3. Installation

3.1. Inspection

Carefully unpack the TS Series MagnaDC power supply 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 MagnaDC power supply models:

3.2. Rack Installation

The 3U, 4U, and 6U TS Series MagnaDC power supply is intended for rack mount installations only into standard 19-inch EIA equipment racks. The 8U, 12U, and 16U TS Series MagnaDC power supply comes on casters and is designed to be used either standalone or installed into standard 19-inch EIA equipment racks.

Additional support, other than that provided by the front panel, is required when installing the TS Series MagnaDC power supply into an equiopment rack. Fixed rear support rails are provided for all models, 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 TS Series side panels using included hardware. Alternatively, angle slides, shelves, or cross beam supports can be used to securely fasten the product to the rack and support the rear weight. The unit should be always be horizontally mounted.

When using Magna-Power’s provided fixed rear support rails, it’s recommend to install these rear rails into the rack first, at the location desired. Using a pallet jack or fork lift, lift the power supply into the rack and align the holes of the rear rails with the inserts on the rear of the power supply’s side panels. Once the holes are aligned, secure the rear support rails to the power supply side panel inserts using the provided 10-32 1/2” mating hardare, including screws, flat washer, and lock washers. Remove the casters of the 8U, 12U, and 16U models.

3.2.1. Cooling Requirements

Each TS Series MagnaDC power supply is cooled by suitable fans exhausting warm air to the rear of the cabinet. Depending on the power level, fresh air intake is either from the sides or from both the front and sides, allowing two or more TS Series supplies 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 TS Series MagnaDC power supply features integrated fans that pull in cool air from the front and/or sides and exhausts warm air from the rear. Equipment racks housing the TS Series MagnaDC power supply should be equipped with either an open back, back with grills, or closed back with cabinet fans to remove heat generated by the TS Series MagnaDC power supply. 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 TS Series MagnaDC power supply 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 TS Series MagnaDC power supply in a fully enclosed cabinet:

TS Series Model Power Level

Maximum Heat Produced

Recommended Cabinet Air Flow
77 °F (25 °C) Room Temperature
Recommended Cabinet Air Flow
104 °F (40 °C) Room Temperature

5 kW

1.7 kBTU/hr

40 CFM

100 CFM

10 kW

3.4 kBTU/hr

80 CFM

200 CFM

15 kW

5.1 kBTU/hr

120 CFM

290 CFM

20 kW

6.8 kBTU/hr

160 CFM

390 CFM

25 kW

8.5 kBTU/hr

200 CFM

490 CFM

30 kW

10.2 kBTU/hr

240 CFM

580 CFM

40 kW

13.6 kBTU/hr

310 CFM

775 CFM

50 kW

17.1 kBTU/hr

390 CFM

965 CFM

75 kW

25.5 kBTU/hr

590 CFM

1450 CFM

100 kW

34.2 kBTU/hr

780 CFM

1930 CFM

Note

The table above accounts for only a single power supply at each respective power level. 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.

3.3. AC Input Connection

Warning

Disconnect AC power from the mains and measure the AC input terminals to ground to ensure 0 Vac is present before attempting any installation procedure.

AC power is wired to the TS Series MagnaDC power supply by attaching three cables plus ground for 3-phase installations or two cables plus ground for 1-phase installations. The TS Series MagnaDC power supply is phase orientation insensitive, allowing the phases to be connected in any order; the ground connection, however, must be connected to ground stud labeled with a ground symbol.

Magna-Power recommends cables per the recommendations of the National Electrical Code or Suggested Ampacities of 4-Conductor Type S or SO Cable, with one end stripped of 0.5 in (12.7 mm) of insulation and securely crimped to a 1/4 in (6.3 mm) ring terminal in accordance with UL486A.

Remove the nut and mating lock washer from the TS Series MagnaDC power supply 1/4”-20 threaded AC input studs. Then place the ring terminal crimped to the AC input wire through the AC input stud, reattach and securely fasten the lock washer and mating nut. The recommended torque for the AC input connection is 4.2 lb-ft (5.7 Nm).

6U and 9U TS Series models have external cables that parallel the modules’ AC input studs to a single module’s AC input studs. Ensure that your external AC input wiring is made only to the AC input studs that have the mating nuts and lock washers. No additional connections are necessary for the module that has metal caps on its AC input studs. In addition, the two modules are grounded together internally; only one ground connection is required, which is on the same module where the external AC input wiring is made.

8U, 12U, and 16U TS Series models have only one exposed AC connection point for each phase. AC cabling should be routed through the provided grommet and connected to the studs behind the AC input cover.

Note

The cable recommendations provided are for reference purposes only. Always consult local electrical code requirements to ensure compliance.

After connections are made, the provided protective covers for the AC input and DC output can optionally be installed and securely fastened to the chassis using three screws per cover. This programmable DC power supply is designed to be permanently connected to the power source requiring a readily accessible disconnect device incorporated into the fixed wiring.

Table 3.1 Suggested Ampacities of Various Conductors as Recommended by the National Electrical Code

Wire Size

60 °C Types

75 °C Types

85 °C Types

90 °C Types

RUW, T, TW

FEPW, RH, RH, RUH, THW, THWN, XHHW, ZW

V, MI

TA, TBS, SA, AVB, SIS, FEP, FEPB, RHH, THHN, XHHW

14 AWG

25 Aac

30 Aac

30 Aac

35 Aac

12 AWG

30 Aac

35 Aac

40 Aac

40 Aac

10 AWG

40 Aac

50 Aac

55 Aac

55 Aac

8 AWG

60 Aac

70 Aac

75 Aac

80 Aac

6 AWG

80 Aac

95 Aac

100 Aac

105 Aac

4 AWG

105 Aac

125 Aac

135 Aac

140 Aac

3 AWG

120 Aac

145 Aac

160 Aac

165 Aac

2 AWG

140 Aac

170 Aac

185 Aac

190 Aac

1 AWG

165 Aac

195 Aac

215 Aac

220 Aac

10 AWG

195 Aac

230 Aac

250 Aac

260 Aac

20 AWG

225 Aac

265 Aac

290 Aac

300 Aac

30 AWG

260 Aac

310 Aac

335 Aac

350 Aac

40 AWG

300 Aac

360 Aac

390 Aac

405 Aac

250 MCM

340 Aac

405 Aac

440 Aac

455 Aac

300 MCM

375 Aac

445 Aac

485 Aac

505 Aac

350 MCM

420 Aac

505 Aac

550 Aac

570 Aac

Table 3.2 Suggested Ampacities of 4-Conductor Type S or SO Cable

Wire Size

Maximum Current

18 AWG

7 Aac

16 AWG

10 Aac

14 AWG

15 Aac

12 AWG

20 Aac

10 AWG

25 Aac

8 AWG

35 Aac

6 AWG

45 Aac

4 AWG

60 Aac

2 AWG

80 Aac

3.3.1. AC Input Current

The AC input current rating is specified on the product’s serial label, typically located on the top cover near the AC input terminals.

The following tables provides the per phase maximum input current rating for the available AC input voltages and power levels of the TS Series. All AC input currents factor in efficiency and power factor. With the product’s AC soft-start circuitry, there is no additional in-rush current; the numbers in the following table provides the peak AC current draw at full load. These same AC input current ratings are also specified on the product’s serial label.

Table 3.3 AC input current ratings for TS Series MagnaDC power supply

Power Level

AC Input Voltage

AC Input Current

5 kW

208/240 Vac, 1Φ

41 Aac

5 kW

208/240 Vac, 3Φ

18 Aac

5 kW

380/415 Vac, 3Φ

10 Aac

5 kW

440/480 Vac, 3Φ

9 Aac

10 kW

208/240 Vac, 3Φ

36 Aac

10 kW

380/415 Vac, 3Φ

20 Aac

10 kW

440/480 Vac, 3Φ

17 Aac

15 kW

208/240 Vac, 3Φ

52 Aac

15 kW

380/415 Vac, 3Φ

29 Aac

15 kW

440/480 Vac, 3Φ

25 Aac

20 kW

208/240 Vac, 3Φ

69 Aac

20 KW

380/415 Vac, 3Φ

38 Aac

20 KW

440/480 Vac, 3Φ

33 Aac

25 kW

208/240 Vac, 3Φ

85 Aac

25 kW

380/415 Vac, 3Φ

47 Aac

25 kW

440/480 Vac, 3Φ

40 Aac

30 kW

208/240 Vac, 3Φ

105 Aac

30 kW

380/415 Vac, 3Φ

57 Aac

30 kW

440/480 Vac, 3Φ

50 Aac

40 kW

380/415 Vac, 3Φ

76 Aac

40 kW

440/480 Vac, 3Φ

66 Aac

50 kW

380/415 Vac, 3Φ

94 Aac

50 kW

440/480 Vac, 3Φ

82 Aac

75 kW

380/415 Vac, 3Φ

141 Aac

75 kW

440/480 Vac, 3Φ

120 Aac

100 kW

380/415 Vac, 3Φ

188 Aac

100 kW

440/480 Vac, 3Φ

160 Aac

The following table provides the per phase maximum input current rating for the available AC input voltage and power levels for specific models of the TS Series that fall outside of the standard power levels in the table above.

Table 3.4 AC input current ratings for TS Series MagnaDC power supply the fall outside of standard power ranges

Model

AC Input Voltage

AC Input Current

TSD5-1800

208/240 Vac, 1Φ

36 Aac

TSD5-1800

380/415 Vac, 3Φ

20 Aac

TSD5-1800

440/480 Vac, 3Φ

17 Aac

TSD5-2700

208/240 Vac, 1Φ

52 Aac

TSD5-2700

380/415 Vac, 3Φ

29 Aac

TSD5-2700

440/480 Vac, 3Φ

25 Aac

TSD10-2700

208/240 Vac, 1Φ

108 Aac

TSD10-2700

380/415 Vac, 3Φ

60 Aac

TSD10-2700

440/480 Vac, 3Φ

24 Aac

TSD10-6000

380/415 Vac, 3Φ

114 Aac

TSD10-6000

440/480 Vac, 3Φ

99 Aac

TSD10-8000

380/415 Vac, 3Φ

152 Aac

TSD10-8000

440/480 Vac, 3Φ

132 Aac

3.3.2. Fuse Rating

MagnaDC power supplies contain a variety of power and control fuses. For TS Series MagnaDC power supply products with a 1-phase input, there are two (2) power fuses and two (2) control fuses. For TS Series products with a 3-phase input, there are three (3) power fuses per module and two (2) control fuses per module. Fuse ratings for TS Series MagnaDC power supply provides the fuses ratings and recommended replacements. Magna-Power recommends using a time-delay fuse.

In the event of a fuse fault, power must be removed from the supply and the fuse must be replaced to correct this condition. A cleared power fuse usually indicates a power stage failure, often requiring factory attention. In addition, a cleared fuse can be caused by power surges from lightning storms or other AC transient events.

Warning

To avoid personal injury or damage to the TS Series MagnaDC power supply, use only the specified replacement fuses.

Note

MT Series Products Only. For the power processing circuitry, MT Series programmable DC power supplies are equipped with a 3-phase AC breaker instead of fuses. In the event the breaker is tripped or if the breaker is not engaged after applying turning on control power via the front panel control power switch, the FSE alarm will indicate. After engaging the breaker to the on position and pressing the Clear button, the FSE alarm will no longer be present.

Table 3.5 Fuse ratings for TS Series MagnaDC power supply

Power Level

AC Input Voltage

Power Fuse Rating

Recommended
Power Fuse(s)

Control Fuse Rating

Recommended
Control Fuse

5 kW

208/240 Vac

Qty (3) at 20 Aac ea.

FNQ20

Qty (2) at 1 Aac ea.

FNQ1

5 kW

380/415 Vac

Qty (3) at 15 Aac ea.

FNQ15

Qty (2) at 1 Aac ea.

FNQ1

5 kW

440/480 Vac

Qty (3) at 15 Aac ea.

FNQ15

Qty (2) at 1 Aac ea.

FNQ1

10 kW

208/240 Vac

Qty (3) at 40 Aac ea.

SC40

Qty (2) at 1 Aac ea.

FNQ1

10 kW

380/415 Vac

Qty (3) at 25 Aac ea.

FNQ25

Qty (2) at 1 Aac ea.

FNQ1

10 kW

440/480 Vac

Qty (3) at 20 Aac ea.

FNQ20

Qty (2) at 1 Aac ea.

FNQ1

15 kW

208/240 Vac

Qty (3) at 60 Aac ea.

SC60

Qty (2) at 1 Aac ea.

FNQ1

15 kW

380/415 Vac

Qty (3) at 35 Aac ea.

ATM30/35

Qty (2) at 1 Aac ea.

FNQ1

15 kW

440/480 Vac

Qty (3) at 30 Aac ea.

FNQ30

Qty (2) at 1 Aac ea.

FNQ1

30 kW

208/240 Vac

Qty (6) at 60 Aac ea.

SC60

Qty (2) at 1 Aac ea.

FNQ1

30 kW

380/415 Vac

Qty (6) at 30 Aac ea.

ATM30/35

Qty (2) at 1 Aac ea.

FNQ1

30 kW

440/480 Vac

Qty (6) at 30 Aac ea.

FNQ30

Qty (2) at 1 Aac ea.

FNQ1

20 kW

380/415 Vac

Qty (3) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

20 kW

440/480 Vac

Qty (3) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

25 kW

380/415 Vac

Qty (3) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

25 kW

440/480 Vac

Qty (3) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

40 kW

380/415 Vac

Qty (6) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

40 kW

440/480 Vac

Qty (6) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

50 kW

380/415 Vac

Qty (6) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

50 kW

440/480 Vac

Qty (6) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

75 kW

380/415 Vac

Qty (9) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

75 kW

440/480 Vac

Qty (9) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

100 kW

380/415 Vac

Qty (12) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

100 kW

440/480 Vac

Qty (12) at 50 Aac ea.

ATM30/50

Qty (2) at 1 Aac ea.

FNQ1

3.4. DC Output Connection

Warning

SHOCK HAZARD. Turn off AC power before making any rear panel connections. Ensure that MagnaDC power supply connections, load wiring, and load connections are either insulated or covered so that no accidental contact with lethal output voltages can occur.

The DC output of the TS Series MagnaDC power supply connects to the DC bus by attaching two cables to the output bus bars. 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 bus bars contain 3/8”-16 threaded inserts. 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.

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:

  1. 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.

  2. Capacity of aluminum wire is approximately 84% of the capacity listed for copper wire.

  3. 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 TS Series MagnaDC power supply model’s maximum rated 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.

3.4.1. Grounding the DC Output

The output of the TS Series MagnaDC power supply is floating up to the DC output isolation specifications. A floating output means the output terminals are not connected electrically to ground and the produced output voltage is from the positive terminal with respect to the negative terminal. Neither output terminal needs to be connected to ground, however if desired, either the positive or negative terminal can be connected to earth ground.

3.5. Remote Sense Connection

_images/connector-remotesense.svg

Fig. 3.1 Remote sense connector

Note

Wired remote sense is only available for models rated ≤ 1000 Vdc and without the High Isolation Output (+ISO) option.

Remote sensing can improve regulation at a remote reference point. Appreciable voltage drop can occur in the wire between the power supply and load as the current increases. By default, the load operates in local sense, where feedback is internally connected at the power supply’s outputs terminals. However, the power supply can also operate in remote sense, and compensate for wire voltage drop by connecting its high-impedance sense wires to the load terminals. When the remote sense setting is enabled the feedback measurements are taken from the remote sense leads.

_images/remote-sensing.svg

Fig. 3.2 Local Sensing (a) and Remote Sensing (b) schematic representation

The remote sense setting is accessible from either the front panel configuration or by computer command. Magna-Power recommends using 20 AWG wires with the remote sense screw terminals. Connect the MagnaDC power supply’s positive remote sense lead to the positive of the DC source terminals. Connect the MagnaDC power supply’s negative remote sense lead to the negative terminal of the DC source. Both remote sense terminals are 6-32 screw connections. Connect the sense leads as close to the load as possible. Do not bundle the sense wire-pair together with the load leads; keep the load wires and sense wires separate.

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.

Enabling remote sense activates the remote sense lead detector. The remote sense lead detector checks that the remote sense leads have been connected to the load. With the power supply configured for remote sensing and upon enabling power output, the sense location is initially set to local. The sense location is switched to remote upon reaching 7.5% of full scale output voltage. Once the power supply is sensing the voltage remote, as long as the voltage detected is greater than 4.5% of full scale output voltage, the sense location remains remote; if the output voltage detected is less than 4.5%, then the sense location will automatically revert back to local.

Caution

WARNING. Switching remote sense leads or disconnecting remote sense leads while the output is enabled can cause device failure. Only switch or disconnect remote sense leads while the power supply is in standby or turned off.

The remote sense indicator on the front panel will flash when the remote sense functionality has been enabled, but the power supply is remaining in local sense. The power supply will remain in local sense with the REM SEN light flashing if the output voltage never exceeds 7.5% of full scale output voltage or the remote sense lead detector has determined sense leads are not connected. The remote sense indicator will remain flashing until the remote sense detector has detected the presence of remote sense voltage within the limits described above.

3.6. Electrical Check

This section describes the electrical checkout procedure for the TS Series MagnaDC power supply. 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.

The electrical check for models with the C Version front panel require use of the Remote Interface Software described in Chapter 4, Remote Interface Software. With the software installed and the power supply connected to the desired communications interface, select the appropriate equivalent front panel in the Configuration Setup Panel. Select the Virtual Control Panel in the View Menu to display the virtual SL Version front panel. Follow the procedure below using the Virtual Control Panel from within the Remote Interface Software.

With the power supply off, disconnect the load, set voltage and current potentiometer controls fully counterclockwise, and set the over voltage trip and over current trip settings to maximum, fully clockwise. Connect the power supply to a suitable source of AC voltage. For this test, only 50% of rated AC current is required. Turn the power switch on and observe the indicator lights going through the startup routine. After initialization, the following indicator lights should be on: STANDBY, INT CTL, EXT CTL, and ROTARY. This is the default configuration from the factory.

Maximum Voltage, Open-Circuit

Press the start switch and advance the current control one turn clockwise. The power and voltage control indicators should light. Increase the voltage set point to maximum and then to minimum. DC voltage should increase smoothly from minimum to maximum to minimum as indicated on the meter. Return the voltage control full counterclockwise. Press the stop switch.

Over Voltage Trip, Open-Circuit

To check over voltage trip, press the menu key. This places the power supply in data entry mode to set over voltage trip. Using the up/down arrow keys, enter an over voltage trip set point at half the rating of the power supply. Once the over voltage trip set point has been entered, press the enter key to save the information.

Press the start switch and slowly increase the voltage set point. Over voltage trip should operate at the over voltage trip set point. The over voltage trip (OVT) indicator should turn on, the power and voltage control indicators should turn off, and the supply should shut down. Press the clear key. Now set the over voltage trip set point to maximum which is 110% the full scale rating of the power supply. Again start the supply and observe that the power supply operates normally. With the main power disconnected, connect a short to the power output terminals on the rear panel. Reconnect the main power, set voltage and current controls full counterclockwise, and turn the power switch on.

Maximum Current, Short-Circuit

With the main power disconnected, connect a short across the output terminals of the power supply. Reconnect the main power, set voltage and current controls full counterclockwise and turn the power switch on.

Press the start switch and advance the voltage control one turn clockwise. Increase the current set point to maximum and then to minimum. The power and current control indicators should light. DC current should increase smoothly from minimum to maximum to minimum as indicated on the meter. Return the current control full counterclockwise. Press the stop switch.

Over Current Trip, Short-Circuit

To check over current trip, press the menu key and then the item key one time. This places the power supply in data entry mode to set over current trip. Using the up/down arrow keys, enter an over current trip set point at half the rating of the power supply. Once the over current trip set point has been entered, press the enter key to save the information.

Press the start switch and slowly increase the current set point. Over current trip should operate at the over current trip set point. The over current trip (OCT) indicator should turn on, the power and current control indicators should turn off, and the supply should shut down. Press the clear key. Now set the over current trip set point to maximum which is 110% the full scale rating of the power supply. Again start the supply and observe that the power supply operates normally.

If any of these events do not occur, the supply is defective and should not be operated. Depending on the circumstances, either warranty service or troubleshooting is required.