Reference Manual
egaP egaP
1.
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. Efciency 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. Certications .....................................................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
Efciency up to 92.9%
Excellent Partial Load Efciency
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 efciency, 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.
Specication 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
Efciency 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
Certication 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, denitions
Turn-on
323V
Rated input
range
V
IN
P
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
6A
01
3
4
0
0.1
0.2
0.4
0.5
0.6
0.8A
Input Current, typ.
Output Current
2
5
0.3
0.7
3
x
4
8
0
V
a
c
3
x
4
0
0
V
a
c
6A
01
3
4
0.35
0.40
0.45
0.50
0.55
Power Factor, typ.
Output Current
2
5
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
L1
PE
+
-
Power Supply
AC
DC
Battery
L2
L3
FUSE
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
4A
peak
-25°C to +70°C
Inrush energy max. 0.5A
2
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.)
0
04 10
8
16
24
56V
32
40
48
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 specied 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, denitions
Hold-up Time at 48Vdc
100ms
80
60
40
20
0
320 360 400 440 3x480Vac
Input Voltage
.
p
y
t
,
A
5
.
2
.
n
i
m
,
A
5
.
2
.
p
y
t
,
A
5
.
n
i
m
,
A
5
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. Efciency and Power Losses
3AC 400V 3AC 480V
Efciency 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 efciency *) 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 efciency 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 Efciency vs. output current at 48V,
typ., 3-phase operation
Fig. 8-2 Losses vs. output current at 48V,
typ., 3-phase operation
Efciency
1
89
91
93
88
94%
6
245
Output Current
3
90
92
3x400Vac
3x480Vac
Power Losses
012 456A
0
4
12
20
24W
3x480Vac
3x400Vac
8
3
16
Output Current
Fig. 8-3 Efciency vs. input voltage at 48V,
5A, typ., 3-phase operation
Fig. 8-4 Losses vs. input voltage at 48V, 5A,
typ., 3-phase operation
Efciency
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
4
12
20
16
8
o
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.