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Sixteen 10 kW Power Supplies Integrated with High-Power DC Output Plug Connectors

Magna-Power customized an integration of its 10 kW SL Series power supplies to include panel-mounted Hubbell DC connectors for easy connection to the customer's load.

Magna-Power designs and manufactures a wide range of rack enclosures, providing its customers with a turn-key solution for the company’s rack-mount MagnaDC power supplies or MagnaLOAD DC electronic loads. Beyond the standard rack and product mounting, Magna-Power has a wide range of standard accessories it offers to ease mechanical and electrical installation. In addition, with in-house sheet metal, powder coating and machining operations, on a case-by-case basis, Magna-Power can perform custom integration work.

Pre-testing of rack integration before adding panels and covers.
Pre-testing of rack integration before adding panels and covers.

A customer required very high-power density of many independently controlled 10 kW outputs in a precisely controlled multi-zone heating application. The 10 kW 1U SL Series was a natural fit for the requirement, meeting the exact voltage and current requirements for the customer in an industry-leading form factor. Magna-Power’s LXI TCP/IP Ethernet option provided addressable communications for each unit. While the products could fit in a smaller rack, Magna-Power larger 24U rack size provided the customer with space for additional testing and measurement equipment.

Sixteen 10 kW SL Series power supplies integrated into two standard 24U Magna-Power rack enclosures.
Sixteen 10 kW SL Series power supplies integrated into two standard 24U Magna-Power rack enclosures.

To support ease of connection and stringent safety requirement, the customer wanted connectorized outputs. Hubbell single pole panel mounted connectors have been a long-time favorite at Magna-Power, dating back to the company’s earliest internal facility power distribution boxes more than 40 years ago. A 150 Adc panel-mounted connector was selected. A custom access panel was designed by Magna-Power to incorporate 4 sets of connectors per panel. The custom panel was punched, surface finished, and powder coated at Magna-Power. The connectors are wired to the outputs of the SL Series power supplies using custom fabricated welding cable crimped with ¾-inch ring terminals from Magna-Power’s Sub-Assembly department.

Sixteen sets of panelized Hubbell DC power connectors integrated onto a Magna-Power fabricated custom access panel.
Sixteen sets of panelized Hubbell DC power connectors integrated onto a Magna-Power fabricated custom access panel.

Additional integration included a single set of copper AC input terminals for the utility connection, circuit breaker, and AC power distribution to all the SL Series power supplies inside the rack.

Magna-Power fabricated AC distribution bus bars mounted directly to the 3-phase circuit breaker for internal power distribution.
Magna-Power fabricated AC distribution bus bars mounted directly to the 3-phase circuit breaker for internal power distribution.
1.5" copper studs for customer connections to 3-phase facility power. Ground stud on mounting rail, not pictured.
1.5" copper studs for customer connections to 3-phase facility power. Ground stud on mounting rail, not pictured.

Originally published January 22, 2024

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