Elmo PSS 3U, PSS 6U User Manual

PSS

User Guide

PSS 3U PSS 6U

November 2006

Important Notice

This guide is delivered subject to the following conditions and restrictions:

 This guide contains proprietary information belonging to Elmo Motion Control Ltd.

Such information is supplied solely for the purpose of assisting users of the PSS and
PSSF series of power supplies.

 The text and graphics included in this manual are for the purpose of illustration and

reference only. The specifications on which they are based are subject to change
without notice.

 Information in this document is subject to change without notice.

Doc. No. MAN-

Copyright © 2003~2006

Elmo Motion Control

All rights reserved

Product Catalog No:

PSS F - 20 / 200 R

Power Supply

Shunt Regulator

Fan Cooling Required

Rated Current

-

Mounting:
R = Rack
H = Horizontal Panel

Output Voltage

Revision History:

Ver. 3.02 Nov 2006 Changes to diagrams in Ch. 2 (MAN-PSSUG.PDF)

Ver. 3.01 March 2005 Non-Isolated AC Supplies eliminated (

MAN-PSSUG.PDF)

Ver. 3.0 April 2003 (PSSUG0403.PDF)
Ver. 2.0 January 1998
Ver. 1.0 October 1993 Initial Release

Elmo Motion Control Inc.

1 Park Drive, Suite 12
Westford, MA 01886
USA
Tel: [phone]
Fax: [phone]

[e-mail]

Elmo Motion Control GmbH

Steinkirchring 1
D-78056, Villingen-Schwenningen
Germany
Tel: [phone]
Fax: [phone]

[e-mail]

PSSUG

www.elmomc.com

Elmo PSS User Guide

MAN-PSSUG (Ver. 3.01)

Contents

Chapter 1: Safety Information............................................................................................... 1-1

1.1 Warnings......................................................................................................................... 1-1

1.2 Cautions.......................................................................................................................... 1-2

1.3 Warranty Information ................................................................................................... 1-2

Chapter 2: Product Description............................................................................................. 2-1

2.1 Standard Features.......................................................................................................... 2-1

2.2 Fault Protection.............................................................................................................. 2-2

2.3 Block Diagram................................................................................................................ 2-3

2.4 Technical Specifications ................................................................................................ 2-3

2.4.1 PSS Power Supplies with Shunt Regulators ..................................................... 2-3

2.4.2 Shunt Regulator Specifications .......................................................................... 2-3

2.5 Dimensional Drawings.................................................................................................. 2-4

2.5.1 PS1 (for PSSF-20/100 and PSSF-20/200)........................................................... 2-5

2.5.2 PS2 (for PSS-15/100 and PSS-12/200) ............................................................... 2-6

2.5.3 PS3 (for PSS-30/200 and PSSF-60/200*)............................................................ 2-7

2.5.4 Rack Mount .......................................................................................................... 2-8

Chapter 3: Installation............................................................................................................ 3-1

3.1 Unpacking the System Components............................................................................ 3-1

3.2 Mounting and Wiring the PSS...................................................................................... 3-1

3.2.1 Wiring Guidelines ...............................................................................................3-1

3.2.2 AC Power Supplies.............................................................................................. 3-1

3.2.3 Wiring Diagrams ................................................................................................. 3-2

3.3 Startup Procedures ........................................................................................................ 3-3

3.3.1 Switching from Single-phase to Three-phase (3U only)................................. 3-3

3.3.2 Capacitor Reforming........................................................................................... 3-4

3.3.3 LED Diagnostics ..................................................................................................3-4

Elmo PSS User Guide

MAN-PSSUG (Ver. 3.01)

Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the PSS power supply, it is imperative
that you implement the safety procedures included in this user guide. This information is
provided to protect you and to keep your work area safe when operating the PSS and
accompanying equipment. Read this chapter carefully before you begin the installation
process.

Only qualified personnel may install, adjust, maintain and repair the power supply. A
“qualified person” has the knowledge and authorization to perform tasks such as
transporting, assembling, installing, commissioning and operating motors.

The PSS power supply contains electrostatic-sensitive components that can be damaged if
handled incorrectly. To prevent any electrostatic damage, avoid contact with highly
insulating materials, such as plastic film and synthetic fabrics. Place the product on a
conductive surface and ground yourself in order to discharge any possible static
electricity build-up.

1-1

To avoid any potential hazards that may cause severe personal injury or damage to the
product during operation, keep all covers and cabinet doors shut.

The following safety symbols are used in this manual:

Warning:
This information is needed to avoid a safety hazard, which might cause
bodily injury.

Caution:
This information is necessary for preventing damage to the product or to
other equipment.

Note:

This is auxiliary information that ensures the correct operation of the
equipment.

1.1 Warnings

To avoid electric arcing and hazards to personnel and electrical contacts,
never connect/disconnect the power supply while the power source is on.

Power cables can carry a high voltage, even when the motor is not in
motion. Disconnect the PSS from all voltage sources before it is
disassembled for servicing.

After shutting off the power and removing the power source from your
equipment, wait at least 5 minutes before touching or disconnecting parts
of the equipment that are normally loaded with electrical charges (such as
capacitors or contacts). Measuring the electrical contact points with a
meter before touching the equipment is recommended.

Elmo PSS User Guide Safety Information

MAN-PSSUG (Ver. 3.01)

1.2 Cautions

The PSS contains hot surfaces and electrically-charged components during
operation.

The maximum AC power supply connected to the instrument must comply
with the parameters outlined in this guide.

1.3 Warranty Information

The products covered in this manual are warranted to be free of defects in material and
workmanship and conform to the specifications stated either within this document or in
the product catalog description. All Elmo products are warranted for a period of 12
months from the time of installation, or 18 months from time of shipment, whichever
comes first. No other warranties, expressed or implied — and including a warranty of
merchantability and fitness for a particular purpose — extend beyond this warranty.

1-2

Elmo PSS User Guide

MAN-PSSUG (Ver. 3.01)

Chapter 2: Product Description

The PSS and PSSF power supplies were designed to complement Elmo servo amplifiers
that do not include an integrated power supply. All PSS/PSSF models include shunt
regulators and feature high capacitance, a low profile and snap-in capacitors. The PSSF
supply requires fan cooling. The power supplies are built around two basic sizes: Eurocard
(3U) and double Eurocard (6U). Two mounting versions are available:

 Surface mount version - has 4 thru-holes for screw assembly

 Panel mount version - connects to 19-inch rack with drop-on slots and connects electrically

via DIN 41612 backplane connectors

All Eurocard (3U) power supplies are shipped for single-phase connections, although they
include a built-in three-phase option. The shunt regulator, included with the PSS and PSSF
supply, is designed for use with high-inertia loads. These supplies incorporate thermal and
duty-cycle protections.

2-1

2.1 Standard Features

The following tables list the features of the PSS, in both Horizontal and Rack mount
version. Table
sizes.

Term.
Block

connector

0 14a, 14c

1 18a, 18c

2 22a, 22c

3 26a, 26c

4 30a, 30c

2-1 covers the Eurocard (3U) and Table 2-1 covers the double Eurocard (6U)

32-pin

16a, 16c

20a, 20c

24a, 24c

28a, 28c

32a, 32c

Function Comment

AC-1 supply input (through
an isolated/floating
transformer)

In single-phase connections (of PSS type 3U),
this terminal is internally shorted to terminal
1 by W2. The power supply is modified for
three-phase connections by removing W2
and connecting the third phase to terminal 1.

AC-3 supply input (through
an isolated/floating

For DIN mounting, all four pins must be
connected.

transformer)

DC Power output return
(PR)

DC Positive power output
(VP+)

AC-2 supply input (through
an isolated/floating

For DIN mounting, all four pins must be
connected.

For DIN mounting, all four pins must be
connected.

For DIN mounting, all four pins must be
connected.

transformer)

5* 6a, 4c Inhibit indication return Internally connected to power output common.

6* 4a Inhibit indication output Whenever power supply is inhibited (e.g.

during thermal/duty cycle), this open
collector output goes into low state
(maximum sink current: 10 mA, 30 VDC).

Table 2-1: PSS Terminal Description: 3U Power Supplies

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2-2

Term.
Block

32-pin

connector

Function Comment

1 12 - 22 (J2) Power output return (PR) For DIN mounting, all six pins must be

connected.

2 24 - 32 (J1) AC-1 supply input (through

an isolated/floating

For DIN mounting, all five pins must
be connected.

transformer)

3 14 - 22 (J1) AC-2 supply input (through

an isolated/floating

For DIN mounting, all five pins must
be connected.

transformer)

4 4 - 12 (J1) AC-3 supply input (through

an isolated/floating

For DIN mounting, all five pins must
be connected.

transformer)

5 24 - 32 (J2) Positive power output (VP+) For DIN mounting, all five pins must

be connected.

6* 4 (J2) Inhibit indication output Whenever power supply is inhibited

(e.g. during thermal/duty cycle), this
open collector output goes into low
state (maximum sink current: 10 mA,
30 VDC).

7** 8 (J2) Fan supply 24 VDC/0.5 A output for an external

brushless fan. Common is available in
terminal 1

Table 2-2: PSS Terminal Description: 6U Power Supplies

* Inhibit indication return is available in terminal 1.
** Available for 60A types only.

2.2 Fault Protection

All PSS products include the following protective functions, which activate the internal
inhibit:

 Over-temperature

Inhibits shunt when heatsink temperature exceeds 90 °C (194 °F).

 Duty cycle

Inhibits shunt whenever On and Off time exceeds 5% to 10% (depending on PSS model).
This feature protects the shunt regulator when high-inertia loads are driven by the servo
amplifier(s) or when too high an AC voltage is applied to the power supply (i.e. DC
output is already above the threshold of the shunt).

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2.3 Block Diagram

Figure 2-1: PSS Block Diagram

2.4 Technical Specifications

2-3

2.4.1 PSS Power Supplies with Shunt Regulators

Feature

Minimum AC supply VAC 14 14 42 42 3 x 42 3 x 42

Maximum AC supply VAC 65 65 135 135 135 135

Minimum DC output VDC 20 20 60 60 60 60

Maximum DC output ± 1% VDC 92 92 191 191 191 191

Continuous current A 15 20 12 20 30 60

Peak current A 40 40 40 40 60 100

Panel size (see section 2.6) PS2 PS1 PS2 PS1 PS3 PS3

Rack size 3U/21T 3U/12T 3U/21T 3U/12T 6U/21T 6U/21T

Weight Kg 1.4 0.7 1.4 0.7 3.0 3.5

Unit

PSS­15/100

PSSF­20/100

PSS­12/200

PSSF­20/200

PSS­30/200

PSSF­60/200

2.4.2 Shunt Regulator Specifications

Feature

Unit

PSS­15/100

PSSF­20/100

PSS­12/200

PSSF­20/200

PSS­30/200

PSSF­60/200

Regulation voltage* ± 1% VDC 92 92 191 191 191 191

Continuous shunt power W 70 100 70 100 200 500**

Shunt current A 50 50 15 15 50 80

* The regulating voltage (Vr) is the voltage at which the shunt regulator is activated.
** Fan cooling rating

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2.5 Dimensional Drawings

There are four basic sizes of the PSS/PSSF models:

 Panel mount PS1, for 3U/12T size

 Panel mount PS2, for 3U/21T size

 Panel mount PS3, for 6U/21T size

 Rack mount

The following sections provide dimensions of the four basic sizes. All dimensions are
given in millimeters.

2-4

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2.5.1 PS1 (for PSSF-20/100 and PSSF-20/200)

2-5

Figure 2-2: PS1 - Top View

Figure 2-3: PS1 - Side View, Length

Figure 2-4: PS1 - Side View, Width

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2.5.2 PS2 (for PSS-15/100 and PSS-12/200)

182

16

70

2-6

Figure 2-5: PS2 - Top View

200

Figure 2-6: PS2 - Side View, Length

4433221100 56

109

Figure 2-7: PS2 - Side View, Width

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2.5.3 PS3 (for PSS-30/200 and PSSF-60/200*)

* Model PSSF-60/200 includes an integrated fan.

217.35

217.35

182

182

2-7

2

3

4

3

4

3

4

16

16

16

Figure

2

2

2-8: PS3 - Top View

200

Figure 2-9: PS3 - Side View, Length

5

5

5

5

111

5

111

5

111

242.35

Figure 2-10: PS3 - Side View, Width

Elmo PSS User Guide Product Description

MAN-PSSUG (Ver. 3.01)

2.5.4 Rack Mount

4 x M3

60.76

7.64

162.54

Figure 2-11: PSS Rack Mount (3U/12T): Side View, Length

1.6

15.64

2-8

43.84

111.76

C

32

128.7

2

A

Figure 2-12: PSS Rack Mount (3U/12T): Side View, Width

Note:

Rack Mount versions of other models are available upon request.

25.0

7.64

60.76

1.6

8

Elmo PSS User Guide

MAN-PSSUG (Ver. 3.01)

Chapter 3: Installation

3.1 Unpacking the System Components

To unpack the PSS:

Carefully remove the power supply from the box and the Styrofoam.

1. Check the supply to ensure that there is no visible damage to the instrument. If any
damage has occurred, report immediately to the carrier that delivered your product.

2. To ensure that the PSS you have unpacked is the appropriate type for your
requirements, find the part number sticker on the side of the supply:

3-1

The P/N number in the middle gives the type designation as follows:

Fan Cooling Required

3. Verify that the PSS model is the one that you ordered, and ensure that the voltage
meets your specific requirements.

ELMO

PSSF-20/200H

S/N:PSS2055016

Power Supply

Shunt Regulator

Rated Current

PSS F - 20 / 200 R

-

Output Voltage

Mounting:
R = Rack
H = Horizontal Panel

3.2 Mounting and Wiring the PSS

For optimum heat dissipation, the power supply should be installed with the heatsink
fins in the vertical direction.

3.2.1 Wiring Guidelines

1. Use flexible wires with the proper cross-section to handle the unit current. Color
coding is recommended.

2. After wiring is completed, carefully inspect all conditions in order to ensure
tightness.

3.2.2 AC Power Supplies

The PSS power supplies do not include inrush current control. Therefore, they

should be connected to an isolating/floating transformer.

Elmo PSS User Guide Installation

MAN-PSSUG (Ver. 3.01)

The AC power supply can be of any voltage in the range defined in the technical
specifications (section 2.4). It must be able to deliver power to the amplifiers (including
peak power), without significant drops. A three-phase supply is always recommended
whenever possible, in order to provide better DC bus voltage stability (low voltage
ripple) under high load conditions.

The recommended AC voltage is:

1.2 x VAC (min) < VAC < 0.9 x VAC (max)

With a single-phase supply, a voltage drop due to loading is expected. The

magnitude of the voltage drop depends on the load current, stiffness of the power
source and the total bus capacitance.

3.2.3 Wiring Diagrams

3.2.3.1 Isolated AC Supplies

3-2

Isolating transformer

Figure 3-1: Isolated PSS Wiring

Ground the DC power common.

Fuse
Fuse
Fuse

AC
AC
AC
+Vs

PSS

DC power common

Heatsink

Elmo PSS User Guide Installation

MAN-PSSUG (Ver. 3.01)

3.2.3.2 Wiring Two or More Supplies in Parallel

3-3

Fuse
Fuse

Fuse

To additional
PSS

Figure 3-2: Parallel PSS Wiring

AC
AC
AC

DC power common

Heatsink

AC
AC
AC

DC power common

Heatsink

PSS

+Vs

PSS

+Vs

TO ADDITIONAL
POWER SUPPLIES

TO AMPLIFIERS

All wiring guidelines for supply connections described previously apply to multiple-PSS
connections.

3.3 Startup Procedures

3.3.1 Switching from Single-phase to Three-phase

(3U only)

Modifying the power supply to a three-phase connection is accomplished by removing
W2 and connecting the third phase to terminal 1.

Terminal Phase

0 AC-1

1 AC-2

Figure 3-3: Converting a Single-phase Connection to a Three-phase Connection

4 AC-3

Elmo PSS User Guide Installation

MAN-PSSUG (Ver. 3.01)

3.3.2 Capacitor Reforming

All PSS power supplies undergo capacitor reforming prior to shipment to the

customer. However, if the power supply has been idle (at the customer site) for a
period of nine months or more, the capacitors must be reformed before startup.

To perform capacitor reforming:

1. Connect a 25-VAC supply at the AC input terminals and a 100-W/220-V (or

50W/110-VAC) light bulb at the power output terminals.

2. Run the power supply for an hour and then increase the voltage to 50 VAC for an

additional hour.

3. For higher-voltage types, run the supply for another hour at 100 VAC.

Noncompliance with these instructions may result in capacitor failure.

3.3.3 LED Diagnostics

3-4

The following LEDs are mounted on the PSS:

LED Indication

L1 (Vs) Existence of internal supply.

L2 (SO) Shunt is on.

L3 (In) Shunt is inhibited.