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Key Technical Specifications
| Parameter | Value |
|---|---|
| Manufacturer | Reliance Electric |
| Part Number | 45C922 |
| Series | Shark XL PLC rack system |
| Product Type | Rack-mounted AC-to-DC power supply module |
| Input Voltage | 115 V AC or 230 V AC, jumper-selectable |
| Input Frequency | 47–63 Hz |
| Maximum Input Current | 600 mA |
| Logic Output | 5 V DC, 1,700 mA maximum |
| Auxiliary Output | 24 V DC, 500 mA maximum |
| Field/Sensor Output | 24 V DC, 250 mA maximum |
| Rack Interface | Dedicated Shark XL power-supply slot; smallest rack connector position |
| Operating Temperature | 0 to +55 °C / +32 to +131 °F |
| Storage Temperature | −20 to +70 °C / −4 to +158 °F |
| Relative Humidity | 30–90%, non-condensing |
| Product Status | Discontinued / legacy spare part |
The Reliance Electric 45C922 is consistently identified as a Shark XL rack-mounted power supply. Available part-specific sources list jumper-selectable 115/230 V AC input, 47–63 Hz operation, a 600 mA maximum input current, and three outputs: 5 V DC at 1.7 A, 24 V DC at 500 mA, and 24 V DC at 250 mA.
Product Introduction
The Reliance Electric 45C922 is an AC-input power supply module for the Shark XL programmable-controller rack. It converts 115 V AC or 230 V AC line power into regulated 5 V DC and 24 V DC rails used by the controller backplane, logic circuits, rack-mounted I/O, and auxiliary field-side circuits.
The 45C922 matters because a power-rail fault can create random I/O errors, controller resets, loss of communications, or a completely dead rack. It is a dedicated Shark XL power module, not a generic 24 V DC DIN-rail power supply. Match the rack position, supply-voltage jumper setting, load budget, and connector condition before installing a replacement.
Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to This Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| Shark XL rack has no LEDs or controller does not boot | Incoming AC missing, fuse open, module not seated, failed 45C922 | ✅ High | Measure line voltage at the module input terminals; confirm 115 V AC or 230 V AC matches the jumper position | Check upstream disconnect, fuses, and supply selection before replacing the module |
| 5 V DC rail is low or absent | Failed power supply, overloaded rack, shorted CPU/I/O module, damaged backplane | ✅ High | Measure 5 V DC at the rack test point or backplane per the Shark XL documentation; remove nonessential I/O modules one at a time with power isolated | Check for an overloaded or shorted module before installing another 45C922 |
| PLC resets during output switching | 5 V DC droop, poor rack connection, overload, intermittent AC input, aging power supply capacitors | ✅ High | Trend the 5 V DC rail while outputs energize; use an oscilloscope if available to check for voltage sag or ripple | Confirm total rack load and connector condition. Replace the PSU if the rail drops below specification under a valid load |
| 24 V DC sensors or field devices do not operate | Auxiliary 24 V rail overload, shorted sensor, blown external fuse, failed field wiring | ⚠️ Medium | Measure the relevant 24 V DC rail at the module and at the affected field terminal; disconnect field branches to isolate a short | Check field wiring and load current first. The 45C922 may be working normally while an external load pulls the rail down |
| Power module gets hot or has a burnt odor | Overload, blocked ventilation, internal component failure, loose high-resistance terminals | ✅ High | Shut down immediately; inspect terminals and rack connector for discoloration, then measure load current before applying power again | Do not continue operating. Correct load or wiring faults before replacing the module |
| New module fails immediately after replacement | Incorrect 115/230 V jumper selection, output short, reversed wiring, damaged rack backplane | ✅ High | With power isolated, verify jumper setting against measured line voltage; check resistance from output rails to return and inspect backplane contacts | Photograph and duplicate jumper setting before removal. Never guess the line-voltage setting |
| PLC works with a lightly loaded rack but fails when expanded | Total 5 V or 24 V current exceeds module limits | ✅ High | Calculate loads: 5 V DC maximum 1.7 A; 24 V DC channels maximum 500 mA and 250 mA; compare against installed module and field-device consumption | Keep a practical 20% current margin. Add external field power or reduce load if the budget is exceeded |
| Replacement module does not seat correctly | Wrong Shark XL supply variant, connector damage, incorrect rack position | ✅ High | Compare module keying, connector face, latch position, and rack slot with the removed part | Do not force the module. Confirm it is an exact 45C922 Shark XL power supply |
| Output voltage is correct but I/O remains dead | Failed CPU, failed I/O module, broken backplane, disabled controller, configuration fault | ❌ Low | Verify the 5 V and both 24 V rails, then check CPU status LEDs and individual I/O-module indicators | Do not replace the PSU again until the controller and backplane are diagnosed |
❗ The 45C922 has a jumper-selectable 115/230 V AC input. This is the installation trap that causes the most expensive failures. Take a clear photo of the old unit’s jumper position before removal, measure the incoming line voltage with a properly rated meter, and set the replacement to match before applying power. Never assume all panels use the same supply voltage.
If you need help, provide photos of the front label, jumper area, rack connector, and incoming-power wiring. Include measured AC input, 5 V DC output, both 24 V DC outputs, the installed rack module count, and all Shark XL CPU diagnostic LEDs.
45C922
45C922
Frequently Asked Questions
What is the Reliance Electric 45C922?
The Reliance Electric 45C922 is a rack-mounted AC-to-DC power supply module for the Shark XL PLC platform. It supplies three regulated rails: 5 V DC for logic and backplane loads, plus two 24 V DC outputs for auxiliary and field-side loads.
Does the 45C922 accept 115 V AC or 230 V AC?
It accepts either 115 V AC or 230 V AC, but the input must be selected with the module’s jumper. Verify the actual incoming line voltage and copy the original jumper setting before energizing the replacement. An incorrect selection can prevent startup or damage the power supply.
What output current can the 45C922 supply?
The published output limits are 5 V DC at 1.7 A maximum, 24 V DC at 500 mA maximum, and a second 24 V DC output at 250 mA maximum. Do not combine the two 24 V ratings unless the Shark XL documentation specifically permits it. Calculate the actual rack and field-device load and retain at least a 20% margin.
Is the 45C922 interchangeable with the 45C920 or 45C921?
No, do not treat them as automatic substitutes. The 45C922 is described as a jumper-selectable 115/230 V AC module. The 45C921 is a 24 V DC input supply, so it needs a completely different incoming power source. The 45C920 and 45C922 are separate part numbers with potentially different input-selection and output characteristics. Compare the original rack BOM, supply input requirements, output ratings, and connector details before substituting.
Can I hot-swap a 45C922 power supply?
No. The Shark XL rack and its legacy power module should be de-energized before removal. Shut down the panel under lockout/tagout, verify the incoming AC supply is isolated, and wait for stored energy to discharge before handling the module or rack connector. Removing a power supply under load can arc contacts and cause a controller reset or backplane damage.
Why does the replacement module still not power the rack?
First verify the 115/230 V jumper position, the incoming line voltage, upstream fuses, terminal tightness, rack connector condition, and backplane integrity. Then isolate downstream loads. A shorted I/O card, a failed CPU, an external 24 V field short, or a damaged backplane can pull the supply down and make a good 45C922 appear defective.
Is the 45C922 obsolete, and should I keep a spare?
Yes. The Shark XL platform and the 45C922 are legacy products, with supply typically limited to New Surplus, used, refurbished, or repair-channel inventory. If the rack supports production-critical equipment, keep at least one correctly verified spare and retain a photo record of its input jumper setting and the rack’s power-load calculation.
What condition and testing should I request before purchase?
For New Original / New Surplus stock, request exact label photos, evidence of clean terminals and rack connector contacts, jumper-position photos, storage-condition review, and a written condition statement. For Refurbished stock, request bench testing at both supported input settings where the design permits, documented 5 V and 24 V output measurements under representative loads, ripple measurement, thermal run testing, protective-function checks, and final QC sign-off.
