•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, AC 230V parameters are valid at 50Hz 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.
Page 2
Bulletin 1606 Switched Mode Power Supplies
IND. CONT. EQ.
Power Supply
• AC 100-240V Wide-range Input
• Width only 65mm
• Efficiency up to 94.0%
• Excellent Partial Load Efficiency
• 20% Output Power Reserves
PLUS
• Safe Hiccup
• Easy Fuse Breaking due to High Overload Current
(typ. 80A for 15ms)
• Active Power Factor Correction (PFC)
• Minimal Inrush Current Surge
• Full Power Between -25°C and +60°C
• DC-OK Relay Contact
• Current Sharing Feature for Parallel Use
• 3 Year Warranty
Overload Mode
General Description
The Allen-Bradley Bulletin 1606-XLE power supplies are cost optimized
without compromising quality, reliability and performance. Cat. No.
1606-XLE480EP offers high efficiency, electronic inrush current
limitation, active PFC, and a wide operational temperature range.
The small size is achieved by a synchronous rectification and further
technological design details.
The Bulletin 1606-XLE line of power supplies includes all the essential
basic functions. The devices have a power reserve of 20% included,
which may even be used continuously at temperatures up to +45°C.
Additionally, Cat. No. 1606-XLE480EP can deliver approximately 4
times the nominal output current for 15ms which helps to trip fuses on
faulty output branches.
High immunity to transients and power surges as well as low
electromagnetic emission, a DC-OK relay contact and a large
international approval package for a variety of applications makes this
unit suitable for nearly every situation.
2Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 3
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 equipment, 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 Mounting Orientations on page 24.
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 15%!
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 suit ability 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. A suitable enclosure must be provided for the end
product which has a minimum protection of IP54 and fulfills the requirements of the EN 60079-15:2010
.
Rockwell Automation Publication 1606-RM001B-EN-P - August 20133
Page 4
Bulletin 1606 Switched Mode Power Supplies
Turn-on
85V
Rat ed
input range
max.
500ms
V
IN
P
OUT
300Vac264V
Shut-down
Start-up
delay
Ri se
Time
Overshoot
- 5%
O utput
Volt age
Input
Volt age
24A
2 4 6 8 10 12 14 16 18
0
1
2
3
4
5
6A
Input C urrent, typ.
20 22
a) 100Vac
b) 120Vac
c) 230Vac
b
a
c
Output Current
P ower Factor, typ.
2 4 6 8 10 12 14 16 1824A
0.75
0.8
0.85
0.9
0.95
1.0
20 22
a) 100Vac
b) 120Vac
c) 230Vac
a, b
c
Out put C urr ent
3.AC-Input
AC inputnom.AC 100-240Vsuitable for TN-, TT- and IT mains networks
AC input rangemin.100-264Vaccontinuous operation
min.85-100Vacshort term or with output derating (1%/V) or with reduced ambient temperature, see
Figure 15-1 on page 13
no damage between 0 and 100Vac
min.264-300Vac< 500ms
Allowed voltage L or N to earthmax.300Vaccontinuous, IEC 62103
Input frequencynom.50–60Hz ±6%
Turn-on voltagetyp.84Vacsteady-state value, see Figu re 3-1
Shut-down voltagetyp.39Vacsteady-state value at 5A load, see Fi gure 3-1
typ.53Vacsteady-state value at 10A load, see Figure 3-1
typ.74Vacsteady-state value at 20A load see Figu re 3-1
AC 100VAC 120VAC 230V
Input currenttyp.5.25A4.36A2.33Aat 24V, 20A, see Figure 3-3
Power factor
Ripple and noise voltagemax.50mVpp20Hz to 20MHz, 50Ohm
Output current nom.20Aat 24V, ambient temperature <60°C, see Figure 6 -1
nom.
nom.17.1Aat 28V, ambient temperature <60°C, see Figure 6-1
nom.
typ.80Aup to 15ms, output voltage stays above 20V, see Figure 6-4 , This peak current is
Output powernom.480Wcontinuously available
nom.
Overload behaviourcont. currentoutput voltage > 13Vdc, see Fig ure 6-1
Short-circuit currentmin.
max.
max.
min.70Aup to 15ms, load impedance <10mOhm, see Figure 6 -4
typ.100Aup to 15ms, load impedance <10mOhm, see Figure 6- 4
Output capacitancetyp.7 000μFincluded inside the power supply
*) Power Boost This power/ current is continuously all owed up to an ambient temperature of 45°C. Above 45°C, do not use this power/ current longer than a duty cycle of 10% and/ or not longer than 1 minute every 10 minutes.
PLUS
**) Hiccup
performed. This cycle is repeated as long as t he overload exists. If the overload has been cleared, the device will op erate normally. See Figure 6-3
***) Discharge current of output capacitors is not inclu ded.
****) This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. It is not guaranteed value which can be achieved. The typ ical value is about 28.5V (in “single use” mode).
Mode At heavy overloads (when output voltage falls below 13V), the power supply delivers continuous output current for 2s. After this, the output is switched off for approx. 18s before a new star t attempt is automatically
Fig. 6-1: Output voltage vs. output current, typ.Fig. 6-2: Output voltage in “parallel u se” mode, typ.
30V
24A
20.6A
576W
Hiccup
35A
45A
15A
****)
*)
*)
*)
***)
***)
***)
PLUS
mode
at clockwise end position of potentiometer
see Figure 6- 1
see Figure 6-2
at 24V, ambient temperature <45°C, seeFigure 6 -1
at 28V, ambient temperature <45°C, see Figure 6-1
available once every five seconds. Refer to Pea k Curren t Capabi lity on page 19 for
more peak current measurements.
Power Boost
**)
output voltage < 13Vdc, see Figure 6-1
® *)
load impedance <10mOhm, see Figure 6 -3
load impedance <10mOhm, see Figure 6 -1
average (R.M.S.) current, load impedance 50mOhm, see Figure 6-3
Fig. 6-3: Short-circuit on output, Hiccup
6Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
PLUS
mode, typ.
Fig. 6-4: Dynamic overcurrent capability, typ.
Page 7
Bulletin 1606 Switched Mode Power Supplies
Output
Cur r ent
0
42A
18s
18s
18s
2s
2s
2s
t
S hort -cir cuit
Normal
operation
Normal
operation
Ou tput Voltage
(dynamic behavior, < 15ms)
0
0
4
8
12
28V
16
20
24
100A402060801030507090
Adjus tment
Range
Output Current
0
10
20
30
40
80ms
90120155190 230Vac
Input Voltage
50
60
Hold-up Time
24V, 20A, typ.
24V, 10A, min.
24V, 10A, typ.
70
24V, 20A, min.
- 5%
Hol d-up Time
Zero Transition
O utput
Volt age
Input
Volt age
100ms
0.9* V
ADJ
<
1ms
10%
open
V
OUT
= V
ADJ
openclosedclosed
>
1ms
7. Hold-up Time
AC 100VAC 120VAC 230V
Hold-up Timetyp.65ms65ms65msat 24V, 10A, see Figure 7-1
min.54ms54ms54msat 24V, 10A, see Fig ure 7-1
typ.26ms26ms26msat 24V, 20A, see Fi gure 7-1
min.21ms21ms21msat 24V, 20A, see Fig ure 7-1
Fig. 7-1: Hold-up time vs. input voltageFig. 7-2: Shut-down behavior, definitions
8. DC-OK Relay
This feature monitors the output voltage, which is produced by the power supply itself. It is independent of a back-fed voltage from a unit connected in
parallel to the power supply output.
Contact closesAs soon as the output voltage reaches 90% of the adjusted output voltage level.
Contact opensAs soon as the output voltage dips more than 10% below the adjusted output voltage.
Short dips will be extended to a signal length of 100ms. Dips shorter than 1ms will be ignored.
min.1mA at 5Vdcmin. permissible load
Fig. 8-1: DC-ok relay contact behavior
on page 14.
Rockwell Automation Publication 1606-RM001B-EN-P - August 20137
Page 8
Bulletin 1606 Switched Mode Power Supplies
Eff i ci ency
4 6 8 101214182024A
86
87
88
89
90
91
92
93
94%
100Vac
120Vac
230Vac
Out put Current
1622
Power Losses
02 68 121424A
10
0
20
30
40
60W
18 20
50
41016
Output C urrent
22
120Vac
100Vac
230Vac
Ef f iciency
120180230 264Vac
89
90
91
92
Input Volta ge
93
94
95%
100
Power Losses
120180230 264Vac
20
25
30
35
Input Volta ge
40
45
50W
100
9. Efficiency and Power Losses
AC 100VAC 120VAC 230V
Efficiency typ.92.0%92.7%94.0%at 24V, 20A
Average efficiency
*)
Power lossestyp.6.5W3.9W2.6Wat 24V, 0A
*) The average efficiency 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. 9-1: Efficiency vs. output current at 24V, typFig. 9-2: Losses vs. output current at 24V, typ.
typ.91.6%92.4%94.0%at 24V, 24A (Power Boost)
typ.91.3%92.0%93.3%25% at 5A, 25% at 10A,
Fig. 9-3: Efficiency vs. input voltage at 24V, 20A, typ.
Fig. 9-4: Losses vs. input voltage at 24V, 20A, typ.
8Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 9
Bulletin 1606 Switched Mode Power Supplies
+
+
-
-
Output
Over -
Voltage
P rotection
PFC
C onv e rter
Output
Voltage
R e gulator
Power
C onv e rter
Output
Filter
Output
Voltage
Monitor
Output
Power
Manage r
Temper -
ature
Shut-
down
Input Fuse
Input Filter
Input Rectifier
Ac tive Inrus h Limiter
V
OUT
L
N
DC-ok
C ontac t
DC-ok
LED
Single /
Parallel
DC-ok
Relay
10. Lifetime Expectancy and MTBF
AC 100VAC 120VAC 230V
Lifetime expectancy
**)
MTBF
SN 29500, IEC 61709468 000h484 000h537 000h
**)
MTBF
MIL HDBK 217F
*) 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
specified in operational hours and is calculated according to the capacitor’s manufacturer specification. The manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years (131 400h).
Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices.
**) 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.
The MTBF figure is a statistical representation of the likelihood of a device to fail. A MTBF figure of e.g. 1 000 000h means that statistically one unit will fail every 100 hours if 10 000 units are installed in the field.
However, it can not be determined if the failed unit has been running for 50 000h or only for 100h.
*)
145 000h
410 000h
*)
*)
150 000h
425 000h
*)
*)
168 000h
475 000h
*)
*)
at 24V, 10A and 40°C
at 24V, 10A and 25°C
64 000h70 000h88 000hat 24V, 20A and 40°C
180 000h
*)
198 000h
*)
249 000h
*)
at 24V, 20A and 25°C
38 000h46 000h61 000hat 24V, 24A and 40°C
109 000h
*)
130 000h
*)
171 000h
*)
at 24V, 24A and 25°C
at 24V, 20A and 40°C
770 000h796 000h882 000hat 24V, 20A and 25°C
254 000h261 000h290 000hat 24V, 20A and 40°C;
Rockwell Automation Publication 1606-RM001B-EN-P - August 20139
Page 10
Bulletin 1606 Switched Mode Power Supplies
Load
+
-
Power
Supply
+ +
- -
Output
Power
Supply
+ +
- -
Out put
max 25A!
continuous
Dis tribution
Terminal s
Load
+
-
Power
Supply
+ +
- -
Output
Power
Supply
+ +
- -
Output
12. Terminals and Wiring
The terminals are IP20 Finger safe constructed and suitable for field- and factory wiring.
Input and outputDC-OK-Signal
Type
Solid wire
Stranded wire
American Wire GaugeAWG20-10AWG26-14
Max. wire diameter2.8mm (including ferrules)1.5mm (including ferrules)
Wire stripping length7mm / 0.28inch7mm / 0.28inch
Screwdriver3.5mm slotted or cross-head No 23.5mm slotted (to open the spring)
Recommended tightening torque1Nm, 9lb.innot applicable
Instructions:
a)Use appropriate copper cables that are designed for minimum operating temperatures of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum
90°C for ambient up to 70°C minimum.
b)Follow national installation codes and installation regulations!
c)Ensure that all strands of a stranded wire enter the terminal connection!
d)Do not use the unit without PE connection.
e)Unused terminal compartments should be securely tightened.
f)Ferrules are allowed.
screw terminalsspring-clamp terminals
0.5-6mm
0.5-4mm
2
2
0.15-1.5mm
0.15-1.5mm
2
2
Daisy chaining:
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 as shown in Figure 12-2
Fig. 12-1: Daisy chaining of outputsFig. 12-2: Using distribution terminals
.
10Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 11
13. Front Side and User Elements
A
D
F
E
C
B
Fig. 13-1: Fig. 13-1 Front side
AInput Terminals (screw terminals)
N, LLine input
PE (Protective Earth) input
B
Output Terminals (screw terminals, two pins per pole)
+ Positive output
– Negative (return) output
C
Output voltage potentiometer
Open the flap to adjust the output voltage. Factory set: 24.1V
D
DC-OK LED (green)
On, when the output voltage is >90% of the adjusted output voltage
The DC-OK relay contact is synchronized with the DC-OK LED.
See DC-OK Relay
on page 7 for details.
Bulletin 1606 Switched Mode Power Supplies
F
“Parallel Use” “Single Use” selector
Set jumper to “Parallel Use” when power supplies are connecte d 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. 4% higher than at nominal load.
See Parallel Use to Increase Output Power
on page 21. A missing jumper is equal to a “Single Use” mode.
Rockwell Automation Publication 1606-RM001B-EN-P - August 201311
Page 12
Bulletin 1606 Switched Mode Power Supplies
14. EMC
The power supply is suitable for applications in industrial environment as well as in residential, commercial and light industry environment without any
restrictions. A detailed EMC report is available on request.
EMC Immunity
Electrostatic discharge EN 61000-4-2contact discharge
Electromagnetic RF fieldEN 61000-4-380MHz-2.7GHz20V/mCriterion A
Fast transients (Burst)EN 61000-4-4input lines
Surge voltage on inputEN 61000-4-5L N
Surge voltage on outputEN 61000-4-5+ -
Surge voltage on DC-OKEN 61000-4-5DC-OK signal PE2kVCriterion A
Conducted disturbanceEN 61000-4-60.15-80MHz20VCriterion A
Mains voltage dipsEN 61000-4-110% of 100Vac
Voltage interruptionsEN 61000-4-110% of 200Vac (=0V)5000msCriterion C
Voltage sagsSEMI F47 0706dips on the input voltage according to SEMI F47 standard
Powerful transientsVDE 0160over entire load range750V, 1.3msCriterion C
Criterions:
A: Power supply shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. No damage or hazards for the power supply will occur.
EMC Emission
Conducted emission
input lines
Conducted emission
output lines
Radiated emissionEN 55011, EN 55022Class B
Harmonic input currentEN 61000-3-2fulfilled for class A equipment
Voltage fluctuations, flickerEN 61000-3-3
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.
**)
According generic standards: EN 61000-6-1 and EN 61000-6-2
8kV
air discharge
output lines
DC-OK signal (coupling clamp)
L PE, N PE
+ / - PE
40% of 100Vac
70% of 100Vac
0% of 200Vac
40% of 200Vac
70% of 200Vac
80% of 120Vac (96Vac)
70% of 120Vac (84Vac)
50% of 120Vac (60Vac)
According generic standards: EN 61000-6-3 and EN 61000-6-4
EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22Class B
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1limits for DC power port according EN 61000-6-3
Criterion A
Criterion C
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
*) tested with constant current loads, non pulsing
**)for information only, not mandatory for EN 61000-6-3
Switching Frequencies
Switching frequency 170kHz to 130kHzPFC converter, input voltage and output power dependent
Switching frequency 280kHz to 140kHzMain converter, output power dependent
12Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
The power supply has two converters with two different switching frequencies included.
Page 13
15. Environment
short
term
short
term
Bulletin 1606 Switched Mode Power Supplies
Operational temperature
*)
-25°C to +70°C (-13°F to 158°F)reduce output power according to Figure 15-1
Storage temperature-40 to +85°C (-40°F to 185°F)for storage and transportation
Output de-rating6.4W/°C
12W/°C
**)
Humidity
Vibration sinusoidal
5 to 95% r.h.
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
45°C to 60°C (113°F to 140°F)
60°C to 70°C (140°F to 158°F)
IEC 60068-2-30
IEC 60068-2-6
2 hours / axis
Shock
30g 6ms, 20g 11ms
IEC 60068-2-27
3 bumps / direction, 18 bumps in total
Altitude0 to 2000m (0 to 6 560ft)without any restrictions
2000 to 6000m (6 560 to 20 000ft)reduce output power or ambient temperature,
see Figure 15-2
IEC 62103, EN 50178, overvoltage category II
Altitude de-rating30W/1000m or 5°C/1000m> 2000m (6500ft), see Figure 15-2
Over-voltage categoryIIIIEC 62103, EN 50178, altitudes up to 2000m
IIaltitudes from 2000m to 6000m
Degree of pollution2IEC 62103, EN 50178, not conductive
LABS compatibilityThe unit does not release any silicone or other LABS-critical substances and is suitable for use in paint shops.
Audible noiseAt load currents below 2A some audible noise will be emitted from the power supply
*) Operational temperature is the same as the ambient temperat ure and is defined as the air temperature 2cm below the unit.
**) Do not energize while condensation is present
Fig. 15-1: Output current vs. ambient temp.Fig. 15-2: Output current vs. altitude
See AC-Input on page 4 for de-rating requirements for input voltages between 85Vac and 100Vac.
Rockwell Automation Publication 1606-RM001B-EN-P - August 201313
Electronically protected against overload, no-load and short-circuits
In case of an internal power supply defect, a redundant circuit limits the maximum
max. 32Vdc
output voltage. The output shuts down and automatically attempts to restart.
Degree of protectionIP 20EN/IEC 60529
Penetration protection> 5mme.g. screws, small parts
Over-temperature protectionyesOutput shut-down with automatic restart
Input transient protectionMOV (Metal Oxide Varistor)
Internal input fuseincludednot user replaceable
*) In case of a protection event, audible noise may occur.
*)
17. Safety Features
Input / output separation
*)
Class of protectionIPE (Protective Earth) connection required
Isolation resistance> 5MOhminput to output, 500Vdc
PE resistance< 0.1Ohm
Touch current (leakage current)typ. 0.14mA / 0.37mA100Vac, 50Hz, TN-,TT-mains / IT-mains
*) double or reinforced insulation
SELVIEC/EN 60950-1
PELVIEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
double or reinforced insulation
The output voltage is floating and has no ohmic connection to the ground. Type and factory tests are conducted by the manufacturer. Field tests may be
conducted in the field using the appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect all inputterminals 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. 18-1: Dielectric strength
Type test60s2500Vac3000Vac1500Vac500Vac
Factory test5s2500Vac2500Vac1000Vac500Vac
Field test5s2000Vac2000Vac1000Vac500Vac
Cut-off current setting> 15mA> 15mA> 20mA> 1mA
To fulfil 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 sha ll 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.
ABCD
14Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 15
19. Certifications
IND. CONT. EQ.
EC Declaration of ConformityThe CE mark indicates conformance with the
- EMC directive 2004/108/EC,
- Low-voltage directive (LVD) 2006/95/EC and
- RoHS directive 2011/65/EU.
UL 508Listed for use as Industrial Control Equipment;
U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01);
E-File: E56639
UL 60950-1
nd
2
Edition
Recognized for use as Information Technology Equipment, Level 5; U.S.A. (UL 60950-1) and
Canada (C22.2 No. 60950-1);
E-File: E168663
20. Standards Compliance
EN 61558-2-17Safety of Power Transformers
EN/IEC 60204-1Safety of Electrical Equipment of Machines
EN/IEC 61131-2Programmable Controllers
EN 50178, IEC 62103Electronic Equipment in Power Installations
SEMI F47-0706Ride-through compliance for the semiconductor industry
Bulletin 1606 Switched Mode Power Supplies
Rockwell Automation Publication 1606-RM001B-EN-P - August 201315
Page 16
Bulletin 1606 Switched Mode Power Supplies
21. Dimensions and Weight
Weight1000g / 2.2lb
DIN-RailUse 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 (127mm) to calculate the total required installation depth.
16Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 17
22. Accessories
22.1 Wall Mounting Bracket (Cat. No. 1606-XLS)
This bracket is used to mount the power supply onto a flat surface without utilizing a DIN-Rail.
Bulletin 1606 Switched Mode Power Supplies
Rockwell Automation Publication 1606-RM001B-EN-P - August 201317
Page 18
Bulletin 1606 Switched Mode Power Supplies
24V
20A
Load
L
N
PE
Failure
Monitor
L N PE
24-28V 480W
Power
Supply
+ +
- -
24V 20A
DCOK
AC Input
Output
*)
Redundancy
Module
Input1Input
2
Output
+-+
-
+
-
L N PE
+ +
- -
24V 20A
DCOK
AC Input
Output
24-28V 480W
Power
Supply
II
*)
also possible
1606-XLSREDS40HE
1606-XLE480EP
1606-XLE480EP
1606-XLSRED40HE
22.2 Redundancy Modules
1606-XLSRED40HE – (2x 20A Inputs, 1x 40A output)
The redundancy modules in the HE-series are specially designed for power supplies, which feature the HiccupPLUS overload behavior. The1606XLSRED40HE is the preferred redundancy module for the 1606-XLE480EP power supply. It is equipped with two input channels, which are individually
decoupled by utilizing mosfet technology. Using mosfets instead of diodes reduces the heat generation and the voltage drop between input and
output. The1606-XLSRED40HE does not require an additional auxiliary voltage and is self-powered even in case of a short circuit across the output.
Due to the low power losses, the unit is very slender and only requires 36mm width on the DIN-rail.
1606-XLSRED40– (2x 20A Inputs, 1x 40A output)
The1606-XLSRED40 redundancy module is a unit, that is also suitable in combination with power supplies, which have a continuous current overload
behavior. Size and performance are the same as the1606-XLSRED40HE. The 1606-XLSRED40 is more complex than the 1606-XLSRED40HE units and
therefore higher in cost. The terminal arrangement of the 1606-XLSRED40 are different then the 1606-XLSRED40HE. The output terminal is located on
top and the input terminals are on the bottom of the unit in order for a better match to the power supplies of the XLS series that do not feature the
HiccupPLUS overload behavior.
1606-XLSREDS40HE – (1x 40A input, 1x 40A output)
The single channel redundancy modules in the HE-series are specially designed for power supplies, which feature the HiccupPLUS overload behavior.
The 1606-XLSREDS40HE is a 40A single channel redundancy module, which is equipped with a plug connector on the output. The plug connector allows
replacing the power supply or the redundancy module while the system is running. The plug connector avoids that the output wires can touch and
short the load circuit.
The 1606-XLSREDS40HE is very slender and only requires 46mm width on the DIN-rail. It also utilizes mosfet technology instead of diodes for low heat
generation and a minimal voltage drop between input and output. It does not require an additional auxiliary voltage and is self-powered even in case
of a short circuit across the output.
Typical 1+1 Redundant Configuration for 20 A with a dual
redundancy module.
Typical N+1 or 1+1 Redundant Configuration for 20 A with multiple 1606XLSREDS40HE redundancy modules.
Failure
Monitor
1606-XLE480EP
24-28V 480W
Power
Supply
DCOK
AC Input
L N PE
+ +
Output
24V 20A
- -
+
-
Output
1606-XLSREDS40HE
Redundancy
Module
Input
+
-
1606-XLE480EP
24-28V 480W
Power
Supply
DCOK
AC Input
L N PE
+ +
Output
24V 20A
- -
+
-
Output
1606-XLSREDS40HE
Redundancy
Module
Input
+
24V
20A
Load
-
18Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
I
L
N
PE
I
Page 19
Bulletin 1606 Switched Mode Power Supplies
10ms/DIV
Output
Voltage
Out put
Current
24V
0A
40A
16V
15ms
1ms/DIV
Output
Volt age
Out put
Cur rent
24V
0A
100A
18V
10ms/DIV
Out put Volt age
O u tpu t Current
24V
0A
90A peak
18V
15ms
23. Application Notes
23.1 Peak Current Capability
The power supply can deliver peak currents (up to several milliseconds) which are higher than the specified short term currents.
This helps to start current demanding loads. 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.
The peak current capability also ensures the safe operation of subsequent circuit breakers of load circuits. The load branches are often individually
protected with circuit breakers or fuses. In case of a short or an overload in one branch circuit, the fuse or circuit breaker need a certain amount of overcurrent to open in a timely manner. This avoids voltage loss in adjacent circuits.
The extra current (peak current) is supplied by the power converter and the built-in large sized output capacitors of the power supply. The capacitors
get discharged during such an event, which causes a voltage dip on the output. The following two examples show typical voltage dips:
Fig. 23-1: - Peak load with 2x the nominal current for 50ms, typ.
Fig.23-2: - Peak load with 5x the nominal current for 5ms, typ.
40A Peak load (resistive) for 50ms
Output voltage dips from 24V to 16V.
Fig.23-3: - 90A Peak load, typ.
Please note: The DC-OK relay triggers when the voltage dips more than 10% for longer
than 1ms.
100A Peak load (resistive) for 5ms
Output voltage dips from 24V to 18V.
High Overload Current (typ. >90A for 15ms) enables easy fuse
tripping
Peak current voltage dips typ.from 24V to 16Vat 40A for 50ms, resistive load
typ.from 24V to 18.5Vat 100A for 2ms, resistive load
typ.from 24V to 18Vat 100A for 5ms, resistive load
Rockwell Automation Publication 1606-RM001B-EN-P - August 201319
Page 20
Bulletin 1606 Switched Mode Power Supplies
MC B
Power Supply
AC
DC
+
-
+
-
Load
Wire length
S1... Fault simulation switch
S1
23.2 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 35V DC.
23.3 External Input Protection
The unit is tested and approved for branch circuits up to 30A (UL) 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 10A B- or C-Characteristic breaker should be used.
23.4 Output Circuit Breakers
Standard miniature circuit breakers (MCB’s or UL 1077 circuit breakers) are commonly used for AC-supply systems and may also be used on 24V
branches.
MCB’s 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 24V 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 PLC's. This requires power supplies with
high current reserves and large output capacitors. Furthermore, the impedance of the faulty branch must be sufficiently small in order for the current to
actually flow. The best current reserve in the power supply does not help if Ohm’s law does not permit current flow. 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.23-4 Test circuit
Maximal wire length*) for a fast (magnetic) tripping:
*)Don’t forget to consider twice the distance to the load (or cable length) when calculating the total wire length (+ and – wire).
20Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 21
Bulletin 1606 Switched Mode Power Supplies
Uni t A
AC
DC
Uni t B
AC
DC
-
+
-
+
Load
+
-
23.5 Parallel Use to Increase Output Power
The 1606-XLE480EP power supplies can be paralleled to increase the output power. 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 shall 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. 4%
higher than at nominal load. See Output
“Single use” mode. Factory setting is “Single use” mode.
If more than three units are connected in parallel, a fuse or circuit breaker with a rating of 30A or 32A is required on each output. Alternatively, a diode
or redundancy module can also be utilized.
Energize all units at the same time to avoid the overload Hiccup
seconds), if the output was in Hiccup
Keep 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 (terminals on bottom of the unit) or in any other
condition where a derating of the output current is required (e.g. altitude, above 60°C, …).
on page 6. If no jumper is plugged in, the unit is in
PLUS
mode. It also might be necessary to cycle the input power (turn-off for at least five
PLUS
mode due to overload or short circuits and the required output current is higher than the current of one unit.
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
23.6 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 other one is automatically able to support the load current without any interruption. Redundant systems for a higher
power demand are usually built in a N+1 method. E.g. five power supplies, each rated for 20A are paralleled to build a 80A redundant system. For N+1
redundancy the same restrictions apply as for increasing the output power, see also Chapter 23.5, Parallel Use to Increase Output Power
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 defective unit becomes a load for the other power supplies and the output voltage can not be maintained any more. This can
be avoided by utilizing redundancy modules, which have decoupling devices (diodes or mosfets) included. Further information and wiring
configurations can be found in chapter 22.3- Redundancy Modules
on page 18.
Recommendations for building redundant power systems:
Use separate input fuses for each power supply.
Set the power supply into “Parallel use” mode.
Monitor the individual power supply units. Therefore, use the DC-OK relay contact of the XLE480EP power supply.
.
It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting.
Rockwell Automation Publication 1606-RM001B-EN-P - August 201321
Page 22
Bulletin 1606 Switched Mode Power Supplies
Uni t A
AC
DC
Uni t B
AC
DC
-
+
-
+
Load
+
-
Ear th
(see notes)
23.7 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 not SELV any more and
can be dangerous. Such voltages must be installed with a protection against touching.
Earthing 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.
Keep 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 series in mounting orientations other than the standard mounting orientation (terminals on bottom of the unit).
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
23.8 Inductive and Capacitive Loads
The unit is designed to supply any kind of loads, including capacitive and inductive loads. If extreme large capacitors, such as EDLCs (electric double layer capacitors or “UltraCaps”) with
a capacitance > 0.5F are connected to the output, the unit might charge the capacitor in the Hiccup
PLUS
mode (See Output on page 6 ).
23.9 Charging of Batteries
The power supply can be used to charge lead-acid or maintenance free batteries. (Two 12V batteries in series)
Instructions for charging batteries:
a. Set output voltage (measured at no load and at the battery end of the cable) very precisely to the end-of-charge voltage.
b. Use a 30A or 32A circuit breaker (or blocking diode) between the power supply and the battery.
c. Ensure that the output current of the power supply is below the allowed charging current of the battery.
d. Use only matched batteries when putting 12V types in series.
e. The return current to the power supply (battery discharge current) is typ. 23mA when the power supply is switched off (except in case a
blocking diode is utilized).
22Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Page 23
Bulletin 1606 Switched Mode Power Supplies
240V
+10%
max.
Fuse
L2
L1
L3
L
N
PE
Power Supply
AC
DC
internal
fuse
23.10 Operation on Two Phases
The power supply can also be used on two-phases of a three-phase-system. Such a phase-to-phase connection is
allowed as long as the supplying voltage is below 240V
+10%
. Use a fuse or a circuit breaker to protect the N input.
The N input is internally not protected and is in this case connected to a hot wire. Appropriate fuses or circuit
breakers are specified in section “External Input Protection”.
23.11 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 defines 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 items are inside the box
Rockwell Automation Publication 1606-RM001B-EN-P - August 201323
Page 24
Bulletin 1606 Switched Mode Power Supplies
Pow er
Supply
OUTPUTINPUT
Output C urrent
0
10203040
60°C
6
12
18
24A
50
A
1
Ambient Temperature
Pow er
Supply
OUTPUTINPUT
Output C urrent
0
10203040
60°C
6
12
18
24A
50
Ambient Temperature
A
2
A
1
Output C urrent
0
10203040
60°C
6
12
18
24A
50
Ambient Temperature
A
1
A
2
Pow er
Supply
OUTPUTINPUT
Output C urrent
0
10203040
60°C
6
12
18
24A
50
Ambient Temperature
A
1
A
2
Pow er
Supply
OUTPUTINPUT
Output C urrent
0
10203040
60°C
6
12
18
24A
50
Ambient Temperature
A
1
A
2
23.12 Mounting Orientations
Mounting orientations other than all terminals on the bottom require a reduction in continuous output power or a limitation in the maximum allowed
ambient temperature. The amount of reduction influences the lifetime expectancy of the power supply. Therefore, two different derating curves for
continuous operation can be found below:
Curve A1Recommended output current.
Curve A2Max allowed output current (results in approximately half the lifetime expectancy of A1).
Fig.23-5:
Mounting Orientation
A
(Standard
orientation)
Fig.23-6:
Mounting Orientation
B
(Upside down)
Mounting Orientation
(Table-top mounting)
Mounting Orientation
(Horizontal cw)
Mounting Orientation
(Horizontal ccw)
Enclosure:Rittal Typ IP66 Box PK 9522 100, plastic, 254x180x165mm
Load: 24V, 16A; (=80%) load is placed outside the box
Input:230Vac
Temperature inside enclosure: 53.5°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 25.3°C
Temperature rise:28.2K
24Rockwell Automation Publication 1606-RM001B-EN-P - August 2013
Fig.23-7:
C
Fig.23-8:
D
Fig.23-9:
E
Page 25
Page 26
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support
code and links to software service packs, and a MySupport feature that you can customize to make the best use of these
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, you can find technical manuals, technical and application notes, sample
for FAQs, technical
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
Te c h C o nn e c t
representative, or visit http://www.rockwellautomation.com/support/
SM
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 Canada1.440.646.3434
Outside United States or CanadaUse the Worl dwide Lo cato r at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local
Rockwell Automation representative.
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Outside United StatesPlease contact your local Rockwell Automation representative for the return procedure.
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