Rockwell Automation 1606-XLE480EPC User Manual

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number:

1606-XLE480EP, 1606-XLE480EPC

Index

1. Intended Use 3

2. Installation Requirements 3

3. AC-In put 4

4. DC-Input 5

5. Input Inrush Current 5

6. Output 6

7. Hold-up Time 7

8. DC-OK Relay Contact 7

9. Efficiency and Power Losses 8

10. Lifetime Expectancy and MTBF 9

11. Functional Diagrams 9

12. Terminals and Wiring 10

13. Front Side and User Elements 11

14. EMC 12

15. Environment 13

16. Protection Features 14

17. Safety Features 14

18. Dielectric Strength 14

19. Certifications 15

20. Standards Compliance 15

21. Dimensions and Weight 16

22. Accessories 17

22.1 Wall Mounting Bracket 17

22.2 Redundancy Modules 18

23. Application Notes 19

23.1 Peak Current Capability 19

23.2 Back-feeding Loads 20

23.3 External Input Protection 20

23.4 Output Circuit Breakers 20

23.5 Parallel Use to Increase Output Power 21

23.6 Parallel Use for Redundancy 21

23.7 Series Operation 22

23.8 Inductive and Capacitive Loads 22

23.9 Charging of Batteries 22

23.10 Operation on Two Phases 23

23.11 Use in a Tightly Sealed Enclosure 23

23.12 Mounting Orientations 24

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, 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.

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.

CATALOG NUMBERS

Power Supply 1606-XLE480EP 24-28V Standard unit

1606-XLE480EPC Conformal coated

Accessories 1606-XLC Wall Mount Bracket

1606-XLSRED40HE Redundancy Module

1606-XLSREDS40HE Redundancy Module

1606-XLSRED40 Redundancy Module

Specifications

Output voltage DC 24V Adjustment range 24 - 28V Output current 20A at 24V, amb <60°C

24A at 24V, amb <45°C

17.1A at 28V, amb <60°C

20.6A at 28V, amb <45°C

Output power 480W ambient <60°C

576W ambient <45°C Output ripple < 50mVpp 20Hz to 20MHz AC Input voltage AC 100-240V -15%/+10% Mains frequency 50-60Hz ±6% AC Input current 4.36 / 2.33A at 120 / 230Vac Power factor 0.99 / 0.95 at 120 / 230Vac AC Inrush current typ. 9 / 7A peak at 120 / 230Vac Efficiency 92.7 / 94.0% at 120 / 230Vac Losses 37.8 / 30.6W at 120 / 230Vac Temperature range -25°C to +70°C operational Derating 12W/°C +60 to +70°C

between 100-85Vac, see chapter 15, Environment

page 13

Hold-up time typ. 26 / 26ms at 120 / 230Vac Dimensions 65x124x127mm WxHxD Weight 1000g / 2.2lb

Certifications

UL 508

UL 60950-1

EMC, LVD, RoHS

2 Rockwell Automation Publication 1606-RM001B-EN-P - August 2013

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 2013 3

Bulletin 1606 Switched Mode Power Supplies

Turn-on

85V

Rat ed

input range

max.

500ms

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

Input C urrent, typ.

20 22

a) 100Vac b) 120Vac c) 230Vac

Output Current

P ower Factor, typ.

2 4 6 8 10 12 14 16 18 24A

0.75

0.8

0.85

0.9

0.95

1.0

20 22

a) 100Vac b) 120Vac c) 230Vac

a, b

Out put C urr ent

3.AC-Input

AC input nom. AC 100-240V suitable for TN-, TT- and IT mains networks AC input range min. 100-264Vac continuous operation

min. 85-100Vac short 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 earth max. 300Vac continuous, IEC 62103 Input frequency nom. 50–60Hz ±6% Turn-on voltage typ. 84Vac steady-state value, see Figu re 3-1 Shut-down voltage typ. 39Vac steady-state value at 5A load, see Fi gure 3-1

typ. 53Vac steady-state value at 10A load, see Figure 3-1

typ. 74Vac steady-state value at 20A load see Figu re 3-1

AC 100V AC 120V AC 230V

Input current typ. 5.25A 4.36A 2.33A at 24V, 20A, see Figure 3-3 Power factor

Crest factor

**)

typ. 0.99 0.99 0.95 at 24V, 20A, see Figure 3-4

typ. 1.5 1.5 1.65 at 24V, 20A Start-up delay typ. 850ms 850ms 650ms see Figure 3- 2 Rise time typ. 85ms 85ms 85ms at 24V, 20A const. current load, 0mF load capacitance,

typ. 150ms 150ms 150ms at 24V, 20A const. current load, 20mF load

Turn-on overshoot max. 200mV 200mV 200mV see Figure 3-2

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

**) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.

see Figure 3 -2

capacitance, see Figure 3 -2

Fig. 3-1: Input voltage range Fig. 3-2: Turn-on behaviour, definitions

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

4 Rockwell Automation Publication 1606-RM001B-EN-P - August 2013

Bulletin 1606 Switched Mode Power Supplies

Output

100mS /D IV

Input

230Vac

24Vdc

Input Current 5A / DIV

4. DC-Input

Do not operate this power supply with DC-input voltage. Use Cat. No. 1606-XLE480EP-D instead.

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 first microseconds after switch-on.

AC 100V AC 120V AC 230V

Inrush current

Inrush energy

Inrush delay typ. 935ms 935ms 735ms start-up delay plus rise time

*) Mains interruptions > 500ms

Fig. 5-1: Typical input inrush current behavior

at nominal load and 25°C ambient

max. 13A

typ. 11A max.

peak

s2.5A

13A

peak

s0.5A

13A

peak

temperature independent temperature independent

temperature independent

Rockwell Automation Publication 1606-RM001B-EN-P - August 2013 5

Bulletin 1606 Switched Mode Power Supplies

Output Voltage

(Single U se, typ.)

025

28V

40A155 10 20 30 35

Adjus tment

Range

Output Current

Continuous

current Fact or y setting

Hiccup

mode

Output Voltage

(Parallel U se , ty p.)

22V

0816

23V

24V

25V

29V

26V

27V

28V

24A20124

Adjus tment

Range

Fact or y setting

Output Current

6. Output

Output voltage nom. 24V Adjustment range min. 24-28V guaranteed

max.

Factory settings typ. 24.1V ±0.2%, at full load, cold unit, in “single use” mode

typ. 24.1V ±0.2%, at full load, cold unit, in “parallel use” mode typ. 25.1V at no load, cold unit, in “parallel use” mode

Line regulation max. 10mV 85-300Vac Load regulation max. 100mV in “single use” mode: static value, 0A  20A;

typ. 1000mV in “parallel use” mode: static value, 0A  20A,

Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm Output current nom. 20A at 24V, ambient temperature <60°C, see Figure 6 -1

nom. nom. 17.1A at 28V, ambient temperature <60°C, see Figure 6-1

nom. typ. 80A up to 15ms, output voltage stays above 20V, see Figure 6-4 , This peak current is

Output power nom. 480W continuously available

nom.

Overload behaviour cont. currentoutput voltage > 13Vdc, see Fig ure 6-1

Short-circuit current min.

max. max.

min. 70A up to 15ms, load impedance <10mOhm, see Figure 6 -4 typ. 100A up to 15ms, load impedance <10mOhm, see Figure 6- 4

Output capacitance typ. 7 000μF included 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

6 Rockwell Automation Publication 1606-RM001B-EN-P - August 2013

PLUS

mode, typ.

Fig. 6-4: Dynamic overcurrent capability, typ.

Bulletin 1606 Switched Mode Power Supplies

Output Cur r ent

42A

18s

S hort -cir cuit

Normal

operation

Normal

operation

Ou tput Voltage

(dynamic behavior, < 15ms)

28V

100A4020 60 8010 30 50 70 90

Adjus tment

Range

Output Current

80ms

90 120 155 190 230Vac

Input Voltage

Hold-up Time

24V, 20A, typ.

24V, 10A, min.

24V, 10A, typ.

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

OUT

= V

ADJ

openclosed closed

1ms

7. Hold-up Time

AC 100V AC 120V AC 230V

Hold-up Time typ. 65ms 65ms 65ms at 24V, 10A, see Figure 7-1

min. 54ms 54ms 54ms at 24V, 10A, see Fig ure 7-1 typ. 26ms 26ms 26ms at 24V, 20A, see Fi gure 7-1 min. 21ms 21ms 21ms at 24V, 20A, see Fig ure 7-1

Fig. 7-1: Hold-up time vs. input voltage Fig. 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 closes As soon as the output voltage reaches 90% of the adjusted output voltage level. Contact opens As soon as the output voltage dips more than 10% below the adjusted output voltage.

Contact ratings max. 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load

Isolation voltage Refer to Dielectric Strength

Short dips will be extended to a signal length of 100ms. Dips shorter than 1ms will be ignored.

min. 1mA at 5Vdc min. permissible load

Fig. 8-1: DC-ok relay contact behavior

on page 14.

Rockwell Automation Publication 1606-RM001B-EN-P - August 2013 7

Bulletin 1606 Switched Mode Power Supplies

Eff i ci ency

4 6 8 101214 1820 24A

94%

100Vac

120Vac

230Vac

Out put Current

16 22

Power Losses

02 68 1214 24A

60W

18 20

4 10 16

Output C urrent

120Vac

100Vac

230Vac

Ef f iciency

120 180 230 264Vac

Input Volta ge

95%

100

Power Losses

120 180 230 264Vac

Input Volta ge

50W

100

9. Efficiency and Power Losses

AC 100V AC 120V AC 230V

Efficiency typ. 92.0% 92.7% 94.0% at 24V, 20A

Average efficiency

Power losses typ. 6.5W 3.9W 2.6W at 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, typ Fig. 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,

25% at 15A. 25% at 20A

typ. 21.1W 20.1W 17.0W at 24V, 10A typ. 41.7W 37.8W 30.6W at 24V, 20A typ. 52.8W 47.4W 36.8W at 24V, 24A (Power Boost)

Fig. 9-3: Efficiency vs. input voltage at 24V, 20A, typ.

Fig. 9-4: Losses vs. input voltage at 24V, 20A, typ.

8 Rockwell Automation Publication 1606-RM001B-EN-P - August 2013

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