MagnaDC Logo

ML Series

Programmable DC Power Supply

The ML Series from Magna-Power Electronics has been engineered from the ground up to set a new standard in power density and performance. Leveraging advanced water-cooling technology, the 500 kW and 1,000 kW ML Series models achieves a nearly fourfold increase in power density compared to Magna-Power’s alternative air-cooled models. With the ability to connect in master-slave parallel configurations, the ML Series can reach power levels exceeding 10 MW. Built upon Magna-Power’s signature reliable current-fed power processing topology and innovative harmonic neutralization technology, the ML Series power supplies provide reliable and efficient power conversion with low harmonic distortion. Designed and manufactured in Flemington, New Jersey, the ML Series power supplies embody Magna-Power’s commitment to quality, reliability, and advanced engineering.


Key Features

  • Voltage and current control
  • 500 kW and 1,000 kW models; expandable to 10 MW
  • 12-bit precision control
  • Remote programming using SCPI commands
  • Programmable protection features
  • Safety interlock for external emergency stop
  • LabVIEW drivers
  • Continuous full power operation up to 50°C ambient
  • 37-pin analog-digital user I/O port
  • Integrated solenoid for condensation control
  • High-performance master-slaving
  • Local, remote, and leadless voltage sensing
  • RS232 standard and LAN TCP/IP Ethernet communications options available
  • RIS Panel software platform included
  • Made in the USA

Build-Time: 20-24 Weeks

CE Mark Logo UKCA Logo
Magna-Power Expert

Talk with an expert

Our applications engineers are here to help!

Current-Fed Topology: Robust Power Conversion

All MagnaDC programmable DC power supplies utilize high-frequency IGBT- and MOSFET-based power processing in a current-fed topology. This topology adds an additional stage over the conventional voltage-fed topology for enhanced control and system protection, ensuring that even under a fault condition, the power supply will self-protect. Due to the self-protecting characteristics of this topology, the possibility of fast rising current spikes and magnetic core saturation is eliminated. This topology coupled with state-of-the-art Silicon Carbide (SiC) power semiconductors enables the MagnaDC power supplies to deliver class-leading power density, reliability, and efficiency with continuous full-power operation up to 50°C ambient.

Read Technical Article

ML Series Current-Fed Topology Image

Water Cooled Design

With over 15 years of expertise in manufacturing water-cooled magnetics, heatsinks, and power supplies, Magna-Power has developed several key advancements for the ML Series to achieve its significant increase in power density. Each power electronics stage is mounted on a dedicated high-heat-transfer aluminum chill plate with press-fit copper tubes, ensuring manufacturability and serviceability. These stages slide into the rack enclosure on rails, secured and interconnected with a wire harness. Magnetic components are wound with chill plates around the transformer core, and a precisely tuned water distribution manifold ensures adequate flow to each stage. An integrated solenoid prevents water flow until internal temperatures reach a set value to minimize condensation, while a solenoid bypass connection is also provided.

The coolant path features brass fittings and solenoids, PEX tubing, and copper. Deionized water is not supported. Fans are incorporated to maintain airflow from bottom to top, preventing the buildup of hotspots and enhancing overall thermal management.

A 1" NPT Female Inlet and 1" NPT Female Outlet are provided on the Power Supply. An internal connection from the Power Supply to the Harmonic Neutralizer is made through a provided quick disconnect. Refer to the product specifications for additional coolant requirements.

ML Series Made in the USA Image

Made in the USA, Available Worldwide

MagnaDC programmable DC power supplies are designed and manufactured at Magna-Power’s 73,500 sq-ft vertically integrated USA manufacturing facility in Flemington, New Jersey. From raw materials to the completed product, Magna-Power has insourced nearly the entire production process to maintain complete control of quality, cost, and build-time. Heat-sinks and various metal assemblies are machined through both automated CNC and EDM. Sheet metal is cut, punched, sanded, bent, and powder coated in-house. Magnetics are wound-to-order from validated designs based on a model’s voltage and current. A full surface mount technology (SMT) with multiple stages of 3D automated optical inspection ensures high-quality printed circuit board assemblies. Finally, after assembly, products undergo comprehensive test and calibration, followed by an extended burn-in period.

Products are sold directly from the factory and through distribution, with a service network around the world.

Tour Our Manufacturing

Standard Safety Features

MagnaDC programmable DC power supplies feature a soft-start circuit to eliminate large peak in-rush currents from the AC mains, ensuring AC current draw never exceeds the current draw at full load. In addition, extensive safety and diagnostic functions are included, as follows:

  • AC Phase Loss
  • Over Voltage Trip (Programmable)
  • Over Current Trip (Programmable)
  • Cleared Fuse
  • Over Voltage on Program Line Input
  • Over Temperature on Internal Heatsinks
  • Safety Interlock / Emergency Stop Fault

When in standby or diagnostic fault, the AC mains are mechanically disconnected by an embedded AC contactor, providing confidence that the unit is only processing power when desired. Users can easily identify faults using the Status message display or by SCPI commands.

Finally, the interlock / emergency stop input is included as standard. This feature provides a 5V interlock input, which when coupled with the provided 5V reference signal, allows for a dry contact to easily trigger a latching interlock fault, while maintaining control power.

ML Series External User I/O Image

External User I/O for PLC Control or PHIL Simulation

Using the rear User 37-pin I/O connector, the MagnaDC power supplies can be completely controlled and monitored using external signals. The voltage, current, over voltage and over current set points are set by applying a 0-10V analog signal. Each diagnostic condition is given a designated pin, which reads +5V when high. Reference +5V and +10V signals are provided, eliminating the need for external voltage signals and allowing the use of dry contacts.

All these pins are isolated from the output terminals and referenced to earth-ground as standard—no additional isolation equipment or options necessary.

The following list summarizes the available I/O from the power supply:

  • 4 analog programming inputs
  • 2 analog measurement outputs
  • 5 digital inputs
  • 15 digital outputs
  • +2.5V, +5V and +10V reference signals

With the High Slew Rate Output (+HS) option equipped, high bandwidth operation is enabled along with fast rise times, allowing MagnaDC power supplies to address requirements for Hardware-in-the-Loop (HIL).


User I/O Pinout Definitions

High Performance Master-Slave Operation

All MagnaDC programmable DC power supplies come with master-slaving capability.

The MagnaDC master-slaving strategy helps to ensures no degradation in performance as units are added in parallel or series by providing gate drive signals directly from the master to the slave units. This strategy ensures one control loop for the system and eliminates the noise susceptibility commonly found when sending analog control references over long distances.

The Universal Interface Device 47 (UID47) accessory eases master-slave parallel or series configuration of Magna-Power DC power supplies, enabling near equal current or voltage sharing, depending on the configuration.

Master-slave series operation is supported to combined voltages up to the product's DC Output Isolation specification. No external blocking diodes are requires for series operation.

Magna-Power Software, NI LabVIEW Drivers, and IVI Drivers

All MagnaDC power supplies come standard with an IVI driver and an NI LabVIEW driver featuring a full set of VIs. Get started quickly with either driver using included example programs.

Magna-Power's included Remote Interface Software (pictured) provides an easy and intuitive method to operate a Magna-Power Electronics power supply with computer control. The software includes a virtual control panel, command panel to explore available commands, register panel to monitor the power supply status, calibration panel for recalibrating internal digital potentiometers, firmware panel for upgrading firmware, and a finally a modulation panel to emulate non-linear profiles.

All communication interfaces are supported across the various methods to program MagnaDC power supplies.

ML Series Software + Drivers Image

Front Panel - Standard

Front Panel - Standard

Front Panel - C Version

Front Panel - C Version
1
Power switch energizes control circuits without engaging main power
2
Engages and disengages main power via integrated mechanical contactor
4
Stepless rotary knob to set voltage-current
5
POWER: Indicates power outputSTANDBY: Indicates control power only
6
Configuration
REM SEN: Remote sense enabled
INT CTL: Front panel start/stop/clear enabled
EXT CTL: External start/stop/clear enabled
ROTARY: Front panel rotary knob input
EXT PGM: External analog voltage-current control
REMOTE: Computer control
7
Diagnostic Alarms
LOC: Interlock
PGL: External input voltage beyond limits
PHL: Under-voltage AC input
THL: Over-temperature condition
OVT: Over-voltage protection has tripped
OCT: Over-current protection has tripped
8
Function Keys
MENU: Selects function
ITEM: Selects item within function
V/I DIS: Displays voltage-current settings
TRIP DIS: Displays OVT and OCT setting
CLEAR: Clears settings or resets fault
ENTER: Select item
9
Memory location indicator, used for autosequencing applications
10
Digital input keypad

Model Ordering Guide

For both ordering and production, ML Series models are uniquely defined by several key characteristics, as defined by the following diagram:

ML Series Ordering Guide

ML Series Models

There are 38 different models in the ML Series spanning power levels: 500 kW and 1000 kW. To determine the appropriate model:

  1. Select the desired Max Voltage (Vdc) from the left-most column.
  2. Select the desired Max Current (Adc) from the same row that contains your desired Max Voltage.
  3. Construct your model number according to the model ordering guide.
  500 kW 1000 kW    
Max Voltage (Vdc) Max Current (Adc) Ripple (mVrms) Efficiency
100 5000 N/A 100 90%
125 4000 N/A 100 90%
160 3125 N/A 120 91%
200 2500 5000 125 91%
250 2000 4000 130 91%
300 1666 3333 160 91%
375 1333 2666 170 92%
400 1250 2500 180 93%
500 1000 2000 220 93%
600 833 1666 300 93%
800 625 1250 400 94%
1000 500 1000 500 94%
1250 400 800 500 94%
1600 312 625 600 94%
2000 250 500 800 94%
2500 200 400 900 94%
3000 166 333 1000 94%
4000 125 250 1100 94%
5000 100 200 1500 94%
6000 83 166 2000 94%

Specifications

The following specifications are subject to change without notice. Unless otherwise noted, all specifications measured at the product's maximum ratings.

AC Input Specifications
Specification Value
Input Voltages Available

AC Input voltage specified at time of order and cannot be modified
440 Vac, 3-phase
480 Vac, 3-phase
Input Voltage Tolerance
± 10%
Input Voltage Frequency
50-60 Hz
Power Factor

Measured at max power
> 0.96
Input Isolation

Measured line-to-ground
± 2000 Vdc
AC Circuit Protection
UL/CSA listed circuit breaker
DC Output Specifications
Specification Value
Voltage Ripple
Model specific. Refer to models table.
Line Regulation
Line regulation is a measure of a power supply's ability to maintain its output voltage (or current) given changes in the input line voltage. Line regulation is expressed as percent of change in the output voltage (or current) relative to the change in the input line voltage.
Voltage control: ± 0.04% of rated voltage
Current control: ± 0.03% of rated current
Load Regulation
Load regulation is a measure of the power supply's ability to maintain its output voltage (or current) given changes in the load, measured while operating at the maximum rated voltage (or current). Load regulation is expressed as the difference between voltage (or current) at full load minus voltage (or current) at min load, divided by the products max voltage (or current) rating.
Voltage control: ± 0.02% of rated voltage
Current control: ± 0.06% of rated current
Stability

FWHM, measured at 25ºC over 8 hrs after 30 min warm-up
± 0.10%
Temperature Coefficient
Voltage control: 0.04%/°C of rated voltage
Current control: 0.06%/ºC of rated current
Efficiency
Up to 94%. Model specific. Refer to Models table.
Slew Rate

Standard Models
< 170 ms, output voltage change from 0 to 63%
< 200 ms, output current change from 0 to 63%
Slew Rate

Models with High Slew Rate (+HS) Option
< 5 ms, output voltage change from 0 to 63%
< 10 ms, output current change from 0 to 63%
Output Isolation
Measured output-to-ground

Measured output-to-ground, models rated ≤ 1000 Vdc
± 1500 Vdc
Output Isolation

Measured output-to-ground, models rated > 1000 Vdc or models with High Isolation Output (+ISO) option
± 6000 Vdc
Programming Specifications
Specification Value
Resolution, Digital Programming

Front panel or communication interfaces
12-bit, 0.025% of rated voltage, current or power
Accuracy, Programming

Output value to set point value
Voltage: ± 0.075% of rated voltage
Current: ± 0.075% of rated current
Accuracy, Measurement

Output value to returned value
Voltage: ± 0.20% of rated voltage
Current: ± 0.20% of rated current
Trip Settings Range
Over Voltage: 10% to 110% of rated voltage
Over Current: 10% to 110% of rated current
Computer Command Protocol
Standard Commands for Programmable Instruments (SCPI) (ASCII-based commands)
Remote Sense Limits

Wired; Available on Models Rated ≤ 1000 Vdc
3% maximum voltage drop from output to load
Analog I/O

4 analog programming inputs, 2 analog measurement outputs, Reference signal provided
Analog programming inputs: 0-10 V
Analog programming impedance: 10 kΩ
Analog measurement outputs: 0-10V, 5 mA capacity
Analog measurement impedance: 100 Ω
Analog reference signal: 10 V, 5 mA capacity, 1 Ω
Digital I/O

5 digital control inputs, 15 digital monitoring outputs, Reference signal provided
Digital control inputs: 5 V
Digital control inputs impedance: 10 kΩ
Digital monitoring outputs: 5 V, 5 mA capacity
Digital reference signal: 5 V, 25 mA capacity
Interace Specifications
Specification Value
Front Panel Programming
Two machined aluminum 10-turn knobs and keypad
Communication Interfaces

Standard
RS232: D-sub DB-9, Female
Communication Interfaces

Optional
LXI TCP/IP Ethernet (+LXI): RJ-45
External User I/O Port

Standard
37-pin D-sub DB-7, female
Referenced to ground; isolated from the DC output
See User Manual for pin layout
Physical Specifications
Specification Value
Size & Weight

500 kW models
Ships as two components: 500 kW Power Supply
76.4” H x 48” W x 31.5” D (194.1 x 121.9 x 80.0 cm)
2500 lbs (1134 kg) 500 kW Harmonic Neutralizer
76.4” H x 24” W x 31.5” D (194.1 x 61.0 x 80.0 cm)
1500 lbs (680 kg)
Size & Weight

1000 kW Models
Ships as two components: 1000 kW Power Supply
76.4” H x 72” W x 31.5” D (194.1 x 182.9 x 80.0 cm)
3750 lbs (1701 kg) 1000 kW Harmonic Neutralizer
76.4” H x 48” W x 31.5” D (194.1 x 121.9 x 80.0 cm)
2850 lbs (1293 kg)
Environmental Specifications
Specification Value
Ambient Operating Temperature
0°C to 50°C
Storage Temperature
-40°C to +85°C
Humidity
Relative humidity up to 95% non-condensing
Air Flow

To ensure even heat distribution for water cooling system
Bottom air inlet, top exhaust
Water Coolant Supply

Requirement for supplied coolant
Maximum inlet temperature: 25ºC
Maximum inlet pressure: 80 psi
Inlet and outlet fittings provided: 1” Female NPT
Materials in coolant path: Copper pipe, PEX tubing, brass solenoid & fittings
Minimum Coolant Flow Rate

500 kW models
15 GPM
Minimum Coolant Flow Rate

1000 kW models
24 GPM
Regulatory Specifications
Specification Value
EMC
Complies with 2014/30/EU (EMC Directive)
CISPR 22 / EN 55022 Class A
Safety
Complies with EN61010-1 and 2014/35/EU (Low Voltage Directive)
CE Mark
Yes

Dimensional Diagrams

The following are vectorized diagrams for the ML Series. Refer to the Downloads section for downloadable drawings.

500 kW Power Supply
500 kW Harmonic Neutralizer
1000 kW Power Supply
1000 kW Harmonic Neutralizer
AC Input Bus
DC Output Bus

Options and Accessories

The following are options and accessories developed specifically for Magna-Power's ML Series

Accessories

External accessories and integration services are available for Magna-Power products

DC Power Cables

DC power cables with wide range voltage ratings, current ratings, and termination options, made-to-order by Magna-Power

UID47: Universal Interface Device 47

Master-slave interface device for load sharing. Includes interface device and (2) D-Sub 37-pin cables with a braided shield.

Additional Accessories

RS485 Converter

Industrial RS232 to Addressable RS485 Converter. Plugs into product's RS232 port.

UID46: Universal Interface Device 46

Master-slave interface device for load sharing. Includes interface device and (2) D-Sub 37 cables.

USB Edgeport Converter

Industrial Plug and Play USB to RS232 Converter. Adapter plugs into product's RS232 port.

Downloads

The following downloads are for the ML Series:

Documentation

ML Series Datasheet [20240710] [EN] [PDF]

Drawings

Drivers

Software

Photovoltaic Power Profiles Emulation [2.0.0.12] [ZIP] [License Required]