ULTRA Plus Series Power Supply Module Installation Manual · 2011. 1. 12. · ULTRA Plus PSM-125C Connections Provides I/O, power, and shunt connector locations and signal descriptions

1398 ULTRA Plus Series Power Supply Module(Catalog Number 1398-PSM-125C)

Installation Manual

Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley® does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

Allen-Bradley is a registered trademark of Rockwell Automation. ULTRA Plus, Ultra3000, and Ultra5000 are trademarks of Rockwell Automation. UL and C-UL are registered trademarks of Underwriters Laboratories, Inc.

ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Table of Contents

PrefaceIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2Related Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3Product Receiving and Storage Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Local Product Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4Technical Product Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4Comments Regarding this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Chapter 1 Mounting the ULTRA Plus PSM-125CChapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Before Mounting Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Storing Your ULTRA PSM-125C Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Unpacking Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Sizing an Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Transformer Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Fuse Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Bonding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Bonding Multiple Subpanels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Mounting Your ULTRA PSM-125C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Chapter 2 ULTRA Plus PSM-125C ConnectionsChapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Understanding PSM-125C Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

PSM to Controller Interface Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5DC Bus Power Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Shunt Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

ii

Publication 1398-IN125B-EN-P — February 2010

Chapter 3 Wiring Your ULTRA Plus PSM-125CChapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Understanding Basic Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Routing High and Low Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Grounding Your ULTRA Plus PSM-125C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Grounding Your System to the Subpanel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Wiring Your ULTRA Plus PSM-125C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5DC Bus Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Dissipative Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6PSM Logic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Chapter 4 Applying Power for the First TimeStart-up Procedure for ULTRA Plus PSM-125C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Chapter 5 Maintaining and Troubleshooting Your ULTRA Plus PSM-125CChapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Diagnostic Light Emitting Diodes (LED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Maintaining Your PSM-125C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Replacing the PSM Shunt Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Appendix A SpecificationsChapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1General Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1Physical and Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2Connector and Wire Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Appendix B Interconnect DiagramsChapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Appendix C Catalog Numbers and AccessoriesChapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1ULTRA Plus PSM-125C Power Supply Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Index

1 Publication 1398-IN125B-EN-P — February 2010

Preface

Introduction Read this preface to familiarize yourself with the rest of the manual. This preface contains the following topics:

• Who Should Use this Manual

• Purpose of this Manual

• Contents of this Manual

• Related Documentation

• Conventions Used in this Manual

• Product Receiving and Storage Responsibility

• Allen-Bradley Support

Who Should Use this Manual

Use this manual for designing, installing, and wiring your ULTRA Plus™ Power Supply Module-125C (PSM-125C). The manual is intended for engineers or technicians directly involved in the installation and wiring of the PSM-125C.

If you do not have a basic understanding of the ULTRA Plus PSM-125C, contact your local Allen-Bradley representative for information on available training courses before using this product.

Purpose of this Manual This manual provides the mounting, wiring, and connecting procedures for the ULTRA Plus PSM-125C when used in conjunction with Rockwell Automation/Allen-Bradley drives and motors.


P-2 Preface

Contents of this Manual Refer to the following listing for the descriptive contents of this installation manual.

Related Documentation The following documents contain additional information concerning related Allen-Bradley products. To obtain a copy, contact your local Rockwell Automation office or distributor, or access the documents on-line at www.theautomationbookstore.com or www.ab.com/manuals/gmc.

Chapter Title Contents

Preface Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended.

1 Mounting the ULTRA Plus PSM-125C Provides mounting information for the ULTRA Plus PSM-125C.

2 ULTRA Plus PSM-125C ConnectionsProvides I/O, power, and shunt connector locations and signal descriptions.

3 Wiring Your ULTRA Plus PSM-125C Provides connection and wiring information for the ULTRA Plus PSM-125C.

Appendix A Specifications Provides physical, electrical, environmental, and functional specifications for the ULTRA Plus PSM-125C. Dimensional, chassis wiring, and power wiring drawings are also provided.

Appendix B Interconnect Diagrams Provides interconnect diagrams for the ULTRA Plus PSM-125C.

Appendix C Catalog Numbers and Accessories Provides catalog numbers and descriptions of the ULTRA Plus PSM-125C and related products.

For: Read This Document: Catalog Number:

Information on mounting, wiring, configuring and troubleshooting ULTRA Plus products

ULTRA Plus Positioning Drive Modules Installation Manual

1398-5.1

Information on Rockwell Automation/Allen-Bradley Motion Control products and accessories

Motion Control Selection Guide GMC-SG001x-EN-P

Active shunt installation instructions for: • 1394-SR9A

• 1394-SR9AF

• 1394-SR36A

• 1394-SR36AF (fan-cooled module)

1394 Shunt Module Packing Data

1394-SRxAx

Information on mounting, wiring, configuring and troubleshooting your Ultra5000™

Ultra5000 Digital Servo Drives Installation Manual

2098-IN001x-EN-P

Information on mounting and wiring your Ultra3000™

Ultra3000 Digital Servo Drives Installation Manual

2098-IN003x-EN-P

Information on configuring and troubleshooting your Ultra3000

Ultra3000 Digital Servo Drives Integration Manual 2098-IN005x-EN-P

How to minimize and control system-level noise

System Design for Control of Electrical Noise GMC-RM001x-xx-x


Preface P-3

Conventions Used in this Manual

The following conventions are used throughout this manual.

• Bulleted lists such as this one provide information, not procedural steps

• Numbered lists provide sequential steps or hierarchical information

• Words that you type or select appear in bold

• When we refer you to another location, the section or chapter name appears in italics

Product Receiving and Storage Responsibility

You, the customer, are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company. Check the item(s) you receive against your purchase order. If any items are obviously damaged, it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill. Should you discover any concealed damage during unpacking, you are responsible for notifying the freight agent. Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment.

Store the product in its shipping container prior to installation. If you are not going to use the equipment for a period of time, store using the following guidelines.

• Use a clean, dry location

• Maintain an ambient temperature range of -40 to 70° C (-40 to 158° F)

• Maintain a relative humidity range of 5% to 95%, non-condensing

• Store it where it cannot be exposed to a corrosive atmosphere

• Store it in a non-construction area


P-4 Preface

Allen-Bradley Support Allen-Bradley offers support services worldwide, with over 75 Sales/Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world.

Local Product Support

Contact your local Allen-Bradley representative for:

• Sales and order support

• Product technical training

• Warranty support

• Support service agreements

Technical Product Assistance

If you need technical assistance, please review the information in Maintaining and Troubleshooting Your ULTRA Plus PSM-125C on page 5-1 first, then contact your local Allen-Bradley representative or Rockwell Automation Technical Support at the phone number or email address listed on the back cover. Please have the catalog numbers of your products available for reference.

Comments Regarding this Manual

To offer comments regarding the contents of this manual, go to www.ab.com/manuals/gmc and download the Motion Control Problem Report form. Mail or fax your comments to the address/fax number given on the form.


Chapter 1

Mounting the ULTRA Plus PSM-125C

Chapter Objectives This chapter provides a brief product introduction, system installation guidelines, and procedures for mechanical installation of your ULTRA Plus PSM-125C. This chapter covers the following topics:

• Product Overview

• Required Tools

• Before Mounting Your System

• Bonding Your System

• Mounting Your ULTRA PSM-125C

Product Overview The ULTRA Plus PSM-125C is a power supply module that may be shared among multiple servo drives and compatible motors to achieve a powerful and economical system package.

The PSM-125C output current rating is 100 A. It requires 100-240V AC, three phase 2 input power, which may be optionally isolated through a transformer. The output is a two wire DC bus.

The PSM-125C requires no adjustments, protects itself, provides troubleshooting diagnostics, and has a built-in solid state soft charge of the DC bus capacitors. It also includes connections for a dissipative shunt regulator that provides quick discharge of the DC bus capacitors and assists absorption of rotational energy.

ATTENTION The following information is a guideline for proper installation. The National Electrical Code and any other governing regional or local codes overrule this information. The Allen-Bradley Company cannot assume responsibility for the compliance or the noncompliance with any code, national, local or otherwise, for the proper installation of this system or associated equipment. If you ignore codes during installation, hazard of personal injury and/or equipment damage exists.


1-2 Mounting the ULTRA Plus PSM-125C

Required Tools Standard mechanical and electrical tools (nutdrivers, screwdrivers, needlenose plier, wire cutter/stripper, etc.) are required to mount and wire a system using the ULTRA Plus PSM-125C.

Before Mounting Your System

Before you mount your ULTRA PSM-125C system make sure you understand the following:

• How to store your ULTRA PSM-125C before installation

• How to unpack the system

• The minimum mounting requirements

• How to size the system and auxiliary components

Storing Your ULTRA PSM-125C Before Installation

The ULTRA PSM-125C should remain in the shipping container prior to installation. If the equipment is not to be used for a period of time, store it as follows:

• Use a clean, dry location

• Maintain an ambient temperature range of -40° to 70° C (-40° to 158° F)

• Maintain a relative humidity range of 5% to 95%, non-condensing

• Store it where it cannot be exposed to a corrosive atmosphere

• Store it in a non-construction area

Unpacking Modules

Each ULTRA PSM-125C ships with one installation manual (publication 1398-IN125B-EN-P — February 2010)

ATTENTIONComplete all drilling, cutting, welding, etc., before mounting the equipment. During installation, protect equipment from metal chips, weld splatters and other debris. Failure to observe this precaution could result in damage to or the destruction of the equipment.


Mounting the ULTRA Plus PSM-125C 1-3

Remove all packing material, wedges, and braces from within and around the components. After unpacking, check the catalog number on the nameplate of each item against the purchase order.

System Mounting Requirements

There are several things that you need to take into account when preparing to mount the ULTRA Plus PSM-125C:

• The PSM-125C must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP55 such that they are not accessible to an operator or unskilled person, in order to comply with UL®. A NEMA 4X enclosure exceeds these requirements providing protection to IP66.

• To minimize DC bus inductance locate the PSM-125C within your system as follows:

− Center the PSM-125C between the controlling drives. − Mount the highest power drives closest to the PSM-125C, and

consequently lowest power drives farthest from the PSM-125C. • The ambient temperature of the location in which you will install the

PSM-125C must not exceed 55° C (131° F).

• You must install the panel on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors.

• You need to maintain minimum clearances (refer to Figure 1.1 and Figure B.1) for proper airflow, easy module access, and proper cable bend radius.

Refer to Appendix A and Appendix B for power dissipation, environmental specifications, and mounting dimensions for the ULTRA PSM-125C.



Ventilation Requirements

This section provides information to assist you in sizing your cabinet and locating your PSM-125C(s) inside the cabinet. Maximum power loss for a PSM-125C is 240 Watts.

Refer to Appendix A for ULTRA Plus PSM-125C power dissipation specifications.

Figure 1.1Minimum Clearance Requirements

Do Not Remove Cover With Power Applied.Do Not Remove Cover With Power Applied.

Removing Power.Removing Power.Dangerous Voltages May Exist Up To 5 Minutes AfterDangerous Voltages May Exist Up To 5 Minutes After

Do Not Apply Power With Cover Removed.Do Not Apply Power With Cover Removed.WARNING:WARNING:

TB1TB1

PSM ReadyPSM ReadyDisabledDisabledOver TempOver TempPhase LossPhase Loss

Ultra Plus SeriesUltra Plus Series

Allen-BradleyAllen-Bradley



Do Not Apply Power With Cover Removed.Do Not Apply Power With Cover Removed.

WARNING:WARNING:

TB1TB1




102 mm (4.0 in.) clearancefor airflow and installation

102 mm (4.0 in.) clearancefor airflow and installation

Allow 12.7 mm (0.5 in.) side clearance

Allow 12.7 mm (0.5 in.) side clearance

Minimum cabinet depth = 280 mm (11.0 in.)Minimum front clearance = 33.6 mm (1.3 in.)

IMPORTANT If the cabinet is ventilated, use filtered or conditioned air to prevent the accumulation of dust and dirt on electronic components. The air should be free of oil, corrosives, or electrically conductive contaminates.



Sizing an Enclosure

As an additional aid in sizing an enclosure, with no active method of heat dissipation, either of the following approximate equations can be used:

Transformer Sizing

The ULTRA PSM-125C does not require isolation transformers. However, a transformer may be required to match the voltage requirements of the controller to the available service. To size a transformer for the main AC power inputs, the power output (KVA) of each axis must be known. This can be derived by calculating the horsepower for each axis and converting that horsepower into units of watts. If you are supplying power to more than one motor and an ULTRA PSM-125C, simply add the kW ratings together from each calculation to get a system kW total.

Definitions:

kW = power or real power kVA = apparent power

Transformer kVA rating = (Sum of average output power of each axis) x 2.0.

Metric Standard English

Where T is temperature difference between inside air and outside ambient (°C), Q is heat generated in enclosure (Watts), and A is enclosure surface area (m2). The exterior surface of all six sides of an enclosure is calculated as

Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in enclosure (Watts), and A is enclosure surface area (ft²). The exterior surface of all six sides of an enclosure is calculated as

A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144

Where d (depth), w (width), and h (height) are in meters.

Where d (depth), w (width), and h (height) are in inches.

IMPORTANT If using an autotransformer, ensure that the phase to neutral/ground voltages do not exceed the input voltage ratings of the unit.

A 0.38Q1.8T 1.1–--------------------------= A 4.08Q

T 1.1–------------------=



Example: sizing a transformer to the voltage requirements of an 2098-DSD-020 and MPL-A320P motor:

The speed/torque curve information for 230V motors is based upon an ULTRA PSM-125C input voltage of 230V AC. For a 115V AC input voltage, the maximum speed can be reduced up to one half.

Fuse Sizing

Fusing for the ULTRA Plus PSM-125C differs from the Ultra Series drives, as this external power supply can power up to six drives. Therefore the four times (4x) motor Full Load Amperage (FLA) rule for controlling drives does not apply.

The ULTRA PSM-125C is listed by Underwriters Laboratories, Inc. with fuses sized as four times (4x) the continuous output current of the drives (FLA), according to UL 508C.

IMPORTANT If you are using the Rockwell Automation/Allen-Bradley system sizing program, the average speed and average torque data has already been calculated and can be used in the above equation. If you are not sure of the exact speed and torque in your application, another approach is to look at the speed/torque curve for your Ultra drive/motor combination and use the values for the worst case continuous speed and torque.

IMPORTANT Calculations are multiplied by a factor to compensate for the power and loss elements within a power system. A factor of 2.0 is used with a single phase system and a factor of 1.5 is used with a three phase system. This factor should minimize the effects of the secondary line voltage sagging in the transformer during peak current periods.



In most cases, fuses selected to match the input current rating should meet the NEC requirements and provide the full power capabilities. Dual element, time delay (slow acting) fuses should be used to avoid nuisance trips during the inrush current of power initialization. Refer to the section General Power in Appendix A for input current and inrush current specifications.

The ULTRA PSM-125C utilizes solid state, short circuit protection rated as shown in the table below.

Refer to Chassis Wiring Diagram - ULTRA Plus PSM-125C (9101-0454) on page B-4 for further information.

Bonding Your System Bonding is the practice of connecting metal chassis, assemblies, frames, shields and enclosures to reduce the effects of electromagnetic interference (EMI).

Bonding Modules

Unless specified, most paints are not conductive and they act as insulators. To achieve a good bond between modules and the subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance exit path for high-frequency energy.

Improper bonding blocks that direct exit path and allows high-frequency energy to travel elsewhere in the cabinet. Excessive high-frequency energy can effect the operation of other microprocessor controlled equipment. The illustrations that follow (refer to Figure 1.2) show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Model: Short Circuit Current Rating with Fuse Restrictions:

1398-PSM-125CSuitable for use on a circuit capable of delivering not more than 200,000 rms symmetrical amperes, 240V maximum, when protected by high interrupting capacity, current limiting fuses meeting UL 198C (Classes CC, G, J, L, R, or T).



Figure 1.2Recommended Bonding Practices

Bonding Multiple Subpanels

Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels. Refer to Figure 1.3 for recommended bonding practices.

Stud-mounting the subpanelto the enclosure back wall

Stud-mounting a ground busor chassis to the subpanel

Subpanel Welded stud

Scrape paint

Flat washer

If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole.Star washer

Nut

Nut

Flat washer

Mounting bracket orground bus

Use a wire brush to remove paint from threads to maximize ground connection.

Back wall of enclosure

Welded stud

Subpanel

Star washer

Use plated panels or scrape paint on front of panel.

Subpanel

Nut

Nut

Star washer

Flat washer

Star washer

Star washerScrape paint on both sides of panel and use star washers.

Tapped hole

Bolt

Flat washer

Ground bus or mounting bracket

If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole.

Bolt-mounting a ground bus or chassis to the back-panel



Figure 1.3Multiple Subpanels and Cabinet

Mounting Your ULTRA PSM-125C

The procedures in this section assume you have prepared your panel and understand how to bond your system. For installation instructions regarding other equipment and accessories, refer to the instructions that came with each of the accessories for their specific requirements.

To mount your ULTRA PSM-125C:

1. Layout the positions for the ULTRA PSM-125C and accessories in the enclosure. Mounting hole dimensions for the ULTRA PSM-125C are shown in Appendix B.

Recommended:Bond the top and bottom of each subpanel to the cabinet using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.

Scrape the paint around each fastener to maximize metal to metal contact.

Bonded cabinet ground bus to

subpanel

ATTENTION This unit contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook.



2. Attach the ULTRA PSM-125C to the cabinet, first using the upper mounting slots of the backpanel and then the lower. The recommended mounting hardware is M5 metric (1/4-20) or #10 MS bolts. Observe bonding techniques as described in Bonding Your System.

3. Tighten all mounting fasteners.


Chapter 2

ULTRA Plus PSM-125C Connections

Chapter Objectives This chapter provides locations and signal descriptions for the I/O connectors and power terminals on your ULTRA Plus PSM-125C. This chapter includes:

• Understanding PSM-125C Connectors

• I/O Connections

Understanding PSM-125C Connectors

The following table provides a brief description of the ULTRA Plus PSM-125C front panel connectors and describes the connector type.

Use the following figure to locate the front panel connections on the ULTRA Plus PSM-125C.

Connector and Labelling Description Connector Type

TB1 Enable±, Status± User Input/Output 4-position screw style barrier terminal strip

TB2

L1 - L3 AC power 3-position screw style barrier terminal strip

POS/NEG DC bus Screw terminal posts

GND Safety (Earth) Ground Screw terminal post

TB3 1,2 Shunt Resistor 2-position screw style barrier terminal strip


2-2 ULTRA Plus PSM-125C Connections

Figure 2.1ULTRA Plus PSM-125C Front and Bottom Panel Connections




TB1TB1




POSPOS NEGNEG L3L3L2L2L1L1

Power Ground Terminal Lug

Logic Interface: TB1-1 STATUS- TB1-2 STATUS+ TB1-3 ENABLE- TB1-4 ENABLE+

Diagnostic LEDs: PHASE LOSS (red) OVERTEMP (red) DISABLED (red) PSM READY (green)

DC Bus: TB3-1 and TB3-2 Shunt Resistor Terminals

AC Input Power Connections:

L1 L2 L3

DC Output Power Terminal Lugs:

POS NEG

Power Interface: TB2 - Power Inputs and Outputs

Cover Release Locks (2):Quarter turn counterclockwise to release


ULTRA Plus PSM-125C Connections 2-3

I/O Connections A description of the PSM-125C input/output is provided on the following pages.

PSM to Controller Interface Logic

The following table provides the signal descriptions and pin-outs for the TB1 controller interface terminal block.

The STATUS and ENABLE signals on the TB1 terminal block interface the PSM with a controller. See Connector and Wire Requirements A on page A-3 for wire gauge and terminal torque recommendations.

Refer to Figure 3.4 on page 3-8 and Figure 3.5 on page 3-8 for internal and external connection examples.

Status

The STATUS- and STATUS+ outputs (TB1-1 and TB1-2 respectively) are the contacts of a normally open relay:

• Closed indicates the PSM is operating properly.

• Open indicates no AC power is applied to the PSM or that a PSM fault has occurred.

This relay is capable of handling up to 0.3 mA at 24V DC.

TB1-Pin Description Signal

1PSM status output from a normally open relay

STATUS-

2 STATUS+

3Control of PSM power output from an optically isolated input

ENABLE-

4 ENABLE+



Enable

The ENABLE- and ENABLE+ inputs (TB1-3 and TB1-4 respectively) are optically isolated inputs which control the power output of the power supply module. The PSM Enable input is turned on by sourcing current through the opto-isolator. The ENABLE signal is functional only if jumper W1 is in Enable Activated position as shown in Figure 2.2.

Note: ENABLE is deactivated as the factory setting for the W1 jumper.

If the ENABLE signal is in the Enable Activated position (shorted across the top 2 pins), the signal logic is:

• ENABLE = ON, the PSM is enabled.

• ENABLE = OFF, the PSM DC bus is turned OFF and the dissipative shunt is turned ON to quickly discharge the DC bus capacitors and dynamically brake synchronous motors. This is to allow time for controlling drives to power-up and apply the ENABLE signal to the PSM if the PSM is to remain on.

If the W1 jumper is in the Enable Deactivated position (shorted across the bottom 2 pins) it has no effect on the PSM operation. The PSM activates itself when three phase voltage in the proper voltage range is applied to the PSM.

Figure 2.2Power Supply Module Jumper Location

ATTENTIONIf the PSM is disabled during a power up, the DC bus voltage will be present for at least two (2) seconds before returning to a zero (0) Volt condition.


ULTRA Plus PSM-125C Connections 2-5

Power Connections A description of the PSM-125C power connections are provided on the following pages.

AC Input Power

The following table provides a description and pin-outs for the L1, L2, and L3 AC power input.

See Connector and Wire Requirements A on page A-3 for wire gauge and terminal torque recommendations.

Refer to Chassis Wiring Diagram - ULTRA Plus PSM-125C (9101-0454) on page B-4 and Power Wiring Connection Diagram - ULTRA Plus PSM-125C System (9101-0462) on page B-5 for connection examples.

DC Bus Power Output

The following table provides a description and terminal connections for the DC bus power output.

See Connector and Wire Requirements A on page A-3 for wire gauge and terminal torque recommendations.


Terminal Label Description

L1

100 to 240V AC, three phase, 50/60 Hz, 100 A input L2

L3

Terminal Label Description

POS DC Power Bus +

NEG DC Power Bus -

GND Safety (Earth) Ground



Shunt Terminals

The following table and Figure 2.3 provide a description and terminal connections for the Return DC bus (shunt) power connections.

See Connector and Wire Requirements A on page A-3 for wire style, wire gauge, and terminal torque recommendations.

Note: Remove or disable any shunting (internal or external) of drives powered by the DC bus output of the ULTRA Plus PSM-125C, when an external shunt is connected to the PSM-125C. Refer to the drive’s installation manual for instructions.


Figure 2.3TB3 - Return DC Bus (Shunt) Connector

TB3-Pin Description Signal

1Return DC Bus Power – External Shunt Connections

DC Bus -

2 DC Bus +

1Return DC Bus Power – PSM Connections

DC Bus -

2 DC Bus +

Output from PSM Input to Shunt

Mounting Screw

1

2

1

2


Chapter 3

Wiring Your ULTRA Plus PSM-125C

Chapter Objectives This chapter provides procedures for wiring your ULTRA Plus PSM-125C and making cable connections. This chapter includes:

• Understanding Basic Wiring Requirements

• Grounding Your ULTRA Plus PSM-125C

• Wiring Your ULTRA Plus PSM-125C

Understanding Basic Wiring Requirements

This section contains basic wiring information for the ULTRA Plus PSM-125C.

ATTENTION Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

IMPORTANT This section contains common PWM servo system wiring configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.


3-2 Wiring Your ULTRA Plus PSM-125C

Building Your Own Cables

When building your own cables, use a twisted pair cable whenever possible, twisting differential signals with each other, and single-ended signals with the appropriate ground return.

Refer to Appendix C for mating connector kit catalog numbers.

Routing High and Low Voltage Cables

Be aware that when you connect and route power and signal wiring on a machine or system, radiated noise from nearby relays (relay coils should have surge suppressors), transformers, and other electronic drives, can be induced into motor or encoder feedback, communications, or other sensitive low voltage signals. This can cause system faults and communication problems. To minimize the levels of radiated noise:

• Route machine power lines separately from other power lines, and especially from signal lines.

• Cross high and low voltage conductors at 90° angles.

• Maximize the distance between high and low voltage cables on parallel runs.

• Minimize the length of unshielded conductors.

Refer to System Design for Control of Electrical Noise (publication GMC-RM001x-xx-x) for additional information on how to minimize and control system-level noise.

IMPORTANT Factory made cables are recommended over hand-built cables and are designed to minimize EMI.


Wiring Your ULTRA Plus PSM-125C 3-3

Figure 3.1Routing Power and Signal Cables Inside Your Cabinet

Grounding Your ULTRA Plus PSM-125C

We recommend that all equipment and components of a machine or process system have a common earth ground point connected to their chassis. A grounded system provides a safety ground path for short circuit protection. Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis. For CE grounding requirements, refer to Appendix B.

1

2

3

Internal

ExternalShunt

TB2

U

V

W

+

-

Motor

DC Bus

TB1

L1

L2

L3

L1AUX

L2/NAUX

100-240 VAC50/60 Hz

1

2

3

Internal

ExternalShunt

TB2

U

V

W

+

-

Motor

DC Bus

TB1

L1

L2

L3

L1AUX

L2/NAUX

100-240 VAC50/60 Hz

1

2

3

Internal

ExternalShunt

TB2

U

V

W

+

-

Motor

DC Bus

TB1

L1

L2

L3

L1AUX

L2/NAUX

100-240 VAC50/60 Hz

1

2

3

Internal

ExternalShunt

TB2

U

V

W

+

-

Motor

DC Bus

TB1

L1

L2

L3

L1AUX

L2/NAUX

100-240 VAC50/60 Hz




TB1TB1




+ - L1 L2 L3

Maximize distance

between high and low voltage

cables on parallel runs.

120/240V AC Power

Motor Power Cables

Low Voltage Communications Control,I/O Wiring, Motor Feedback Cables

Cross high and low voltage

conductors at 90° angles.

To reduce the effects of EMI and RFI:

Separate all low voltage signal wiring from high voltage power wiring.

Unshielded Conductors

Minimize unshielded lead length.

DC Bus Cable

Note: 120V/240V Power shown supplying auxiliary power to drives after DC Bus power is removed. (e.g., to retain diagnostics).



Grounding Your System to the Subpanel

Figure 3.2Safety Ground Configuration for ULTRA Plus PSM-125C System on One Panel

Grounding Multiple Subpanels

To ground multiple subpanels, refer to Figure 3.3.

Figure 3.3Subpanels Connected to a Single Ground Point

ATTENTION The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system. Refer to the illustration below for details on grounding your ULTRA Plus PSM-125C. Refer to Appendix B for the power wiring diagram for your ULTRA Plus PSM-125C.

U

V

W

+

-

L1

L2/N

L1AUX

L2/NAUX

1

2

3

Motor

DC Bus

100-240 VAC50/60 Hz

Internal

ExternalShunt

TB1

TB2




TB1TB1




U

V

W

+

-

L1

L2/N

L1AUX

L2/NAUX

1

2

3

Motor

DC Bus

100-240 VAC50/60 Hz

Internal

ExternalShunt

TB1

TB2

U

V

W

+

-

L1

L2/N

L1AUX

L2/NAUX

1

2

3

Motor

DC Bus

100-240 VAC50/60 Hz

Internal

ExternalShunt

TB1

TB2

U

V

W

+

-

L1

L2/N

L1AUX

L2/NAUX

1

2

3

Motor

DC Bus

100-240 VAC50/60 Hz

Internal

ExternalShunt

TB1

TB2

Bonded Ground Bar (optional)

Bonded Cabinet Ground Bus

Always follow NEC and applicable local codes.All ground wiring must comply with local codes.

Ground grid or power distribution ground.

Ultra3000 Digital Servo

Drives

Ultra3000 Digital Servo

Drives

ULTRA PSM-125C

Safety Ground

Terminal

Always follow NEC and applicable local codes.

Ground grid or power distribution ground.



Wiring Your ULTRA Plus PSM-125C

These procedures assume you have bonded and mounted your ULTRA Plus PSM-125C to the subpanel and that there is no power applied to the system.

The following sections provide information and procedures on how to wire your ULTRA Plus PSM-125C. The PSM-125C can supply DC power to as many as six controllers.

AC Input Power

Three phase AC power, 115/230V AC, is the recommended input power for the PSM. Phasing of the input power at the L1, L2, and L3 terminals is arbitrary, however the input power may require isolation through a transformer.

Field wiring must be copper, with a minimum rating of 75° C (167° F). An earth ground connection is required for safe and proper system operation. Appendix A specifies wire sizing and terminal block torque connections. Supply fuses or disconnecting devices must be supplied by the machine builder and connected externally for safety and maintenance purposes.

The ULTRA Plus PSM-125C will continue to operate with reduced capacity with the loss of one phase. The red phase loss LED on the front of the PSM will turn ON to indicate the loss of the phase.

Refer to Refer to Power Wiring Connection Diagram - ULTRA Plus PSM-125C System (9101-0462) on page B-5 for additional details. This drawing shows an optional AC line filter, and shielded motor cables. These can be used in conjunction with the grounded metal enclosure to meet the Electromagnetic

ATTENTION This unit contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook.

ATTENTIONThe power supply module allows for operation to continue even in the event of loss of one phase or during power disruption on the three phase AC inputs. Under these conditions, the Phase Loss LED will light, but the power supply is not disabled. Extended operation of this product with an AC phase input missing will reduce the life of the product.



Compatibility requirements of the European Machinery Directive. Refer to System Design for Control of Electrical Noise for a discussion of EMC.

DC Bus Output Power

The DC bus from the PSM supplies power for up to six drive controllers. The DC bus must be connected as shown in drawing Power Wiring Connection Diagram - ULTRA Plus PSM-125C System (9101-0462), with the PSM in the center.

See Connector and Wire Requirements on page A-3 for wire gauge and terminal torque recommendations.


Dissipative Shunt

The dissipative shunt connector allows an external resistive shunt to drain excess regenerative power, to discharge the DC bus capacitors, and doubles as an emergency synchronous motor dynamic brake. The shunt should be connected as shown in drawing Power Wiring Connection Diagram - ULTRA Plus PSM-125C System (9101-0462), but wiring polarity is arbitrary.

See Connector and Wire Requirements on page A-3 for wire gauge and terminal torque recommendations.

ATTENTIONDC bus wires must meet the requirements stated in Appendix A, Specifications, as a minimum, and should always be installed per local codes.



Note: Remove or disable any shunting (internal or external) of drives powered by the DC bus output of the ULTRA Plus PSM-125C, when an external shunt is connected to the PSM-125C. Refer to the drive’s installation manual for instructions on how to do this.

PSM Logic Interface

The STATUS and ENABLE signals listed below interface the PSM with one or more servo controllers.

Typical internal circuitry for the interface, and sample external connections with the controller are shown below.

ATTENTIONThe external shunt resistors and module enclosures can reach temperatures up to 350° C (662° F). Shunt wiring must meet the requirements stated in Appendix A, Specifications, as a minimum and should always be installed per local codes.

To avoid the hazard of shock or burn and ignition of flammable material, provide appropriate guarding. Do not handle a shunt module that has been operational until it has cooled sufficiently. Failure to observe this precaution may result in damage to or destruction of the equipment.

TB1-Pin Signal Name

1 STATUS-

2 STATUS +

3 ENABLE-

4 ENABLE +



Figure 3.4PSM Interface – Internal Circuit Examples

Figure 3.5PSM Interface – External Connection Examples

Shield Termination of Power Cables

ATTENTIONShielded power cables must be grounded at a minimum of one point for safety. Failure to ground a shielded power cable will result in potentially lethal voltages on the shield and anything connected to it.


Chapter 4

Applying Power for the First Time

Outlined below are the steps that should be followed when applying power to the equipment for the first time. This procedure covers only the ULTRA Plus PSM-125C.

These start-up procedures assume that the equipment is properly mounted and wired, but power has not been applied.

Start-up Procedure for ULTRA Plus PSM-125C

Start-up of an ULTRA Plus PSM-125C involves starting a Power Supply Module (PSM) and the controller. The PSM is checked first and then the controller. Perform the start-up procedure on all controllers attached to the PSM at the same time.

Power Supply Module

1. Prior to applying power to the PSM, ensure that the supply voltage is in the proper range (100–240V AC three phase).

2. With power off, remove the PSM shunt connection and cover and ensure proper connections have been made to terminals L1, L2, and L3 and that a proper ground is connected. Phasing of the input power connections is arbitrary.


ATTENTIONDangerous voltages may exist after power is removed! Check DC bus voltage each time power is removed before working on the ULTRA Plus Power Supply Module.


4-2 Applying Power for the First Time

3. Disconnect all wires from the PSM DC bus terminal posts marked POS and NEG. Install the PSM cover and shunt connections, then turn on input power. Verify that:

• DC bus voltage is in the proper range (325V DC nominal with 230V AC input).

• The green PSM READY LED is on and that all three red LEDs are off.

• The PSM fans are operating.

4. Disconnect input power and check that the green LED goes off and the DC bus voltage falls to less than 15V DC within one second.

5. Remove PSM cover and shunt connections.

6. Reconnect the DC bus wires to the POS and NEG terminals, ensuring that proper polarity is maintained.

7. Install the PSM cover and shunt connections.

ATTENTIONDC bus wires must meet the requirements stated in Appendix A, Specifications, as a minimum, and should always be installed per local codes.


Chapter 5

Maintaining and Troubleshooting Your ULTRA Plus PSM-125C

Chapter Objectives This chapter provides procedures for maintaining and troubleshooting your ULTRA Plus PSM-125C and making cable connections. This chapter includes:

• Diagnostic Light Emitting Diodes (LED)

• Maintaining Your PSM-125C

The ULTRA Plus PSM-125C is designed to provide troubleshooting aids that help isolate any problems to a “module” in the system. A module may be incoming power, PSM-125C, controller, motor and encoder, cables, or the mechanical system. The PSM circuitry is designed to prevent problems in any one module from damaging any other module. The modular package allows very simple field replacement.

Maintenance of the ULTRA Plus PSM-125C is virtually unnecessary. The primary consideration is to ensure that the fans are operational and PSM is operated in a properly sized and ventilated enclosure with proper fusing.

Diagnostic Light Emitting Diodes (LED)

The PSM front panel LEDs provide a first level of diagnostics.

If all LEDs are OFF (red and green), and incoming line voltages are found to be correct, there may be a PSM failure. Replace the PSM with another module.

LED Label LED Color Description

PHASE LOSS RED

OFF = OK (Normal Operation)

ON = Loss of one phase of incoming AC power. The PSM will continue to run on two phases and the fault LED remains ON.

OVERTEMP REDOFF = OK (Normal Operation)

ON = Excessive main heatsink temperature

DISABLED REDOFF = Not disabled (Normal Operation)

ON = DC bus disabled by external enable input

PSM READY GREENOFF = No DC bus voltage

ON = DC bus charged (Normal Operation)


5-2 Maintaining and Troubleshooting Your ULTRA Plus PSM-125C

Maintaining Your PSM-125C

This section details common maintenance and fault correction actions for the ULTRA Plus PSM-125C.

Replacing the PSM Shunt Fuse

A DC Bus shunt fuse is located in the Power Supply Module. Refer to Shunt Fuse Location on page 5-3 for the location. To check and/or replace this fuse:

1. Measure voltages at L1, L2, and L3 phase-to-phase to ensure incoming power is OFF. Make sure that the green PSM READY LED is OFF.

2. Remove the shunt connections, PSM cover, and the shunt fuse and test with an ohmmeter.

3. Test the continuity and resistance of the shunt fuse with an ohmmeter.

4. If necessary, replace the fuse, and then reinstall the PSM cover and shunt connections.

ATTENTION This product contains stored energy devices. To avoid hazard of electrical shock, verify that all voltages on the system bus network have been discharged before attempting to service, repair or remove this unit.

Only qualified personnel familiar with solid state control equipment and safety procedures in publication NFPA 70E or applicable local codes should attempt this procedure.

Failure to observe this precaution could result in damage to the equipment or severe bodily injury.

IMPORTANT Always replace the shunt fuse with a DC rated fuse.


Maintaining and Troubleshooting Your ULTRA Plus PSM-125C 5-3

Figure 5.1Shunt Fuse Location

Power Supply Module

20 Ampere KLKD-20 or KLM-20

Shunt Fuse

DC Bus Terminal


5-4 Maintaining and Troubleshooting Your ULTRA Plus PSM-125C


Appendix A

Specifications

Chapter Objectives This appendix provides information on the following topics:

• General Power

• Physical and Environmental

• Power Dissipation

• Connector and Wire Requirements

The following sections provide specifications and requirements for the ULTRA Plus PSM-125C.

General Power The table below lists general power specifications and requirements for the ULTRA Plus PSM-125C.

Specification Description

AC Input Voltage 1 100-240V AC, three phase 2

AC Input Frequency 47 - 63 Hz

AC Input Current Nominal (230V AC, three phase input) Maximum inrush (230V AC, three phase input)

82 Arms 100 A (0-peak)

Peak Output Current (DC) 450 A

Continuous Output Current (DC) 100 A

Output Voltage 100-340V DC (325V DC with 230V AC Input)

Shunt Power 3 Peak Continuous

40 kW 1.2 kW

Fuse:Class RK5 rated 90 A (5000 AIC).

Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 240 V maximum, when protected by high interrupting capacity, current limiting fuses.

1 Specification is for nominal voltage. The absolute limits are 58-265V AC, three phase, 50/50 Hz, 100 A. 2 Single phase power may be used, with reduced capability. Refer to AC Input Power on page 3-5 for limitations. 3 The PSM-125C may use an external shunt rated at 4 Ohm, 600 Watt minimum.


A-2 Specifications

Physical and Environmental The table below lists physical and environmental specifications and requirements.

Power Dissipation Use the following table to size an enclosure and calculate required ventilation for the ULTRA Plus PSM-125C. Typical heat losses run approximately one-half maximum power losses. The maximum power losses are shown below.

As an additional aid in sizing an enclosure, with no active method of heat dissipation, the following approximate equation is used:

T = 4.08 (Q/A) + 1.1

Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in enclosure (Watts), and A is enclosure surface area (ft²).

The exterior surface of all six sides of an enclosure is calculated as

A = (2dw + 2dh + 2wh)/144

Where d (depth), w (width), and h (height) are in inches.

Specification Description

Weight 11.9 kg (26.2 lb)

Operating Temperature 0o C to 55o C (32o F to 131o F)

Storage Temperature -40o C to 70o C (-40o F to 158o F)

Humidity 5% to 95% non-condensing

Altitude 1500m (5000 ft) Derate 3% for each 300 m above 1500m

VibrationOperating/Non-operating 5 to 2000 Hz, 2.5 g peak, 0.015 in.maximum displacement

ShockNon-operating 15 g 11 ms half sine

Field WiringAC PowerShunt

Copper, rated 75° C (167° F) minimumStranded wire rated to 600 V, 250° C (482° F) minimum

UL Listed to U.S. and Canadian safety standards UL 508 C File E145959, Vol. 1, Section 3

Catalog Number Maximum Loss (Watts)

ULTRA Plus PSM-125C 240

3.0 kVA Transformer 350

TF-03 (3 kW transformer) 350




Specifications A-3

Connector and Wire Requirements

The table below lists connector and wire specifications for the ULTRA Plus PSM-125C.

Connector Terminal / Pin Connector TypeWire Gauge 1 Terminal Torque

Descriptionmm2 (AWG) N•m (lb•in)

TB1 1 - 4 4-position screw style barrier terminal strip 1.5 (16) 2.71 (24.0) User Input/Output

TB2

L1 - L3 3-position screw style barrier terminal strip 16 – 50 (6 – 0) 2.71 (24.0) AC power

POS/NEG Screw terminal posts 8 – 14 (12 – 6) 4.0 (36.0) DC bus

GND Screw terminal post 16 – 50 (6 – 0) 4.0 (36.0) Safety (Earth) Ground

TB3 1 - 2 (both sides) 2-position screw style barrier terminal strip 2.5 (14) 1.5 – 1.8 (13.0 – 16.0) Shunt Resistor

1 Wire sizes are minimum recommended values. Local regulations should be observed. Refer to Physical and Environmental,: Field Wiring for recommended minimum wire ratings.


A-4 Specifications


Appendix B

Interconnect Diagrams

Chapter Objectives This appendix provides the following drawings:

• Outline and Mounting Diagram - ULTRA Plus PSM-125C (9101-0456)

• Outline and Mounting Diagram - ULTRA Plus PSM Auxiliary Transformer Mounting

• Chassis Wiring Diagram - ULTRA Plus PSM-125C (9101-0454)

• Power Wiring Connection Diagram - ULTRA Plus PSM-125C System (9101-0462)


B-2 Interconnect Diagrams

Dimensions The following diagrams show the dimensions and mounting hole locations for the PSM-125C and optional Auxiliary Transformer. Chassis and Power Wiring diagrams for the PSM-125C are also included.

Figure B.1Outline and Mounting Diagram - ULTRA Plus PSM-125C (9101-0456)

POS

POS

NEG

NEG

TTSS

RR




TB1TB1

PSM ReadyPSM Ready

DisabledDisabled

Over TempOver Temp

Phase LossPhase Loss



114.3(4.30)

34.9(1.38)

34.9(1.38)

6.4(0.25)

11.4(0.45)

380.4(14.98)

362.0(14.25)

Minimum Clearances:102.0 (4.0) above and below unit for airflow.13.0 (0.50) both sides and between adjacent units for air flow.280 (11.0) from backpanel to front of unit for cable clearance.

277.4(10.92)

246.4(9.70)

396.2(15.60)

AIR EXHAUST

AIR INTAKE

Dimensions are in millimeters (inches).


Interconnect Diagrams B-3

Figure B.2Outline and Mounting Diagram - ULTRA Plus PSM Auxiliary Transformer Mounting

Wiring Diagrams The diagrams starting page B-4 on show suggested Chassis and Power Wiring diagrams for the PSM-125C.

Dimensions are in inches



Figure B.3Chassis Wiring Diagram - ULTRA Plus PSM-125C (9101-0454)


Interconnect Diagrams B-5

Figure B.4Power Wiring Connection Diagram - ULTRA Plus PSM-125C System (9101-0462)

1. 3 5 7 10

16

1010

1010

11

17

17

12 18

18

14 1513

13

13

33

3

3

14

14

15

16

16

1616

86 942

2

95

87 6

4

11

12

9101

-046

2

75A

DRIV

E MOD

ULE

75A

DRIV

E MOD

ULE

150A

DRI

VE M

ODUL

E15

0A D

RIVE

MOD

ULE

POW

ER S

UPPL

Y M

ODUL

E

L2 A

UX

TB2

TB2

TB2

TB2

TB1

TB1

TB1

TB1

L2 A

UXL2

AUX

L2 A

UXL1

AUX

L1 A

UXL1

AUX

L1 A

UX

L3L3

L3L3

L2L2

L2L2

L1L1

L1L1

DC-

DC-

DC-

DC-

DC+

DC+

DC+

DC+

WW

WW

33

33

VV

VV

22

22

UDC B

USDC

BUS

DC B

USDC

BUS

UU

U

11

11

3 PHA

SE IS

OLAT

ION

ORAU

TO TR

ANSF

ORM

ER

(OPT

IONA

L: NO

T REQ

UIRE

DW

HEN

DESI

RED

INPU

T VOL

TAGE

IS A

VAILA

BLE D

IREC

TLY

FROM

THE L

INE).

TRAN

SFOR

MER

CHAS

SIS

3 PHA

SE A

C LIN

E50

/60 H

z

FUSE

D DI

SCON

NECT

100 T

O 24

0 VAC

RM

SFO

R AC

LINE

FILT

ER:(3

PLCS

)

TO PR

OTEC

TIVE

MAC

HINE

COM

MON

PHAS

ING

OF L1

,L2 A

ND L3

3 PHA

SE IN

PUT P

OWER

EART

H TE

RMIN

ALGR

OUND

ING

BUS

BAR

INPU

T POW

ER IS

ARB

ITRAR

Y

LINE

FILTE

RAC

M1

COM

MON

GRO

UNDI

NG

MOD

ULE S

YSTE

MSU

PPLY

-DRI

VEPO

INT F

OR PO

WER

22

2 2

2

2 2

MP M

OTOR

MP M

OTOR

MP M

OTOR

MP M

OTOR

1 2

TB3

EXTE

RNAL

SHU

NT

2

2 2

2

2

2 2

2

2

2 2

mm (A

WG)

(75

C C

OPPE

R M

IN.)

TERM

INAL

S

MOT

OR

DRIV

E

DRIV

E

MOT

OR PO

WER

MAT

ING

CONN

ECTO

R CO

NTAC

TSI

ZE m

m (A

WG)

TERM

INAL

S

CURR

ENT R

EQUI

REM

ENT,

MIN

IMUM

REC

OMM

ENDE

D

MOT

OR PO

WER

CON

NECT

OR

RECO

MM

ENDE

D PO

WER

WIR

E

MAX

IMUM

(AM

PS D

C)

POW

ER W

IRE m

m (A

WG)

(75 C

COP

PER

MIN

.)

DC+,D

C-

L1 A

UX,

L2 A

UX

MPL

A540

2098

-DSD

-150

X-XX

DC+,D

C-

L1 A

UX,

L2 A

UX

MPL

A560

MPL

A660

2098

-DSD

-075

X-XX

2098

-DSD

-075

X-XX

2098

-DSD

-150

X-XX

PSM

-125

2098

-DSD

-150

X-XX

2098

-DSD

-150

X-XX

4mm

(12 A

WG)

DC+,D

C-

2098

-DSD

-075

X-XX

2098

-DSD

-075

X-XX

4mm

(12 A

WG)

4mm

(12 A

WG)

DC+,D

C-

L1 A

UX,

L2 A

UX

L1,L2

,L3

46A

1 AM

P AT 1

00-2

40VO

LTS

AC S

INGL

E PHA

SE

6mm

(10 A

WG)

AU

PINSI

GNAL

16mm

(6 A

WG)2

3A

1 AM

P AT 1

00-2

40VO

LTS

AC S

INGL

E PHA

SE

6mm

(10 A

WG)

BV

6mm

(10 A

WG)

C D

W

MOT

OR C

ASE

16mm

(6 A

WG)

1,5mm

(16 A

WG)

16-5

0mm

(6-0

AW

G)

DIGI

TAL D

RIVE

MOD

ULE I

NPUT

CUR

RENT

REQ

UIRE

MEN

TS

MOT

OR PO

WER

WIR

ES U

, V, W

AND

GND

INPU

T POW

ER W

IRES

NOTE

: POW

ER IN

ITIAL

IZATIO

N RE

QUIR

ES A

SHO

RT PE

RIOD

OF I

NRUS

H CU

RREN

T OF 9

5A FO

R TH

E

F

USE S

IZES

MUS

T BE S

ELEC

TED

ACCO

RDIN

G TO

LOCA

L REG

ULAT

IONS

.

AUX

ILIAR

Y IN

PUT.

DUAL

ELEM

ENT T

IME D

ELAY

(SLO

W B

LOW

) FUS

ES A

RE R

ECOM

MEN

DED.

POS

GND

NEG

L1L2

L3

M6 T

ERM

INAL

POST

M6 N

UT CON

NECT

ING

LUGS

GROU

ND TE

RMIN

AL PO

STS

POSI

TIVE,

NEGA

TIVE T

ERM

INAL

POST

S

M6 T

ERM

INAL

POST

M6 N

UT

SPRI

NG D

ISK

WAS

HERS

FLAT

WAS

HER

CONN

ECTIN

G LU

GS

DRIV

E OR

POW

ERSU

PPLY

BUS

BAR

TERM

INAL

POST

BAS

E

CAUT

ION

DO N

OT O

VERT

IGHT

EN.

USE N

UT D

RIVE

R ON

LY.

36 LB

-IN (4

.0 Nm

) ABS

OLUT

EM

AXIM

UM TI

GHTE

NING

TORQ

UE

NOTE

S:

THE P

OWER

SUP

PLY

MOD

ULE M

UST B

E CEN

TERE

D BE

TWEE

N TH

E DRI

VE M

ODUL

ES

MAY

BE U

SED

TO K

EEP L

OGIC

SEC

TION

OF D

RIVE

MOD

ULE S

UPPL

IES PO

WER

ED A

FTER

BUS

CURR

ENT R

ATIN

GS A

RE IN

DEPE

NDEN

T OF T

HE IN

PUT V

OLTA

GE. R

EDUC

ED V

OLTA

GE W

ILL R

ESUL

T

DRIV

E ENA

BLE I

NPUT

MUS

T BE O

PENE

D W

HEN

BUS

POW

ER IS

REM

OVED

AND

AUX

ILIAR

Y PO

WER

ISPR

ESEN

T, OR

A D

RIVE

FAUL

T WILL

OCC

UR.

TERM

INAT

E THE

MOT

OR PO

WER

CAB

LE S

HIEL

D BY

CLA

MPIN

G IT

TO TH

E DRI

VE W

ITH TH

E BRA

CKET

PROV

IDED

.

BEFO

RE PO

WER

ING

UP TH

E 75A

AND

150A

DRI

VE M

ODUL

ES, R

EMOV

E INT

ERNA

L SHU

NT

IF US

ING

AN A

UTOT

RANS

FORM

ER, E

NSUR

E THE

PHAS

E TO

NEUT

RAL/

GROU

ND V

OLTA

GE D

OES

NOT E

XCEE

D TH

E INP

UT

TERM

INAT

E EXT

ERNA

L SHU

NT R

ESIS

TORS

USI

NG 2.

5mm

(14 A

WG)

, 600

V, 25

0 C S

TRAN

DED

WIR

E.

RATIN

GS O

F THE

CON

VERT

ER.

TORQ

UE TE

RMIN

AL B

LOCK

TB3 C

ONNE

CTIO

NS TO

1.5-

18 N

m (13

-16 I

N-LB

S).

TORQ

UE TO

24 IN

-LBS.

EXTE

RNAL

SHU

NT TO

BE 4

OHM

S, R

ATED

AT 6

00W

MIN

IMUM

.

TORQ

UE TO

2.26

Nm

(20 IN

-LBS)

. WIR

E RAN

GE 8-

14mm

(12-

6 AW

G).

TORQ

UE TO

2.71

Nm

(24 IN

-LBS)

. WIR

E RAN

GE 16

-50m

m (6

-0 A

WG)

.

TORQ

UE TO

1.25

Nm

(11 IN

-LBS)

. WIR

E RAN

GE 0.

5-6m

m (2

2-10

AW

G).

AC LI

NE FI

LTER

AND

SHI

ELDE

D M

OTOR

CAB

LE A

RE TO

BE U

SED

FOR

IMPR

OVIN

G EL

ECTR

OMAG

NETIC

COM

PATIB

ILITY

CONV

ERTE

R RA

TED

100-

240 V

AC R

MS,

THRE

E PHA

SE IN

PUT V

OLTA

GE (2

30 V

AC S

TAND

ARD)

.

WIR

E SIZE

S AR

E MIN

IMUM

REC

OMM

ENDE

D VA

LUES

. THE

REQ

UIRE

MEN

TS O

F LOC

AL R

EGUL

ATIO

NS S

HOUL

D BE

OBS

ERVE

D.

A SU

PPLY

DIS

CONN

ECTIN

G DE

VICE

IS R

EQUI

RED

FOR

MAI

NTEN

ANCE

AND

SAF

ETY.

LOCA

L REG

ULAT

IONS

SHO

ULD

BE O

BSER

VED.

TO M

INIM

IZE TH

E DC

BUS

INDU

CTAN

CE S

O TH

AT A

N EQ

UIVA

LENT

NUM

BER

OFDR

IVES

ARE

LOCA

TED

ON EA

CH S

IDE O

F THE

PSM

. THE

HIG

HEST

POW

ER

DRIV

ES W

IRED

FURT

HEST

FROM

THE P

SM.

DRIV

ES M

UST B

E WIR

ED C

LOSE

ST TO

THE P

SM, W

ITH TH

E LOW

EST P

OWER

SUPP

LY IS

TURN

ED O

FF. (E

XAM

PLE:

TO R

ETAI

N DI

AGNO

STIC

STA

TUS

OF D

RIVE

MOD

ULE.)

DISC

ONNE

CTIN

G DE

VICE

IS R

EQUI

RED

FOR

SAFE

TY A

ND M

AINT

ENAN

CE.

IN A

RED

UCTIO

N IN

SPE

ED, B

UT N

OT IN

TORQ

UE.

THIS

BRA

CKET

CAN

BE U

SED

IF NO

N-SH

IELDE

D CA

BLES

ARE

USE

D. D

O NO

T OVE

R TIG

HTEN

BRA

CKET

SCR

EWS.

NEVE

R TO

RQUE

SCR

EWS

OVER

10 IN

-LBS.

CONN

ECTO

RS TH

AT C

ONNE

CT B

ETW

EEN

POSI

TIONS

1 AN

D 2 O

N TB

2 ON

EACH

DRI

VE.

OF TH

E SYS

TEM

. CAU

TION:

AC

LINE F

ILTER

S HA

VE LA

RGE L

EAKA

GE C

URRE

NTS

AND

REQU

IRE D

ISCH

ARGE

TIM

E UPO

NPO

WER

REM

OVAL

. WIR

ING

BETW

EEN

THE D

RIVE

MOD

ULE A

ND FI

LTER

SHO

ULD

BE K

EPT A

S SH

ORT A

S PO

SSIB

LE.

THE C

OMM

ON G

ROUN

D BU

S BA

R SH

OULD

BE A

S CL

OSE T

O TH

E DRI

VE A

S PO

SSIB

LE.

FUSE

SIZE

: PSM

-125

-UL C

LASS

RK5

90 A

MP (

5000

AIC

) A

9101

-046

2

DIAG

, POW

ER W

IRIN

G CO

NNEC

TION

S,13

98-P

SM-1

25C

.XXX

.010

DECI

MAL

S.XX

.020

FRAC

TIONS

: 1/6

4"

DO N

OT S

CALE

DRA

WIN

GUN

LESS

OTH

ERW

ISE S

PECI

FIED

ANGL

ES 1

TO

LERA

NCE O

N:FIL

LETS

AND

ROU

NDS

.02 R

MAX

BREA

K AL

L EDG

ES .0

2 MAX

DIM

ENSI

ONS

ARE I

N IN

CHES

DATE

DATE

8-16

-02

D

PART

NO.

DWG

SIZE

SHEE

TSC

ALE

N/A

11

of

REV

ECO

CHKR

DATE

REVI

SION

DES

CRIPT

ION

BYDE

SIGN

ENGR

DRAW

N BY

--BK

--

02R2

063

--01

BK--

RELE

ASED

PART

NO.

Eden

Prair

ie, M

N 55

344

ROCK

WEL

L AUT

OMAT

ION

Conf

ident

ial In

form

ation

of


Appendix C

Catalog Numbers and Accessories

Chapter Objectives This appendix lists the ULTRA PSM-125C and accessory item catalog numbers. It provides a brief description of the following components:

• ULTRA Plus PSM-125C Power Supply Module

• Transformers

Contact your local Allen-Bradley sales office for additional information. Refer to the Motion Control Selection Guide (publication GMC-SG001x-EN-P) for details on products.

ULTRA Plus PSM-125C Power Supply Module

Use the following table to identify an ULTRA Plus PSM-125C 240V Power Supply Module.

Transformers Use the following table to identify transformers compatible with an ULTRA Plus PSM-125C.

Description Catalog Number

ULTRA Plus PSM-125C Power Supply Module 1398-PSM-125C

Part Number Description

0020-5093 Auxiliary PSM transformer (ULTRA Plus PDM-25, 50, 100 or 150)


C-2 Catalog Numbers and Accessories

Index

Aac

input current A-1

ac power input 3-5

accessoriescatalog numbers C-1

airflow requirements B-2

Allen-Bradley supportsee back cover

altitude A-2

Bbonding electrical subpanels 1-7

building your own cables 3-2

Ccables

building your own cables 3-2

catalog numbersPSM-125C C-1transformers C-1

chassis wiringPSM-125C B-4

clearance requirements B-2

connecting your PSM-125C 3-1

connectors A-3

controls interfacedescribed 2-3logic 2-3, 3-7

Ddc bus 3-6

diagnostics 5-1

diagramschassis wiring B-4power wiring B-5PSM-125C outline B-2transformer B-3

dimensionsPSM-125C B-2transformer B-3

documentationon-line and print P-2

EEMI (ElectroMagnetic Interference)

bonding to reduce 1-7

enable input 2-4

enclosure sizing A-2

Ffront panel connections 2-1

illustrated 2-2

fuse sizing 1-6

fuse, shuntreplacement 5-2

Ggrounding

multiple subpanels 3-4system to subpanel 3-4

Hheat losses for sizing enclosures A-2

high frequency energy 1-8

humidity A-2

II/O

enable 2-4status 2-3

Index-2

installationac input pinouts 2-5bonding guidelines 1-7dc bus pinouts 2-5enable jumper 2-4front panel connections 2-1fuse sizing 1-6general information 1-1jumper (W1) 2-4minimum clearances 1-4mounting requirements 1-1mounting unit 1-2procedure 1-9required tools 1-2shunt pinouts 2-6spacing requirements 1-3storage before use 1-2system mounting requirements 1-3transformer sizing 1-5ventilation 1-4wiring requirements 3-1

interconnect diagramgrounding 3-4grounding multiple subpanels 3-4high/low voltage cables 3-2

interconnect diagramspower wiring B-5

introduction P-1

Jjumper location 2-4

LLED display 5-1

Mmaintenance 5-1

shunt fuse 5-2

manualssee documentation

mountingbefore mounting 1-2bonding 1-7procedure 1-9system requirements 1-3

mounting requirements 1-3

Nnoise reduction

bonding 1-7

Ooutput current

continuous A-1peak A-1

Ppin-outs

ac input 2-5dc bus 2-5shunt 2-6

powerlosses A-2

power connectionsac input 2-5dc bus input 2-5drive shunts 2-6shunt 2-6

power dissipation A-2enclosure sizing A-2

power interfacedescribed 2-5

power wiring B-5system level example B-5

product support P-4

PSM-125Ccatalog number C-1

purpose of this manual P-1

Rrelated documentation

on-line and printed documentation P-2

required tools 1-2

Sshock A-2

shunt 3-6

shuntsremove/disable drive shunt 2-6

Index-3

specifications A-1, A-2ac input current A-1altitude A-2connectors A-3controls interface 2-3general power A-1I/O 2-3, 2-5I/O, enable 2-4I/O, status 2-3output current continuous A-1peak output current A-1physical and environmental A-2power dissipation A-2power interface 2-5power loss A-2shock A-2storage temperature A-2vibration A-2

start-up procedure 4-1

statusoutput 2-3

storage A-2before installation 1-2responsibility P-3

supportlocal product P-4technical assistance P-4

system mounting requirementsfuse sizing 1-6installation 1-3minimum clearances 1-4spacing 1-3transformer sizing 1-5ventilation 1-4

Ttechnical support

contacting, see back cover

temperature A-2

transformer sizing 1-5

transformers C-1

troubleshooting 5-1

Vvibration A-2

WW1 jumper 2-4

who should use this manual P-1

wiringac power connections 3-5building your own cables 3-2dc bus connections 3-6grounding 3-4power wiring diagram B-5requirements 3-1routing high/low voltage cables 3-2shunt connections 3-6system level example B-5

Index-4

Publication 1398-IN125B-EN-P — February 2010 0013-2060-002Copyright © 2010 Rockwell Automation. All rights reserved. Printed in USA.

For more information refer to our web site: www.ab.com/motionFor Allen-Bradley Technical Support information refer to: www.ab.com/support or Tel: (1) 440.646.5800

www.rockwellautomation.com

Corporate HeadquartersRockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201

Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing SolutionsAmericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Headquarters for Dodge and Reliance Electric ProductsAmericas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433Europe/Middle East/Africa: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 17741Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 6356-9077, Fax: (65) 6356-9011

1398 ULTRA+ Front CoverImportant User InformationTable of ContentsPrefaceIntroductionWho Should Use this ManualPurpose of this ManualContents of this ManualRelated DocumentationConventions Used in this ManualProduct Receiving and Storage ResponsibilityAllen-Bradley SupportLocal Product SupportTechnical Product AssistanceComments Regarding this Manual

Chapter 1: Mounting the ULTRA Plus PSM-125CChapter ObjectivesProduct OverviewRequired ToolsBefore Mounting Your SystemStoring Your ULTRA PSM-125C Before InstallationUnpacking ModulesSystem Mounting RequirementsVentilation RequirementsSizing an EnclosureTransformer SizingFuse Sizing

Bonding Your SystemBonding ModulesBonding Multiple Subpanels

Mounting Your ULTRA PSM-125C

Chapter 2: ULTRA Plus PSM-125C ConnectionsChapter ObjectivesUnderstanding PSM-125C ConnectorsI/O ConnectionsPSM to Controller Interface LogicStatusEnable

Power ConnectionsAC Input PowerDC Bus Power OutputShunt Terminals

Chapter 3: Wiring Your ULTRA Plus PSM-125CChapter ObjectivesUnderstanding Basic Wiring RequirementsBuilding Your Own CablesRouting High and Low Voltage Cables

Grounding Your ULTRA Plus PSM-125CGrounding Your System to the SubpanelGrounding Multiple Subpanels

Wiring Your ULTRA Plus PSM-125CAC Input PowerDC Bus Output PowerDissipative ShuntPSM Logic InterfaceShield Termination of Power Cables

Chapter 4: Applying Power for the First TimeStart-up Procedure for ULTRA Plus PSM-125CPower Supply Module

Chapter 5: Maintaining and Troubleshooting Your ULTRA Plus PSM-125CChapter ObjectivesDiagnostic Light Emitting Diodes (LED)Maintaining Your PSM-125CReplacing the PSM Shunt Fuse

Appendix A: SpecificationsChapter ObjectivesGeneral PowerPhysical and Environme

Documents

ULTRA Plus Series Power Supply Module Installation Manual · 2011. 1. 12. · ULTRA Plus PSM-125C Connections Provides I/O, power, and shunt connector locations and signal descriptions