different current levels are shown in the table below.
Wire Size (USA) |
Equivalent Wire Size
(International)
|
Wires Per Output Terminal |
Maximum Current |
|---|---|---|---|
6 AWG |
10 mm2 |
1 |
85 Adc |
4 AWG |
25 mm2 |
1 |
110 Adc |
3 AWG |
25 mm2 |
1 |
130 Adc |
2 AWG |
35 mm2 |
1 |
150 Adc |
1 AWG |
50 mm2 |
1 |
170 Adc |
1/0 AWG |
50 mm2 |
1 |
200 Adc |
2/0 AWG |
70 mm2 |
1 |
235 Adc |
3/0 AWG |
95 mm2 |
1 |
275 Adc |
4/0 AWG |
120 mm2 |
1 |
315 Adc |
1/0 AWG |
50 mm2 |
2 |
400 Adc |
2/0 AWG |
70 mm2 |
2 |
470 Adc |
3/0 AWG |
95 mm2 |
2 |
550 Adc |
4/0 AWG |
120 mm2 |
2 |
630 Adc |
1/0 AWG |
50 mm2 |
4 |
800 Adc |
2/0 AWG |
70 mm2 |
4 |
940 Adc |
3/0 AWG |
95 mm2 |
4 |
1100 Adc |
4/0 AWG |
120 mm2 |
4 |
1260 Adc |
Notes:
Capacity for AWG wires derived from the National Electric Code. Maximum ambient temperature: 40°C. Maximum wire temperature: 90°C. Continuous duty with wires in free air, not bundled or in conduit.
Capacity of aluminum wire is approximately 84% of the capacity listed for copper wire.
For higher current levels, it’s recommended to use bus bars with holes for additional cable feeds or direct bus bar connection to the load.
Warning
FIRE HAZARD. Select a wire size large enough to carry the maximum planned operating current to prevent overheating of the wires. Make sure power cable connections are secured tightly in accordance with the torque recommendation to prevent overheating of the bus bars.
4.6. Remote Sense Connection¶
Remote sensing can improve regulation at a remote reference point. Voltage drop can occur across lead wires and across the diodes in the BDx Module. A MagnaDC power supply can be configured to operate with remote voltage sensing, using high impedance wires connected to the load, providing a remote voltage measurement for the power supply. By default, a MagnaDC power supply measures voltage at its output terminals, but when the remote sense setting is enabled, the feedback measurements are taken from the remote sense leads. Refer to the respective MagnaDC power supply manual for guidance on enabling this feature.
The BDx Module provides a single positive polarity voltage sensing location. The BDx Module is equipped with a 6-32 screw connection designated as remote sense, which provides a voltage sensing location at the DC output terminal. Magna-Power recommends using 20 AWG wires with the remote sense screw terminal. Do not bundle the sense wire-pair together with the load leads; keep the load wires and sense wires separate.
When using the remote sense connection on the BDx Module, the positive remote sense terminal from the MagnaDC power supply is connected to the single remote sense terminal on the BDx Module. The negative remote sense terminal from the power supply is then connected to the return point after the load.
Caution
Always ensure that the positive remote sense lead corresponds to the positive DC bus and, likewise, that the the negative remote sense lead corresponds to the negative DC bus. Connecting sense wires with an incorrect polarity can result in equipment damage.
Caution
WARNING. Switching remote sense leads or disconnecting remote sense leads while the output is enabled can cause a MagnaDC power supply failure. Only switch or disconnect remote sense leads while the power supply is in standby or turned off.
4.7. Protective Cover¶
The BDx Module includes a single protective cover for the DC input, DC output, and remote sense terminals. For oritentation and extra mechanical security, a small notch on the BDx Module’s top panel is designed to mate with the lip on cover. Additional, there are three mating screws, detailed further below.
Before attaching the cover, power and remote sense connections should first be made to the terminals.
Open the cover’s insulative feed-through by locating the larger of the two black fiberglass pieces. Loosen this black fiberglass piece by turning the screw on both sides of this piece one full turn counterclockwise.
With power and remote sense connections made, feed the other end of these cables through the inside of the protective cover. A small insulated circular cutout is located to the left of the black fiberglass piece, intended for the remote sense connection. The power cables should be fed between the larger black fiberglass pieces. Slide the cover back on the BDx Module and mate the cover to the notch on the BDx Module’s top panel. Align the screw holes and secure the cover using included mating hardware.
Finally, tighten the black fiberglass insulator on the cables and secure this insulator in place by tightening its screws.
Fig. 4.4 Included BDx Module protective cover¶
4.8. Electrical Check¶
This section describes the electrical checkout procedure for the BDx Module. This brief electrical checkout procedure validates the product’s power circuitry and safety features. This procedure should be followed upon receipt of the product and before it is placed into use.
Diode Verification
Ensure there is no voltage being applied at the BDx Module DC input terminal.
Using a handheld multimeter, set it to Diode Test mode, indicated by a diode symbol on the multimeter’s dial. Diode Test mode produces a small voltage between test leads. The multimeter then displays the voltage drop when the test leads are connected across a diode when forward-biased. Connect the test leads between the BDx Module DC Input and DC Output bus bars. The red (positive) test lead should be on the DC Input bus bar and the black (negative) test lead should be on the DC Output bus bar. This forward-bias test should display a voltage drop of 0.5 Vdc to 0.8 Vdc. Reverse the test leads and again record the measurement displayed. This reverse bias test should show overload (OL), indicating that the internal diodes are functioning properly.
If your handheld multimeter does not have a diode test mode, you can instead use the multimeter’s Resistance Mode. Set the multimeter to Resistance Mode, indicated by an ohm (Ω) symbol on the multimeter’s dial. Connect the test leads between the BDx Module DC Input and DC Output bus bars. The red (positive) test lead should be on the DC Input bus bar and the black (negative) test lead should be on the DC Output bus bar. This forward-bias test should display a resistance of 1000 Ω to 10 MΩ. Reverse the test leads and again record the measurement displayed. This reverse bias test should show greater than 10 kΩ, indicating that the internal diodes are functioning properly.
If the diode fails the forward- or reverse-bias tests, please contact Magna-Power support.
Cooling Verification
The BDx Module is side air intake, rear exhaust with rear mounted fans. Models BDx-A1-1000-300/UI and BDx-A1-150-600/UI cooling fans only on one side, while models BDx-A1-1000-600/UI and BDx-A1-150-1200/UI have cooling fans on both sides.
While the product has internal temperature monitoring and will shut the MagnaDC power supply down in the event of a temperature alarm, it’s important to periodically check that the fans are operating properly.
A simple test for airflow is to use a sheet of printer paper and, while holding it from the short edge, place it behind the unit and observe for displacement.