Rockwell Automation 1606-XLE960DX-3N User Manual

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLE960DX-3N

Index

1. Description ...........................................................1

2. Specication Quick Reference ............................1

3. Catalog Numbers .................................................1

4. Certication Marks ..............................................1

5. AC Input

6. Input Inrush Current

7. Output .................................................................5

8. Hold-up Time.......................................................6

9. Efciency and Power Losses................................7

10. Functional Diagram.............................................8

11. Front Side and User Elements.............................8

12. Terminals and Wiring..........................................9

13. Reliability .............................................................9

14. EMC ....................................................................10

15. Environment ......................................................11

16. Protection Features ...........................................12

17. Safety Features ..................................................12

18. Dielectric Strength ............................................12

19. Certications

.............................................................3

..........................................4

.....................................................13

Terminology and Abbreviations

Environmental Compliance ........................... 13

20.

21. Physical Dimensions and Weight .................... 14

22. Installation and Operating Instructions ..........14

23. Accessories ........................................................ 15

24. Comparison between the 160 a Transformer and a Traditional Switched-

Mode Power Supply .........................................15

25. Application Notes

25.1. Periodic PeakPower Capability

25.2. Charging Batteries ..................................16

25.3. Output Circuit Breakers ................17

25.4. External Input Protection ......................... 18

25.5. Back-Feeding Loads ...................................18

25.6. Parallel Use to Increase Output Power ....18

25.7. Parallel Use for Redundancy ....................18

25.8. Series Operation .......................................19

25.9. Inductive and Capacitive Loads ................19

25.10 Loss of One Input Phase ...........................19

25.11. Use in a Tightly Sealed Enclosure ............19

25.12. Mounting Orientations ............................20

........................................... 16

Page

6-XLE960DX-3N,

.................16

•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.

• 3AC 400V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)

included. 3AC means three phase input. E.g.: DC 12V describes a 12V battery disregarding whether it is charged (13.7V) or discharged (10V). If not otherwise stated, 3AC 400V parameters are valid at 50Hz and 3AC 480V parameters are valid at 60Hz mains frequency.

• 3x 400Vac—A figure with the unit (Vac) at the end is a value used during testing without any additional tolerance included. 3x 400Vac means a three phase input.

Bulletin 1606 Switched Mode Power Supplies

Semi-Regulated Power Supply

••

Alternative or Replacement for AC Transformer

•

Three Phase Input – DC Output

•

Mountable on a Din Rail

•

Width only 96mm

•

95.5% Eciency

•

125% Peak Power Capability

•

No Input Inrush Current

•

Active Input Transient Blocker

•

Full Power Between -25°C and +60°C

•

Easy Failure Diagnostics

•

No Electrolytic Capacitors on Input Side

•

Cost Eective and Robust

•

3 Year Warranty

1. Description

2. Specication Quick Reference

Output voltage DC 24V Factory setting to

24.1V Adjustment range none Output current 40A continuous

50A for typ. 15s

Output power 960W continuous

1200W for typ. 15s

Output ripple < 1500mVpp 20Hz-2kHz

< 200mVpp 2kHz to 20MHz

Input voltage 3AC 480V 1606-XLE960DX-3N

Mains frequency 50-60Hz ±6% AC Input current 1.4A / phase 3x480V

Power factor 0.93 24V, 40A AC Inrush current typ. 2A peak Eciency 95.5% Losses 45.2W Temperature range -25°C to +70°C operational Derating 24W/°C +60 to +70°C

The power supplies in the three-phase (-3) series feature a new and innovative concept for generating an isolated DC voltage from a three-phase mains system.

A semi-regulated resonant converter enables a very compact design, maximum eciency and extremely competitive pricing with only a small compromise in the output voltage regulation, output ripple and hold-up time.

Weighing just 1.4 kg, the device provides 960 watts of continuous output power and an additional 25% power reserve for dynamic loads. The light-weight design along with compact dimensions facilitate straightforward mounting on DIN rail.

Primary use are applications involving supplies to motors, valves and other load circuits with a high power consumption, where an accurate output voltage regulation which is standard on traditional switched-mode power supplies is not required. Furthermore, these switched-mode power supplies can often replace mains transformers with rectiers.

Dimensions 96x124x159mm WxHxD

3. Catalog Numbers

4. Certication Marks

Power Supply

1606-XLE960DX-3N 480V Input

IND. CONT. EQ.

18WM

LISTED

UL 508

UL 60950-1

EMC, LVD

Accessory 1606-XLSBUFFER24 24V Buffer Unit

Marine RINA

GOST R

C-Tick

All parameters are specified at 24V, 40A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2 Rockwell Automation Publication 1606-RM024A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

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.

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 section 25-14

in this 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, 40A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM024A-EN-P — April 2014 3

Bulletin 1606 Switched Mode Power Supplies

5. AC-Input

1606-XLE960DX-3N

AC input nom. 3AC 480V Mains arrangement

TN-, TT- or IT-Mains. Consult factory if one phase is grounded.

AC input range

min.

3x 432-528Vac fully regulated output (±2%), Pout > 48W

min. 3x 360-552Vac

permanently allowed, see Fig. 5-1 for output voltage regulation

max. 3x 565Vac Absolute maximum input voltage with no

damage to the power supply. Output might be o at this level.

Input frequency

nom. 50 – 60Hz ±6%

Turn-on voltage typ. 3x 390Vac see

Fig. 5-2

Shut-down voltage typ.

3x 355Vac see Fig. 5-2

Input current

nom. 1.4A at 40A, symmetrical input, see Fig. 5-4 Power factor **) typ. 0.93 at 40A, symmetrical input, see Fig. 5-5 Turn-on overshoot typ. 480mV see

Fig. 5-3

Start-up delay ***) typ. 350ms over the entire load range, see Fig. 5-3 Rise time typ. 40ms 0mF, 40A, see

Fig. 5-3

typ. 70ms 40mF, 40A, see

Fig. 5-3

*) A minimum voltage of 3x408Vac is required to turn the power supply on. **) The power factor is the ratio of the true (or real ) power to the apparent power in an AC circuit. ***) The start-up delay for mains voltage interruptions up to 350ms is close to zero. In such cases, the power supply will

immediately generate the output voltage once the mains voltage interruption is over. Do not use the 1606-XLSBUFFER24 buer module as an accessory when longer mains interruptions need to be bridged (see section 23).

Input Voltage Range

Fig. 5-1

Output voltage vs. input voltage and input current

Changes of the input voltage will be fully regulated within certain limits. The output voltage will only start to change proportionally to the input voltage with extreme under or over-voltages. The yellow LED reports an input voltage problem if exceeded by a window of ±15%. The maximum increase of the output voltage is limited to the 29.9V OVP level. This level will be kept regulated for 2s before the power supply will shut down and re ports “Shut-down” by the red LED.

24V

20V

26V

22V

504456 576Vac384

OUT

1606-XLE: 480

28V

528 552432408 360

OUT

> 48W (5%)

OUT

= 0W

4 Rockwell Automation Publication 1606-RM024A-EN-P — April 2014

All parameters are specified at 24V, 40A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Fig. 5-2 Input Voltage Range Fig. 5-3 Turn-on behavior denitions

Turn-on

fully regulated

range

OUT

3x 528Vac

Shut-down

3x 432Vac480V Version:

3x 440Vac3x 360Vac400V Version:

Start-up

delay

Rise

Time

Overshoot

- 5%

Output Voltage

Intput Voltage

Fig. 5-4 Input current vs. output load Fig. 5-5 Power factor vs. output load

50A

510 30 45

0.3

0.6

0.9

1.2

1.5

1.8A

Input Current per Phase, typ.

Output Current

15 20 25 35 40

50A

510 30 45

0.70

0.75

0.8

0.85

0.9

0.95

1.0

Power Factor, typ.

Output Current

15 20 25 35 40

6. Input Inrush Current

There is virtually no input inrush current surge as there are no electrolytic bulk-capacitors used on the input side of the power supply.

The charging current into the EMI suppression capacitors is disregarded for the rst millisecond after switch-on.

1606-XLE960DX-3N

Inrush current

max. 4A

peak

-25°C to +70°C, see Fig. 6-1

Inrush energy max. 5A2s -25°C to +70°C, see

Fig. 6-1

Inrush delay

typ. 350ms see

Fig. 6-1

Fig. 6-1 Input inrush current

Input Current

Input Voltage

Output Voltage

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 40A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM024A-EN-P — April 2014 5

Bulletin 1606 Switched Mode Power Supplies

7. Output

Output voltage nom. 24.1V Output voltage adjustment range

none The output voltage is xed. No adjustment possible.

Output current

nom. 40A continuous, see Fig. 7-1

50A up to 15s with full output voltage, see Fig. 7-1

Short-circuit current

typ. 180A load impedance 25mOhm, see

Fig. 7-1

Note: The short-circuit current is available for 0.1s.

Output power

nom. 960W continuous

1200W up to 15s

Line regulation

max. ±2% see Fig. 5-1

Load regulation max. 800mV static value, 0A 40A 0A

max. 200mV static value, 5A 40A 5A

Ripple and noise voltage *)

max. 1500mVpp 20Hz-2kHz, 50Ohm

max. 50mVpp 2kHz to 20MHz, 50Ohm

Output capacitance

typ. 20 000μF

*) The ripple and noise voltage mostly consist of a mains ripple with 300Hz (50Hz mains) or 360Hz (60Hz mains). The ripple and noise voltage can be reduced by using external capacitors.

The power supply is also designed to support loads with a higher short-term current and power requirement. The short-term duration is rmware-controlled by an output power manager. If the nominal output power is exceeded for a certain period of time which is dened in zone A, B and C, the power supply responds with an automatic shutdown. Pressing the reset button or cycling the input power (10s o time is required) initiates a restart attempt. If the fault has been cleared the device will operate normally.

The short term power can be used periodically . See section 25.1 for further information.

Fig. 7-1 Output voltage vs. output current, typ.

OUT

40A A041A0580A

15s

24V

200A60A A081A061A021A001

A02

12V

OUT

0.1s

3x 408V 3x 480V 3x 552V

Zone A : 25% extra output power for typ. 15s

Zone B:

100% higher output current for typ. 5s

Zone C:

Quick-acting shut-down after typ. 0.1s

6 Rockwell Automation Publication 1606-RM024A-EN-P — April 2014

All parameters are specified at 24V, 40A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

8. Hold-up Time

1606-XLE960DX-3N

Hold-up Time typ. 2.0ms 40A, resistive load, see

Fig. 8-2

ees ,daol rewop tnatsnoc ,A04 sm8.1 .pyt

Fig. 8-2

sm0.4 .pyt

20A, resistive load

daol rewop tnatsnoc ,A02 sm6.3 .pyt

Hold-up Time min. 1.6ms 40A, resistive load, see

Fig. 8-2

ees ,daol rewop tnatsnoc ,A04 sm54.1 .nim Fig. 8-2

sm2.3 .nim 20A, resistive load

daol rewop tnatsnoc ,A02 sm9.2 .nim

Fig. 8-1 Hold-up time, denitions

The energy is stored in the output capacitor. As soon as the input is turned o, the output capacitor will be discharged and the voltage will dissipate according to the curves in Fig 8-2. The lighter the load, the longer the hold-up time. Half the load means twice the hold-up time. The hold-up time depends on the load characteristic. The curves below show the hold-up time for a load with a resistive and a constant power characteristic. The hold-up time is dened as the period of time when the input is turned o and until the output voltage falls below 24V

–15% (20.4V). This value is dened in the IEC61131-2 as the lower limit for the supplying voltage.

-15%

Hold-

Time

Zero Transition

Output Voltage

Intput Voltage

Fig. 8-2 Hold-up time vs. input voltage

24V

12V

18V

14V

OUT

22V

16V

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

5.5 6.0 6.5 7.0 7.5 8.05.0 8.5 9.0ms

40A, constant power load, typ.

40A, resistive load, typ.

40A, constant power load, min.

40A, resistive load, min.

20.4V

Note: At no load, the hold-up time can be up to one minute. The green DC-ok LED is on at this time.

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 40A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM024A-EN-P — April 2014 7

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