Industrial Water-Cooled DC Power Supplies: 500 kW to 10 MW+

1. Thermal Management & Heat Transfer Coefficients

The volumetric thermal capacity of water is approximately 3,500 times higher than that of ambient air ($C_v \approx 4.184 \text{ J/cm}^3\text{K}$ versus $0.0012 \text{ J/cm}^3\text{K}$). In high-power DC test installations operating continuously above 500 kW, air-cooled rectifiers require massive airflow volumes (tens of thousands of CFM), which in turn demand substantial facility HVAC investments, noisy ductwork, and constant cleanroom filter maintenance. Liquid-cooled DC power supplies utilize micro-channel copper or aluminum cold plates mounted directly beneath high-power IGBT switches, high-frequency planar transformers, and output rectifiers.

By conducting semiconductor switching losses directly into a closed liquid loop (water-glycol mixture or deionized water), Magna-Power’s ML Series Water-Cooled DC Power Supplies extract heat at the source. This preserves internal component junction temperatures ($\Delta T_{j-c}$) well below thermal derating thresholds, ensuring consistent MTBF operating lifecycles exceeding 100,000 continuous hours.

2. Current-Fed Inverter Topology Meets Liquid Cold-Plate Cooling

Traditional voltage-fed power supplies store bulk energy in massive electrolytic capacitor banks across the high-voltage DC link. In the event of a output short circuit or semiconductor pass-through fault, these capacitors discharge instantly with destructive energy levels, posing severe hazards in high-power test environments. Magna-Power’s proprietary current-fed power processing topology places a high-frequency inductor at the primary energy storage stage.

This inductive energy bus naturally restricts fault currents ($\text{d}i/\text{d}t$), rendering the power supply inherently short-circuit tolerant and arc-resistant. When combined with water cooling, the primary power magnetics—typically the hottest components in traditional power units—are directly liquid-jacketed. This eliminates thermal hot spots, drastically reduces physical enclosure dimensions (up to 70% floor space savings compared to air-cooled equivalents), and operates with virtually zero external acoustic noise generation.

MagnaDC ML Series — Water-Cooled DC Power Supplies (500 kW to 10 MW+)

The ML Series integrates heavy-duty internal liquid manifolds, integrated flow rate switches, over-temperature interlocks, and leak protection sensors inside a rugged floor-standing industrial cabinet. Featuring master/slave digital control capability, multiple ML Series cabinets can be paralleled seamlessly to construct megawatt-scale power systems.

Integrated Test Infrastructure — MagnaLOAD & MagnaCTRL Software

Pair liquid-cooled MagnaDC power supplies with MagnaLOAD linear MOSFET electronic loads for complete bidirectional power loop testing. Managed by MagnaCTRL software and the PPPE Solar Emulation Suite, engineers can execute dynamic load sweeps, battery charge/discharge profiles, and grid-tied solar inverter validation under real-time DSP control.