Rockwell Automation 1606-XLE240F-3 User Manual

Reference Manual

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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.

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