Next-Generation Rack-Mount DC Power Supplies: High Power Density & Precision Control

The Physics of Current-Fed Power Conversion

Traditional switch-mode DC power supplies utilize voltage-fed topologies with large electrolytic capacitor banks directly across the DC output. While inexpensive to manufacture, high output capacitance creates severe engineering liabilities: sluggish dynamic dynamic performance, massive peak energy discharge during unexpected load short-circuits, and shortened operational lifespan due to thermal degradation of filter capacitors.

Magna-Power’s MagnaDC rack-mount DC power supplies utilize a proprietary micro-computer controlled current-fed power processing topology. By integrating a high-frequency input inductor before the primary inverter bridge, energy is stored in magnetic fields rather than electric fields. This foundational difference provides three distinct operational advantages for global procurement teams and test systems engineers:

• Inherent Short-Circuit Immunity: Because the input inductor limits the rate of current rise ($di/dt$), the power supply tolerates sustained output short circuits, high-voltage plasma arcing, and inductive kickback without semiconductor failure.
• Ultra-Low Stored Output Energy: Output capacitance is reduced by up to 80% compared to equivalent voltage-fed units. In wide-bandgap (SiC/GaN) double pulse testing, low output capacitance minimizes parasitic energy transfer, preventing device-under-test (DUT) destruction during breakdown analysis.
• Wide Constant Power Operating Envelope: Rather than limiting maximum power to a single nominal voltage/current point, Magna-Power current-fed units deliver full rated kilowatt power across a wide dynamic output profile.

Vertically Integrated Manufacturing in Flemington, New Jersey

Global buyers in aerospace, automotive, defense, and semiconductor manufacturing face continuous supply chain disruptions when relying on fragmented OEM power supply integrators. Magna-Power solves lead-time volatility through deep vertical integration at its 160,000+ sq. ft. headquarters in Flemington, New Jersey, USA.

Unlike competitors who assemble outsourced offshore sub-assemblies, Magna-Power maintains total design and process control under one roof:

• Precision Metal Fabrication: Computer-controlled laser cutting, punch presses, and CNC bending produce robust powder-coated steel chassis optimized for standard 19-inch EIA racks.
• Custom Magnetics Winding: High-frequency planar transformers, inductors, and current transducers are wound, potted, and tested in-house for optimal thermal dissipation.
• Automated SMT PCB Assembly: High-speed surface-mount lines populate micro-controller logic, digital signal processing (DSP), and gate-driver boards with 100% automated optical inspection (AOI).
• 100% Full-Power Burn-In: Every rack-mount DC power supply undergoes rigorous burn-in under maximum thermal and electrical load conditions before shipment, backed by traceable ISO-compliant calibration data.

SLx Series — 1U Ultra-High Density Rack-Mount (1.5 kW – 10 kW)

The SLx Series represents the peak of power density engineering, packing up to 10 kW of programmable DC power into a ultra-compact 1U (1.75-inch) 19-inch rack-mount profile. Designed for automated test racks, laboratory benchtop research, and high-density semiconductor test stations, the SLx delivers high efficiency without sacrificing thermals.

• Power Envelope: 1.5 kW, 3 kW, 6 kW, and 10 kW models
• Voltage Ranges: 0-5 Vdc up to 0-1000 Vdc
• Current Ranges: 0-1.5 Adc up to 0-250 Adc
• Automation: Standard SCPI command set over Ethernet/LXI, USB, and RS-232

SL Series — 1U Compact Rack-Mount DC Power (1.5 kW – 10 kW)

Proven in tens of thousands of installations globally, the SL Series offers high reliability in a 1U package. Featuring intuitive front panel digital encoders, dual LCD displays, and extensive remote analog programming capabilities, the SL Series is ideal for industrial production lines and aerospace test systems.

• Power Envelope: 1.5 kW, 3 kW, 6 kW, and 10 kW ratings
• Cooling Architecture: Front-to-back forced air cooling with variable speed fans
• Control Modes: Constant Voltage (CV), Constant Current (CC) automatic crossover
• Isolation: Isolated 37-pin analog I/O interface standard

XR Series — 2U Ruggedized Rack-Mount DC Power (2 kW – 10 kW)

When additional thermal headroom, high output voltage isolation, or enhanced internal heatsinking is required, the 2U XR Series delivers. The extra vertical space accommodates larger magnetic components and generous component derating margins, making it the preferred choice for continuous 24/7 industrial manufacturing facilities.

• Power Ratings: 2 kW, 4 kW, 6 kW, 8 kW, and 10 kW
• Output Options: High speed output option (+HS), blocking diodes (+BD)
• Voltage Profile: Models from 0-5 Vdc to 0-1000 Vdc
• Ruggedization: Conformal coating and heavy-duty chassis bracing

TS Series — 3U to 16U High-Power Rack-Mount (5 kW – 100 kW)

The TS Series brings megawatt-grade power processing down into standard 19-inch rack profiles spanning 3U to 16U. Delivering up to 100 kW per single unit chassis and master/slave paralleling capabilities up to 1 MW+, the TS Series powers heavy industrial applications including electric vehicle traction motor testing, particle accelerator magnets, and industrial electrolysis.

• Power Range: 5 kW, 10 kW, 15 kW, 20 kW, 25 kW up to 100 kW
• Form Factors: 3U, 4U, 6U, 8U, 10U, 14U, and 16U chassis
• Current Ratings: Up to 4,000 Adc continuous output
• Cooling: Heavy-duty internal heatsinks with multi-fan forced air flow