4. Installation¶
4.1. Inspection¶
Carefully unpack the DBx 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 DBx Module Add-On models:
DBx Module
DC input/output metal protective cover
DBx Module 15-pin male to 37-pin male 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
IEC 60320 C13 AC power cord
4.2. Rack Installation¶
The DBx Module is intended for rack mount installations only and is designed to fit in standard 19-inch EIA equipment racks. The DBx 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 DBx 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 DBx Module (inches). Click for a larger view.¶
4.2.1. Cooling Requirements¶
Each DBx 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 DBx 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 DBx 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 DBx Module to be stacked with zero clearance between units. Equipment racks housing the DBx Module should be equipped with either an open back, back with grills, or closed back with cabinet fans to remove heat generated by the DBx 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 DBx 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 DBx Module in a fully enclosed cabinet:
Note
The table above accounts for only a single DBx Module Add-On. 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 DBx Module includes a 15-pin D-Sub male to 37-pin D-Sub male interface cable to integrate the DBx Module with a MagnaDC programmable DC power supply.The interface cable connection is required to allow DBx Module can control the power supply, providing an interface from the DBx Module’s 15-pin DBx Module Interface connector to the power supply’s JS1 37-pin external user I/O connector.
Fig. 4.2 DBx Module Configuration A1 and B1 Interface Cable connection from DBx Module (top) to MagnaDC programmable DC power supply (bottom), along with user provided DC power cable connections.¶
The Interface Cable’s 15-pin connector is attached to the DBx 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 DBx Module Add-On fans and control circuits. The AC input power requirements are defined on the DBx Module product rating label. The AC input requirements are further defined in this section.
To provide AC power to the DBx Module, connect the provided power cord to the IEC 60320 C13 AC power receptacle, as shown in DBx Module IEC 60320 C13 AC power receptacle.
Fig. 4.3 DBx 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 DBx 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 DBx 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 DBx 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 external devices. The DBx Module 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, the DBx Module measures voltage at its DC output terminals, but when the remote sense setting is enabled, the feedback measurements are taken from the remote sense leads.
The DBx Module provides a positive polarity and negative polarity voltage sensing location. The DBx 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 DBx Module, the positive remote sense terminal is connected as close to the point of load as possible. 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.
Note
The maximum available DC output is determined by the power supply connected to the DC input of the DBx Module. Even with the DBx Module’s remote sense leads connected, the maximum ratings of the connected power supply cannot be exceeded. For DBx Module Configuration A1, an ~1.5 Vdc drop occurs between the DC input and DC output, which reduces the overall voltage available from the DC power supply.
4.7. Protective Cover¶
The DBx Module includes two protective covers: one for the DC input bus bars, and one DC output bus bars and remote sense terminals. For oritentation and extra mechanical security, a small notch on the DBx Module’s top panel is designed to mate with the lip on the covers. 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.
For both covers, 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 the remote sensing and DC power connections made, feed the other end of these cables through the inside of the protective cover. On the DC output cover, a small insulated circular cutout is located to the right 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 DBx Module and mate the cover to the notch on the DBx 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 DBx Module DC input cover¶
Fig. 4.5 Included DBx Module DC output and remote sense lead cover¶
4.8. Electrical Check¶
This section describes the electrical checkout procedure for the DBx 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.