Rockwell Automation 1606-XLE240F-3 User Manual

Download

Reference Manual

egaP egaP

Intended Use .......................................................3

2. Installation Requirements...................................3

3. AC-Input...............................................................4

4. DC-Input...............................................................5

5. Input Inrush Current ...........................................5

6. Output .................................................................6

7. Hold-up Time.......................................................7

8. Efciency and Power Losses................................8

9. Functional Diagram.............................................9

10. Front Side and User Elements.............................9

11. Terminals and Wiring........................................10

12. Reliability ...........................................................10

13. EMC ....................................................................11

14. Environment ......................................................12

15. Protection Features ...........................................13

16. Safety Features ..................................................13

17. Dielectric Strength ............................................13

18. Certications .....................................................14

19.

Environmental Compliance ............................. 14

20. Physical Dimensions and Weight ..................... 15

21. Accessories ........................................................ 16

22. Application Notes ............................................. 17

22.1. Peak Current Capability ...........................17

22.2. Back-feeding Loads ..................................17

22.3. Charging Batteries ...............................18

22.4. Output Circuit Breakers ............................18

22.5. External Input Protection .........................19

22.6. Using only 2 Legs of a 3-Phase System ....19

22.7. Inductive and Capacitive Loads ................20

22.8. Parallel Use to Increase Output Power ....20

22.9. Parallel Use for Redundancy ....................20

22.10. Daisy Chaining of Outputs .......................21

22.11. Series Operation .......................................21

22.12. Use in a Tightly Sealed Enclosure ............ 21

22.13. Mounting Orientations ............................22

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLE240F-3

Index

Terminology and Abbreviations

•PE and symbol—PE is the abbreviation for Protective Earth and has the same meaning as the symbol .

•Earth, Ground—This document uses the term “earth” which is the same as the U.S. term “ground”.

• T.b.d.—To be defined, value or description will follow later.

• AC 230V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)

included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)

• 230Vac—A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.

• 50Hz vs. 60Hz—As long as not otherwise stated, AC100V and AC230V parameters are valid at 50Hz and AC120V parameters are valid at 60Hz

mains frequency.

•may—A key word indicating flexibility of choice with no implied preference.

•shall—A key word indicating a mandatory requirement.

•should—A key word indicating flexibility of choice with a strongly preferred implementation.

Bulletin 1606 Switched Mode Power Supplies

Power Supply

3AC 380-480V Wide-range Input 2 or 3-Phase Operation Possible Width only 62mm Efciency up to 92.9% Excellent Partial Load Efciency 20% Output Power Reserves Easy fuse tripping Due to High Overload Current Input -Transient Blanking Circuit Included Minimal Inrush Current Surge Three Input Fuses Included Current Sharing Feature for Parallel Use Full Power Between -25°C and +60°C 3 Year Warranty

Description

Our power supplies are cost- optimized without compromising quality, reliability or performance. The most outstanding features of our 1606-XLE240F-3 power supply are its high efciency, electronic inrush current limitation, active input transient lter and wide operational temperature range.

The 1606-XLE240F-3 includes all the essential basic functions. It includes a power reserve of 20% that can be used continuously at temperatures up to +45° C. In addition, the 1606-XLE240F-3 is able to deliver three times the nominal output current for 10ms which helps to trip fuses on faulty output branches.

Specication Quick Reference

Output voltage DC 48V Adjustment range 48-56V Output current 5 – 4.3A ambient <60°C 6 – 5.2A ambient <45°C Output power 240W ambient <60°C 288W ambient <45°C Output ripple < 100mVpp 20Hz to 20MHz Input voltage AC 380-480V -15%/+20% Mains frequency 50-60Hz ±6% AC Input current 0.7 / 0.6A at 3x400 / 480Vac Power factor 0.53 / 0.52 at 3x400 / 480Vac AC Inrush current typ. 4A peak Efciency 92.8 / 92.9% at 3x400 / 480Vac Losses 18.6 / 18.3W at 3x400 / 480Vac Temperature range -25°C to +70°C operational Derating 6W/°C +60 to +70°C Hold-up time typ. 34 / 54ms at 3x400 / 480Vac Dimensions 62x124x117mm WxHxD

Catalog Numbers

Power Supply 1606-XLE240F-3 48-56V Standard unit

Accessory 1606-XLB Wall mount bracket

1606-XLERED Decoupling module 1606-XLSBUFFER48 Buffer unit

Certication Marks

IND. CONT. EQ.

UL 508

UL 60950-1

Marine

EMC, LVD

Marine RINA

GOST R

C-Tick

2 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

1. Intended Use

• This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office, communication, and instrumentation equipment.

• Do not use this power supply in aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or threaten human life.

• This device is designed for use in non-hazardous, ordinary or unclassified locations.

2. Installation Requirements

• This device may only be installed and put into operation by qualified personnel.

• This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.

• If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.

• Mount the unit on a DIN rail so that the terminals are located on the bottom of the unit. For other mounting orientations, refer to derating

requirements in the present document.

• This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid (e.g. cable conduits) by more than 30%!

• Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat source (e.g. another power supply).

SHOCK HAZARD: Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input

block for earth connection and not one of the screws on the housing.

- Turn power off before working on the device. Protect against inadvertent re-powering

- Make sure that the wiring is correct by following all local and national codes

- Do not modify or repair the unit

- Do not open the unit as high voltages are present inside

- Use caution to prevent any foreign objects from entering the housing

- Do not use in wet locations or in areas where moisture or condensation can be expected

- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.

WARNING: EXPLOSION HAZARDS!

Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment or S/P jumper unless power has been switched off or the area is known to be non-hazardous.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 3

Bulletin 1606 Switched Mode Power Supplies

3. AC Input

AC input nom. 3AC 380-480V TN, TT, IT-mains networks,

grounding of one phase is allowed except for UL508

applications AC input range 3x 323-576Vac continuous operation 3x 576-700Vac for max. 1 second, occasional (not periodical) 3x 200-323Vac full power for 200ms, no damage between 0 and 200Vac Allowed Voltage Phase to Earth 500Vac IEC 62103 Input frequency nom. 50–60Hz ±6% Turn-on voltage typ. 3x 260Vac steady-state value, see Fig. 3-1 Shut-down voltage typ. 3x 185Vac steady-state value, see Fig. 3-1

3AC 400V 3AC 480V

Input current typ. 0.7A 0.6A at 48V, 5A, symmetrical phase voltage,

see Fig. 3-3 Power factor *) typ. 0.53 0.52 at 48V, 5A, see Fig. 3-4 Start-up delay typ. 90ms 90ms see Fig. 3-2 Rise time typ. 55ms 55ms 0mF, 48V, 5A, see Fig. 3-2 typ. 140ms 140ms 5mF, 48V, 5A, see Fig. 3-2 Turn-on overshoot max. 300mV 300mV see Fig. 3-2

*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.

Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, denitions

Turn-on

323V

Rated input

range

OUT

185V 576V

Shut-down

260V 3x700Vac

< 1s

Start-up

delay

Rise

Time

Overshoot

- 5%

Output Voltage

Input Voltage

Fig. 3-3 Input current vs. output load at 24V Fig. 3-4 Power factor vs. output load

0.1

0.2

0.4

0.5

0.6

0.8A

Input Current, typ.

Output Current

0.3

0.7

0.35

0.40

0.45

0.50

0.55

Power Factor, typ.

Output Current

3x480Vac

3x400Vac

4 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

4. DC Input

DC input nom.

DC 600V

DC input range 450-780Vdc continuous operation Allowed Voltage Line to Earth max. 820Vdc IEC 62103 DC input current typ. 0.58A / 0.34A 450Vdc / 780Vdc, at 48V, 5A Turn-on voltage typ. 370Vdc steady state value Shut-down voltage typ. 260Vdc steady state value

Fig. 4-1 Wiring for DC Input

Instructions for DC use:

Load

Power Supply

Battery

FUSE

a) Use a battery or similar DC source.

For other sources, contact Rockwell Automation. b) Connect +pole to L1 and –pole to L2. c) Terminal L3 remains unused, terminal screw of L3 must be

securely tightened. d) Use appropriate external fuses in the + and – lines which

are suitable for the DC voltage. e) Connect the PE terminal to a earth wire or to the machine

ground. f) DC operation is not included in the UL approval.

Additional testing might be necessary.

5. Input Inrush Current

An active inrush limitation circuit limits the input inrush current after turn-on of the input voltage and after short input voltage interruptions.

The charging current into EMI suppression capacitors is disregarded in the rst microseconds after switch-on.

3AC 400V 3AC 480V

Inrush current max. 10A

peak

10A

peak

-25°C to +70°C

typ. 4A

peak

-25°C to +70°C

Inrush energy max. 0.5A

s 0.5A2s -25°C to +70°C

Fig. 5-1 Input inrush current, typical behavior

Output Voltage

Input Voltage

Input Current

20ms / DIV

Input: 3x 400Vac Output: 48V, 5A Ambient: 25°C Upper curve: Input current 1A / DIV Middle curve: Input voltage 500V / DIV Lower curve: Output voltage 20V / DIV Time basis: 20ms / DIV

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 5

Bulletin 1606 Switched Mode Power Supplies

6. Output

Output voltage nom. 48V Adjustment range min. 48-56V guaranteed max. 60V at clockwise end position of potentiometer Factory setting typ. 48.0V ±0.2%, at full load, cold unit, in “single use” mode typ. 46.0V ±0.2%, at full load, cold unit, in “parallel use” mode typ. 48.0V at no load, cold unit, in “parallel use” mode Line regulation max. 10mV 3x 323-576Vac Load regulation max. 100mV in “single use” mode: static value, 0A 5A

typ. 2000mV in “parallel use” mode: static value, 0A

5A, see Fig.

6-2 Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm Output capacitance typ. 2 400μF Output current nom. 6A at 48V, ambient < 45°C, see Fig. 6-1 nom. 5A at 48V, ambient < 60°C, see Fig. 6-1 nom. 5.2A at 56V, ambient < 45°C, see Fig. 6-1 nom. 4.3A at 56V, ambient < 60°C, see Fig. 6-1 Output power nom. 288W ambient < 45°C nom. 240W ambient < 60°C Short-circuit current min. 9.5A continuous, load impedance 200mOhm, see Fig. 6-1 max. 11.5A continuous, load impedance 200mOhm, see Fig. 6-1 min. 14A <20ms, load impedance 200mOhm, see Fig. 6-1

max. 16A <20ms, load impedance 200mOhm, see Fig. 6-1

discharge current of output capacitors not included

Fig. 6-1 Output voltage vs. output current,

typ.

Fig. 6-2 Output voltage in “parallel use”

mode, typ.

Output Voltage

(Single Use, typ.)

04 10

56V

1462 8 12 16

Adjustment

Range

Output Current

Extra current for 20ms

Continuous

current

Output Voltage

(Parallel Use, typ.)

42V

024

44V

46V

48V

56V

50V

52V

54V

6A531

Adjustment

Range

Factory

setting

Output Current

Peak current capability (up to several milliseconds)

The power supply can deliver a peak current which is higher than the specied short term current. This helps to start current demanding loads or to safely operate subsequent circuit breakers.

The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be discharged and causes a voltage dip on the output. Detailed curves can be found in section 23.1.

Peak current voltage dips typ. from 48V to 34V at 10A for 50ms, resistive load typ. from 48V to 35V at 25A for 2ms, resistive load typ. from 48V to 28V at 25A for 5ms, resistive load

6 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time

3AC 400V 3AC 480V Hold-up Time typ. 34ms 54ms at 48V, 5A, see Fig. 7-1 typ. 68ms 108ms at 48V, 2.5A, see Fig. 7-1

Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, denitions

Hold-up Time at 48Vdc

100ms

320 360 400 440 3x480Vac

Input Voltage

Output Voltage

L1 L2 L3

Hold-up

Time

- 5%

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 7

Bulletin 1606 Switched Mode Power Supplies

8. Efciency and Power Losses

3AC 400V 3AC 480V

Efciency typ. 92.8% 92.9% at 48V, 5A, 3-phase operation

typ. 92.4% 92.6% at 48V, 5A, when using only two legs of a 3-

phase system, see also section 23.6.

Average efciency *) typ. 92.0% 91.7% 25% at 1.25A, 25% at 2.5A, 25% at 3.75A.

25% at 5A, 3-phase operation Power losses typ. 2.3W 2.6W at 0A, 3-phase operation typ. 18.6W 18.3W at 48V, 5A, 3-phase operation typ. 23.5W 22.8W at 48V, 6A, 3-phase operation

*) The average efciency is an assumption for a typical application where the power supply is loaded with 25% of the nominal load for 25%

of the time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of the time and with 100% of the nominal load for the rest of the time.

Fig. 8-1 Efciency vs. output current at 48V,

typ., 3-phase operation

Fig. 8-2 Losses vs. output current at 48V,

typ., 3-phase operation

Efciency

94%

245

Output Current

3x400Vac

3x480Vac

Power Losses

012 456A

24W

3x480Vac

3x400Vac

Output Current

Fig. 8-3 Efciency vs. input voltage at 48V,

5A, typ., 3-phase operation

Fig. 8-4 Losses vs. input voltage at 48V, 5A,

typ., 3-phase operation

Efciency

320 360 400 440 480

94%

91.5

92.5

93.5

93.0

92.0

91.0 520 560

Input Voltage Vac, 3-Phase

Power Losses

320 360 400 440 480

24W

520 560

Input Voltage Vac, 3-Phase

8 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

9. Functional Diagram

Fig. 9-1 Functional diagram

OUT

Output

Over-

Voltage

Protection

PFC

Inductor

Inrush

Limiter

Transient

Filter

Input Fuses

Input Filter

Input Rectier

Output

Voltage

Regulator

Power

Converter

Output

Filter

Output

Power

Manager

Temper-

ature

Shut-

down

DC-ok LED

L2 L3

Single / Parallel

10. Front Side and User Elements

Output Terminals Screw terminals, dual terminals per pole + Positive output

- Negative (return) output

Input Terminals Screw terminals L1, L2, L3 Phase input

PE (Protective Earth) input

Output voltage potentiometer Open the ap to set the output voltage. Factory set: 48.0V

“Parallel Use” “Single Use” selector

Set jumper to “Parallel Use” when power supplies are connected in parallel to increase the output power. In order to achieve a sharing of the load current between the individual power supplies, the “parallel use” regulates the output voltage in such a manner that the voltage at no load is approx. 5% higher than at nominal load. See also Fig. 6-2. A missing jumper is equal to a “Single Use” mode. Factory setting is “Single Use” mode.

DC-OK LED (green) On when the voltage on the output terminals is > 36V

Fig. 10-1 Front side

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 9

Bulletin 1606 Switched Mode Power Supplies

11. Terminals and Wiring

Input Output

Type

screw terminals screw terminals Solid wire 0.5-6mm2 0.5-6mm2 Stranded wire 0.5-4mm2 0.5-4mm2 American Wire Gauge 20-10 AWG 20-10 AWG Wire stripping length 7mm / 0.275inch 7mm / 0.275inch Screwdriver 3.5mm slotted or Pozidrive No 2 3.5mm slotted or Pozidrive No 2 Recommended tightening torque 0.8Nm, 7lb.in 0.8Nm, 7lb.in

Instructions:

a) Use appropriate copper cables that are designed for an operating temperature of:

60°C for ambient up to 45°C and 75°C for ambient up to 60°C minimum.

b) Follow

national installation codes and installation regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Up to two stranded wires with the same cross section are permitted in one connection point (except PE wire). e) Do not use the unit without PE connection. f) Screws of unused terminal compartments should be securely tightened. g) Ferrules are allowed, but not required.

12. Reliability

3-Phase operation 3AC 400V 3AC 480V Lifetime expectancy

*) 122 000h 126 000h at 48V, 5A and 40°C

249 000h 226 000h at 48V, 2.5A and 40°C 78 000h 88 000h at 48V, 6A and 40°C 345 000h 355 000h at 48V, 5A and 25°C MTBF

**) SN 29500, IEC 61709 1 051 000h 1 048 000h at 48V, 5A and 40°C

1 805 000h 1 799 000h at 48V, 5A and 25°C MTBF

**) MIL HDBK 217F 438 000h 424 000h at 48V, 5A and 40°C; Ground Benign GB40

585 000h 568 000h at 48V, 5A and 25°C; Ground Benign GB25

Operation on only 2 legs of the three phase system 2AC 400V 2AC 480V

Lifetime expectancy

*) 114 000h 120 000h at 48V, 5A and 40°C

253 000h 234 000h at 48V, 2.5A and 40°C 76 000h 81 000h at 48V, 6A and 40°C 322 000h 341 000h at 48V, 5A and 25°C MTBF

**) SN 29500, IEC 61709 1 019 000h 1 023 000h at 48V, 5A and 40°C

1 765 000h 1 771 000h at 48V, 5A and 25°C MTBF

**) MIL HDBK 217F 437 000h 425 000h at 48V, 5A and 40°C; Ground Benign GB40

584 000h 569 000h at 48V, 5A and 25°C; Ground Benign GB25

*) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime

expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specied in operational hours and is calculated according to the capacitor’s manufacturer specication. The prediction model allows only a calculation of up to 15 years from date of shipment.

**) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a

device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.

10 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

13. EMC

The power supply is suitable for applications in industrial environment as well as in residential, commercial and light industry environment without any restrictions. The CE Mark indicates conformance with EMC guideline 89/336/EC, 93/68/EC and 2004/108/EC and the low-voltage directive (LVD) 73/23/EC and 2006/95/EC. A detailed EMC report is available on request.

EMC Immunity

Electrostatic discharge EN 61000-4-2 Contact discharge

Electromagnetic RF eld EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A Fast transients (Burst) EN 61000-4-4 Input lines

Surge voltage on input EN 61000-4-5 L1 L2, L2 L3,

Surge voltage on input EN 61000-4-5 L1 / L2 / L3 PE 4kV Criterion A Surge voltage on output EN 61000-4-5 + -

Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A Mains voltage dips

(Dips on three phases) Mains voltage dips

(Dips on two phases)

Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C Voltage sags SEMI F47 0706 Dips on two phases according to section 7.2.

80% of 380Vac

Powerful transients VDE 0160 over entire load range 1550V, 1.3ms Criterion A

Criteria: A: Power supply shows normal operation behavior within the dened limits.

C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. No damage or hazard to the power supply

will occur.

EMC Emission

Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B, input lines Radiated emission EN 55011, EN 55022 Class B Harmonic input current EN 61000-3-2 fullled Voltage uctuations, icker EN 61000-3-3 fullled This device complies with FCC Part 15 rules.

Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Switching frequency

Generic standards: EN 61000-6-1 and EN 61000-6-2

8kV

Air discharge

15kV

4kV

Output lines

2kV 2kV Criterion A

500V

+ / -

EN 61000-4-11 0% of 380Vac

0% of 480Vac

EN 61000-4-11 40% of 380Vac

40% of 480Vac 70% of 380Vac 70% of 480Vac

500V

0Vac, 20ms 0Vac, 20ms

200ms 200ms 500ms 500ms

of the SEMI F47 standard

1000ms 70% of 380Vac 50% of 380Vac

500ms

200ms

Generic standards: EN 61000-6-3 and EN 61000-6-4

Variable between 50kHz and 140kHz depending on load and input voltage

Criterion A Criterion A

Criterion A Criterion A Criterion A Criterion A

Criterion A Criterion A Criterion A

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 11

Bulletin 1606 Switched Mode Power Supplies

14. Environment

Operational temperature

*) -25°C to +70°C (-13°F to 158°F) reduce output power according Fig. 14-1

Storage temperature -40 to +85°C (-40°F to 185°F) for storage and transportation Output de-rating 3.2W/°C 45-60°C (113°F to 140°F) 6W/°C 60-70°C (140°F to 158°F) Humidity

**) 5 to 95% r.H. IEC 60068-2-30

Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g

2 hours / axis

IEC 60068-2-6

Shock 30g 6ms, 20g 11ms

3 bumps / direction, 18 bumps in total

IEC 60068-2-27

Altitude 0 to 6000m (0 to 20 000ft) reduce output power or ambient temperature

above 2000m sea level. Altitude de-rating 15W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 14-2 Over-voltage category III IEC 62103, EN 50178, altitudes up to 2000m II altitudes from 2000m to 6000m Degree of pollution 2 IEC 62103, EN 50178, not conductive

*) Operational temperature is the same as the ambient temperature and is dened as the air temperature 2cm below the unit. **) Do not energize in the presence of condensation.

Fig. 14-1 Output current vs. ambient temp. Fig. 14-2 Output current vs. altitude at 48V

-25 0 20 40

70°

Ambient Temperature

Allowable Output Current at 48V

0 2000 4000

6000m

Altitude

Allowable Output Current at 48V

12 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

15. Protection Features

Output protection Electronically protected against overload, no-load and short-circuits

Output over-voltage protection typ. 58.5Vdc

max. 60Vdc

In case of an internal power supply defect, a redundant circuit limits the maximum output voltage. The output

shuts down and automatically attempts to restart. Degree of protection IP 20 EN/IEC 60529 Penetration protection > 3.5mm e.g. screws, small parts Over-temperature protection yes output shut-down with automatic restart Input transient protection MOV (Metal Oxide Varistor) and active transient lter Internal input fuse 3x T3.15A H.B.C. not user replaceable

*) In case of a protection event, audible noise may occur.

16. Safety Features

Input / output separation

SELV IEC/EN 60950-1 PELV IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41 Class of protection I PE (Protective Earth) connection required Isolation resistance > 5MOhm Input to output, 500Vdc PE resistance < 0.1Ohm Touch current (leakage current) typ. 0.17mA 3x 400Vac, 50Hz, TN mains typ. 0.24mA 3x 480Vac, 60Hz, TN mains < 0.22mA 3x 440Vac, 50Hz, TN mains < 0.31mA 3x 528Vac, 60Hz, TN mains

*) Double or reinforced insulation

17. Dielectric Strength

The output voltage is oating and has no ohmic connection to the ground. Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the eld using the appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect all phase-terminals together as well as all output poles before conducting the test. When testing, set the cut-off current settings to the value in the table below.

Fig. 17-1 Dielectric strength

A B C

Type test 60s 2500Vac 3000Vac 500Vac

Factory test 5s 2500Vac 2500Vac 500Vac

Field test 5s 2000Vac 2000Vac 500Vac

Cut-off current setting > 10mA > 10mA > 30mA

Input

Earth

Output

To fulll the PELV requirements according to EN60204-1 § 6.4.1, we recommend that either the + pole, the – pole or any other part of the output circuit shall be connected to the protective earth system. This helps to avoid situations in which a load starts unexpectedly or can not be switched off when unnoticed earth faults occur.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 13

Bulletin 1606 Switched Mode Power Supplies

18. Certications

UL 508

IND. CONT. EQ.

18WM LISTED

LISTED E56639 for use in the U.S.A. (UL 508) and Canada (C22.2 No. 14-95)

UL 60950

RECOGNIZED E1168663 for use in the U.S.A. (UL 60950-1) and Canada (C22.2 No. 60950) Information Technology Equipment, Level 3

EN 60950-1, EN 61204-3 Complies with CE EMC and CE Low Voltage Directives

Marine RINA

RINA (Registro Italiano Navale) certied. See below for link to the Certicate.

GOST R

GOST R certication is applicable for products intended for sale and use within Russia. See below for link to the Certicate.

C-TICK C-Tick compliance is for products intended for sale and use within

the Australian market. See below for link to the C-Tick Declarations of Conformity.

Marine GL

GL (Germanischer Lloyd) classied for marine and oshore applications. Environmental category: C, EMC2. See below for link to Certicate.

19. Environmental Compliance

The unit does not release any silicone and is suitable for the use in paint shops. The unit conforms to the RoHS directive 2002/96/EC Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems. Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated. The production material within our production does not include following toxic chemicals:

Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCT), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrom Biphenyll (PBB), Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO), Cadmium, Asbestos, Mercury, Silicia

Product certification information (including Certificates and Declarations of Conformity) can be found at www.ab.com/certifications.

14 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

20. Physical Dimensions and Weight

Weight 750g / 1.65lb DIN Rail Use 35mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.

The DIN rail height must be added to the unit depth (117mm) to calculate the total required installation depth.

Installation Clearances See section 2.

Fig. 21-1 Front view Fig. 21-2 Side view

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 15

Bulletin 1606 Switched Mode Power Supplies

21. Accessory

1606-XLB Wall mounting bracket This bracket is used to mount specific units onto a at surface without using a DIN rail. The two aluminium

brackets and the black plastic slider of the unit have to be removed, so that the two steel brackets can be mounted.

Fig. 22-1 1606-XLB Wall mounting bracket Fig. 22-2 Assembled wall mounting bracket *)

*) Picture of the power supply is for representation only.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

16 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

22. Application Notes

22.1. Peak Current Capability

Solenoids, contactors and pneumatic modules often have a steady state coil and a pick-up coil. The inrush current demand of the pick-up coil is several times higher than the steady-state current and usually exceeds the nominal output current (including the PowerBoost). The same situation applies when starting a capacitive load.

Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit, the fuse needs a certain amount of over-current to trip or to blow. The peak current capability ensures the safe operation of subsequent circuit breakers.

Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the power supply can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The following two examples show typical voltage dips:

Fig. 22-1 Peak load 10A for 50ms, typ. Fig. 22-2 Peak load 25A for 5ms, typ.

10ms/DIV

Output Voltage

Output Current

48V

10A

34V

1ms/DIV

Output Voltage

Output Current

48V

25A

28V

Peak load 10A (resistive) for 50ms Output voltage dips from 48V to 34V.

Peak load 25A (resistive) for 5ms Output voltage dips from 48V to 28V.

22.2. Back-feeding Loads

Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called return voltage immunity or resistance against Back- E.M.F. (E

lectro Magnetic Force).

This power supply is resistant and does not show malfunctioning when a load feeds back voltage to the power supply. It does not matter, whether the power supply is on or off.

The maximum allowed feed-back-voltage is 63Vdc. The absorbing energy can be calculated according to the built-in large sized output capacitor which is specied in section 6.

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 17

Bulletin 1606 Switched Mode Power Supplies

22.3. Charging Batteries

The power supply can be used to charge lead-acid or maintenance free batteries. (4x 12V batteries in series)

Instructions for charging batteries:

a) Set jumper on the front of the unit into “Parallel Use” b) Set output voltage (measured at no load and at the battery end of the cable) very precisely to the end-of-charge

voltage.

End-of-charge voltage 55.6V 55V 54.3V 53.6V

Battery temperature 10°C 20°C 30°C 40°C

c) Use a 10A circuit breaker (or blocking diode) between the power supply and the battery. d) Ensure that the output current of the power supply is below the allowed charging current of the battery. e) Use only matched batteries when putting 12V types in series. f) The return current to the power supply (battery discharge current) is typ. 4.4mA when the power supply is

switched off (except in case a blocking diode is utilized).

22.4. Output Circuit Breakers

Standard miniature circuit breakers (MCBs or UL1077 circuit breakers) are without a doubt one of the most efcient and economical ways to open circuits on faulty branches. Most of these breakers may also be used on 48V branches.

MCBs are designed to protect wires and circuits. If the ampere value and the characteristics of the MCB are adapted to the wire size that is used, the wiring is considered as thermally safe regardless of whether the MCB opens or not.

To avoid voltage dips and under-voltage situations in adjacent 48V branches which are supplied by the same source, a fast (magnetic) tripping of the MCB is desired. A quick shutdown within 10ms is necessary corresponding roughly to the ride-through time of PLCs. This requires power supplies with high current reserves and large output capacitors. Furthermore, the impedance of the faulty branch must be sufciently small in order for the current to actually ow. The best current reserve in the power supply does not help if Ohm’s law does not permit current ow. The following table has typical test results showing which B- and C-Characteristic MCBs magnetically trip depending on the wire cross section and wire length.

Fig. 22-3 Test circuit

Maximal wire length for a magnetic (fast) tripping

0.75mm² 1.0mm² 1.5mm² 2.5mm²

C-2A 52m 70m 94m 148m C-3A 33m 42m 64m 97m C-4A 19m 23m 33m 48m C-6A 8m 9m 13m 22m C-8A - - - C-10A - - - B-6A 18m 22m 33m 46m

MCB

Power Supply

Load

B-10A 4m 5m 10m 13m

Wire length

S1...... Fault Simulation Switch

*) Remember to take into account twice the distance to the load (or cable length) when calculating the total wire length (+ and – wire).

18 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

22.5. External Input Protection

The unit is tested and approved for branch circuits up to 30A (U.S.A.) and 32A (IEC). An external protection is only required, if the supplying branch has an ampacity greater than this. Check also local codes and local requirements. In some countries local regulations might apply.

If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of the circuit breaker. A minimum value of 6A B- or 3A C-Characteristic breaker should be usee.

22.6. Using Only 2 Legs of a 3-Phase System

oss

The power supply is allowed to run permanently on two legs of a 3-phase system, when the output power is reduced according to the curves below. A long-term exceeding of these limits will result in a thermal shut-down of the unit. No external protection device is required to protect against a phase-l failure. EMC performance, hold-up time and losses differ from a three phas operation. Therefore, check suitability of your individual application. The screw of the terminal which remains unused must be securely tightened. Using only two legs of a 3-phase system is not included in the UL approval. Therefore, additional testing might be necessary.

open

L1 L2 L3

Power Supply

Fig. 22-4

Allowed output current for use on only two

legs of a 3-phase system

Fig. 22-5

Hold-up time for use on only two legs

of a 3-phase system

Allowed Output Current at 48V

-25 0 20

70°

40 60

Ambient Temperature

A... 2x 340-576Vac, 3x 320-576Vac B... 2x 320-340Vac

100ms

320 360 400 440 2x480Vac

Input Voltage

Hold-up Time at 48Vdc

Fig. 22-6

Efciency vs. output current at 24V for use on

only two legs of a 3-phase system

Fig. 22-7

Losses vs. output current at 24V for use on

only two legs of a 3-phase system

Efciency

94%

245

Output Current

2x400Vac

2x480Vac

Power Losses

012 456

24W

2x480Vac

2x400Vac

Output Current

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 19

Bulletin 1606 Switched Mode Power Supplies

22.7. Inductive and Capacitive Loads

The unit is designed to supply any kind of load, including unlimited capacitive and inductive loads.

22.8. Parallel Use to Increase Output Power

1606-XLE240F-3 power supplies can be paralleled to increase the output power. This power supply can also be paralleled with power supplies of the same type. The output voltage of all power supplies shall be adjusted to the same value (±100mV) in “Single use” mode with the same load conditions on all units, or the units can be left with the factory settings. After the adjustments, the jumper on the front of the unit must be moved from “Single use” to “Parallel use”, in order to achieve load sharing. The “Parallel use” mode regulates the output voltage in such a manner that the voltage at no load is approx. 5% higher than at nominal load. See also section 6. If no jumper is plugged in, the unit is in “Single use”. Factory setting is “Single use” mode. A fuse or diode on the output of each unit is required only if you connect more than three units in parallel. If using a fuse or circuit breaker, choose one with approximately 150% of the rated output current of the power supply. Maintain an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power supplies on top of each other. Do not use power supplies in parallel in mounting orientations other than the standard mounting orientation (input terminals on the bottom and output terminals on top of the unit) or in any other condition where a derating of the output current is required (e.g. altitude, above 60°C, …). Please note that leakage current, EMI, inrush current and harmonics increase when using multiple power supplies.

Unit A

Unit B

Fuse

Load

22.9. Parallel Use for Redundancy

Power supplies can be paralleled for redundancy to gain higher system availability. Redundant systems require a certain amount of extra power to support the load in case one power supply unit fails. The simplest way is to put two power supplies in parallel. This is called a 1+1 redundancy. In case one power supply unit fails, the second is automatically able to support the load current without interruption. Redundant systems for a higher power demand are usually built in a N+1 method (for instance, ve power supplies, each rated for 5A are paralleled to build a 20A redundant system). For N+1 redundancy the same restrictions apply as for increasing the output power; see section 22.8.

Please note: This simple way to build a redundant system does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a case, the failing unit becomes a load for the other power supplies and the output voltage can no longer be maintained. This can only be avoided by using the decoupling diodes included in the 1606-XLERED decoupling module.

Recommendations for building redundant power systems: a) Use separate input fuses for each power supply. b) Set the power supply into “Parallel Use”. c) Monitor the individual power supply units. A DC-ok lamp and a DC-ok contact is included in the 1606-XLERED

redundancy module. This feature reports a faulty unit.

d) It is recommanded to set the output voltages of all units to the same value (± 100mV) or leave it on the factory setting.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

20 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

22.10. Daisy Chaining of Outputs

Daisy chaining (jumping from one power supply output to the next) is allowed as long as the average output current through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.

Fig. 22-8 Daisy chaining of outputs Fig. 22-9 Using distribution terminals

max 25A!

Load

Output

+ +

- -

Power Supply

Output

+ +

- -

Power

Supply

Load

Output

+ +

- -

Output

+ +

- -

Power

Supply

Power

Supply

Input

Distribution Terminals

22.11. Series Operation

Power supplies of the same type can be connected in series for higher output voltages. It is possible to connect as many units in series as needed, providing the sum of the output voltage does not exceed 150Vdc. Voltages with a potential above 60Vdc are no longer SELV and can be dangerous. Such voltages must be installed with a protection against touching. Grounding of the output is required when the sum of the output voltage is above 60Vdc. Avoid return voltage (e.g. from a decelerating motor or battery) which is applied to the output terminals. Maintain an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power supplies on top of each other. Please note that leakage current, EMI, inrush current and harmonics

Unit A

Unit B

Load

Earth (see notes)

all increase when using multiple power supplies.

22.12. Use in a Tightly Sealed Enclosure

When the power supply is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than outside. In such situations, the inside temperature denes the ambient temperature for the power supply.

The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure. The power supply is placed in the middle of the box; no other heat producing item is inside the box. Enclosure: Rittal Typ IP66 Box PK 9519 100, plastic, 180x180x165mm

Load: 48V, 4A; (=80%) load is placed outside the box. Input: 3x 400Vac Temperature inside enclosure: 48.9°C (in the middle of the right side of the power supply with a distance of 2cm) Temperature outside enclosure: 24.7°C Temperature rise: 24.2K

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM031A-EN-P — April 2014 21

Bulletin 1606 Switched Mode Power Supplies

22.13. Mounting Orientations

Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the max. allowed ambient temperature. The amount of reduction inuences the lifetime expectancy of the power supply. Therefore, two different derating curves for continuous operation can be found below:

Curve A1 Recommended output current. Curve A2 Max allowed output current (results in approximately half the lifetime expectancy of A1).

Fig. 22-10 Mounting Orientation A

(Standard orientation)

Power

Supply

OUTPUT

INPUT

Output Current

10 20 30

60°

Ambient Temperature

Fig. 22-11

Mounting Orientation B

(Upside down)

Power

Supply

OUTPUT

INPUT

Output Current

10 20 30

60°

Ambient Temperature

Fig. 22-12 Mounting Orientation C

(Table-top mounting)

Output Current

10 20 30

60°

Ambient Temperature

Fig. 22-13 Mounting Orientation D

(Horizontal cw)

Power

Supply

OUTPUT

INPUT

Output Current

10 20 30

60°

Ambient Temperature

Fig. 22-14 Mounting Orientation E

(Horizontal ccw)

Power

Supply

OUTPUT

INPUT

Output Current

10 20 30

60°

Ambient Temperature

22 Rockwell Automation Publication 1606-RM031A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://

www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums,

software updates, and to sign up for product notification updates.

, you can find technical manuals, technical and application

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer Tec hCon ne ct representative, or visit http://www.rockwellautomation.com/support/

support programs. For more information, contact your local distributor or Rockwell Automation

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Wo rld wide Loca tor at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local

Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

distributor to complete the return process.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002

literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf.

Publication 1606-RM031A-EN-P — April 2014

, available at http://

Rockwell Automation 1606-XLE240F-3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual