3. Installation

3.1. Inspection

Carefully unpack the MagnaLOAD and accessories saving all packing materials and included enclosures. Inspect the 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: www.magna-power.com/support.

The following parts are included with all MagnaLOAD models:

  • WRx Series MagnaLOAD
  • USB cable (Type A to Type B)
  • Rear metal cover with required fastening hardware
  • Qty (2) rear support brackets
  • Qty (16) 10-32 screws
  • Qty (8) 10-32 flat washers and lock washers
  • CD with software, drivers, and digital documentation
  • Calibration certificate with Declaration of Conformity
  • AC input cable

3.2. Rack Installation

The 15 kW WRx Series MagnaLOAD is intended for rack-mount installation, designed to fit in a standard 19” equipment rack. When installing into a rack, both front and rear support is required. Fixed rear rack-mount support brackets are provided for the the product’s rear. The unit should be horizontally mounted.

Caution

The WRx Series MagnaLOAD is too heavy for one person to safely lift and mount. To avoid injury, always seek assistance from a co-worker before trying to lift and install the product into a rack.

The following steps, which reference Figure 148, should be followed when installing the WRx Series MagnaLOAD into a rack:

  1. Install 8 clip nuts on the rack frame; 4 for front support and 4 for rear support.
  2. Install the rear rails onto the MagnaLOAD, but not the mating rear rail ears.
  3. While providing support for the MagnaLOAD, fasten the front ears to the rack using the provided 10-32 screws.
  4. While continuing to provide support for the MagnaLOAD, attach the mating rear rail ears onto the rear rails using SCREW TYPE HERE. Adjust the position of the rear rail ears to align snuggly with the rear rack rails before tightening.
  5. Fasten the rear ears to the rack using the provided 10-32 screws.

Figure 129: Rack mount installation diagram for the WRx Series

3.2.1. Cooling Requirements

3.3. AC Input Connection

A single-phase AC input connection is used to provide a ground reference and power for the MagnaLOAD‘s fans and control circuits. The AC input power requirements are defined for each MagnaLOAD on its product rating label. The AC input requirements are further defined in this section.

Connect the provided power cord to the IEC 60320 AC power receptacle on the rear of the MagnaLOAD. The type of connector used depends on the MagnaLOAD‘s AC input power. For low-power units, an IEC 60320 C13 receptable is used, as shown in Figure 149. For high-power units, an IEC 60320 C19 receptable is used, as shown in Figure 150.

Figure 130: WRx Series IEC 60320 C13 AC power receptacle

Figure 131: WRx Series IEC 60320 C19 AC power receptacle

Warning

The power cord provides a chassis ground through a third conductor. Be certain that your power outlet is of the three-conductor type with the correct pin connected to earth ground.

Note

The AC input voltage is fixed at time of order due to the cabinet fan requirement.

The following table provides the AC input requirements for the various WRx Series MagnaLOAD power levels:

WRx Series Rated Power Level AC Input Voltage Range AC Input Current Range (Maximum) AC Power Receptacle Style
15 kW 85 - 265 Vac 1.8 - 0.7 Aac IEC 60320 C13
30 kW 85 - 265 Vac 8.0 - 2.6 Aac IEC 60320 C13
60 kW 85 - 265 Vac 11.3 - 3.6 Aac IEC 60320 C13
90 kW 85 - 265 Vac 14.5 - 4.7 Aac IEC 60320 C19
120 kW 187 - 265 Vac 17.8 - 5.7 Aac IEC 60320 C19

Note

The AC Input Current Range specified in the table above is relative to the AC Input Voltage Range. For example, referring to the 15 kW WRx Series model, the AC input current will be 1.8 Aac at 85 Vac and 0.7 Aac at 265 Vac. Using a linear interpolation, at 120 Vac the AC input current would be 1.6 Aac.

3.4. DC Input Connection

Caution

Disconnect AC power from the mains before attempting any installation procedure.

The input of the WRx Series MagnaLOAD is connected to the DC bus by attaching two cables to the input bus bars, as shown in Figure 151. Magna-Power recommends 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 175 in-lbf (19.77 N-m).

A chassis ground reference is also provided on the rear near the DC bus bars, which is tied to the AC input ground. The recommended torque for the ground stud is 55 in-lbf (6.21 N-m).

After connections are made, screw the four standoffs into the back panel and place the protective shield over the connections.

Figure 132: DC input connection for the WRx Series

Caution

Make sure DC connections are tight to avoid overheating of the bus bars.

The following table provides the suggested DC ampacities of AWG (American Wire Guage) copper wire. Paralleled DC cables may be required for larger-ampacity |product_type|s. Ampacity ratings ar based on single conductor in 25 °C ambient free air, with a conductor rated for 60 °C.

Tip

For DC cabling, Magna-Power highly recommends flexible General Cable Carol® Brand Carolprene® cable, used by Magna-Power and many of its customers.

Wire Size (AWG) Wire Size (Metric, Rounded) Maximum Current (Adc)
12 4 mm2 30
10 6 mm2 40
8 10 mm2 60
6 16 mm2 86
4 26 mm2 110
3 30 mm2 130
2 35 mm2 150
1 40 mm2 170
1/0 50 mm2 200
2/0 70 mm2 235
3/0 95 mm2 275
4/0 120 mm2 315

For DC bus connections exceeding 315 Adc, Magna-Power recommends multiple runs of 4/0 cabling in parallel. Custom DC bus work may be required to either extend the MagnaLOAD‘s DC bus bars allowing additional DC wire connections, or to make a direct connection with the DC bus work. With increased cable bundling, the ampacity rating of the DC cables will decrease, as less surface area is in free air to cool the wires.

3.4.1. Remote Sense Connection

Remote sensing is used to improve the degradation of regulation which will occur at the MagnaLOAD inputs terminals when the DC voltage drop from the connected DC source to the MagnaLOAD is appreciable. Compensation is achieved by connected the MagnaLOAD‘s high impedance sense wires to the connected DC source’s input and configuring the MagnaLOAD for remote sensing either from the front panel configuration or by computer command. When enabled, the MagnaLOAD will voltage measurements will be taken from the remote location.

When remote sense is enabled and operating properly, []

Magna-Power recommends 20 AWG wires, with MagnaLOAD‘s positive remote sense terminal to the positive of the DC source and connect the MagnaLOAD‘s negative remote sense terminal to the negative of the DC source.

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.

The MagnaLOAD features Smart Sense Detection to protect the product in the event remote sense is enabled but the sense leads are broken or disconnected.

3.5. External User I/O Connection

The WRx Series MagnaLOAD has a 25-pin External User I/O port located in the product’s rear. The External User I/O connector is a standard female D-Sub 25-pin connector. The removable screw-locks provide means of securing mating connectors with commercially available 4-40 threaded hardware. The torque limit for the screw locks is 2 in-lb (0.23 N-m) applied from the mating face side. The maximum push out force is 20 lb-force (89 N) applied from the mating face side.

Figure 133: External User I/O D-Sub 25-pin connector and pin layout

3.6. Computer Connection

This section describes how to connect various communication interfaces to your MagnaLOAD. Beyond installation, more detailed information about the communication interfaces and programming instructions is described in: Operation: Computer Programming.

3.6.1. USB

3.6.2. RS485

The WRx Series MagnaLOAD supports RS485 communications through an RJ45 connector located on the rear communications panel, as shown in Figure 134. The signals A (Data +), B (Data -), and GND are wired to pins 1, 2, and 7 of the RS485 RJ45 connector, respectively. The remaining pins are electrically disconnected.

Figure 134: RS485 RJ45 connector and pin layout

Connection to a computer can be established using standard Ethernet cable, with one end connected to the MagnaLOAD and the other to a controlling device. The RS485 configuration parameters are as follows:

Parameter Value
Baud 115200
Data bits 8
Stop bits 1
Parity None
Flow Control XON/XOFF

Internally, RS485 operates on a shared communications bus with USB, LXI TCP/IP Ethernet, and IEEE-488 GPIB interfaces; only one interface can be active at a time. If none of these interfaces are connected, the MagnaLOAD defaults to RS485. The presently active communication interface is denoted in the front panel status menu display.

Note

Refer to the ANSI/TIA-568 telecommunications standard for the most common pin-to-pair assignments found on Ethernet cables: T568A and T568B.

3.6.3. LXI TCP/IP Ethernet

Figure 135: LXI TCP/IP Ethernet RJ45 connector and pin layout

3.6.4. IEEE-488 GPIB

Figure 136: IEEE-488 GPIB connector and pin layout

3.7. Electrical Check

Turn on the MagnaLOAD using the black control power switch on the bottom left of the front panel. Immediately after turn-on, the MagnaLOAD undergoes a self-test that check control and input circuitry. The Magna-Power emblem should be displayed during this self-test along with the the word MagnaLOAD.

Note

After turning the unit on, it will take about 5 seconds for the MagnaLOAD to initialize before it is ready for use.

When self-test is complete, the Menu display should show the unit’s Standby status, the voltage meter should show whatever the DC bus voltage is, and the current meter should show 0.000. The fans should be running at a low speed.

If the self test fails, the fans do not come on, or the unit fails to come into standby, power off the MagnaLOAD off and back on with the black power switch. If you continue to have similar issues, contact Magna-Power support for further assistance.

3.8. Firmware Update

Firmware update is achieved via the MagnaWEB software.