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

V

OUT

V

IN

1606-XLE: 480

28V

528 552432408 360

P

OUT

> 48W (5%)

P

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

V

IN

P

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

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

A

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.

V

OUT

40A A041A0580A

0

A

15s

24V

200A60A A081A061A021A001

A02

12V

I

OUT

B

5s

C

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-

up

Time

Zero Transition

Output
Voltage

Intput
Voltage

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

24V

12V

18V

14V

V

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.

T

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

Bulletin 1606 Switched Mode Power Supplies

9. Eciency and Power Losses

1606-XLE960DX-3N

A04 %5.59 .pyt ycneiciffE
A04 W2.54 .pyt sessol rewoP

A0 W2.81 .pyt

Fig. 9-1 Eciency vs. output current Fig. 9-2 Losses vs. output current

Eciency

04015

88

89

90

91

92

93

Output Current

94

95

96%

15 20 25 30 35

Power Losses

0481216202428 40

0

10

20

30

40

50W

32 36

Output Current

Fig. 9-3 Eciency vs. input voltage, 24V, 40A Fig. 9-4 Losses vs. input voltage, 24V, 40A

Eciency

350 400 450 500 3x550

Va

c

94.6

94.8

95.0

95.2

Input Voltage

95.4

95.6

95.8%

Power Losses

350 400 450 500 3x550

Va

c

40

42

44

46

Input Voltage

48

50

52W

A

8 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.

A

10. Functional Diagram

Fig. 10-1 Functional diagram

+

-

Active

Transient

Blocker

Input
Filter

Input

Rectier

Reset

Output
Voltage
Monitor

Over-

Voltage

Protection

Output

Power

Manager

Temp.

Shut­down

Input
Voltage
Monitor

L3

L2

L1

Semi-

regulated

Power

Converter

Output

Filter

DC-ok
LED

Warning
LED

Shut-down
LED

11. Front Side and User Elements

Fig. 11-1 Front side of 1606-XLE960DX-3N

A. Output Terminals

Large screw terminal

+ Positive output

- Negative (return)

output

See section 12
“Terminals and
Wiring” to choose
appropriate wire size.

B. Input Terminals

Screw terminals

L1, L2, L3:

Line inputs

PE (Protective

Earth) input

C. DC-ok LED (green)

Indicates a normal operation. The LED is on
if the output voltage is higher than 21.6V.

D. Warning LED (yellow)

- A steady-state light indicates an output
current higher than the nominal current
and that the internal shutdown timer is
running.

- A double ash indicates a phase-loss or
too low / too high input voltage.
(1606-XLE960DX-3N:
< 3x400Vac or > 3x560Vac)

- A fast ash warns of an impending
temperature shut-down. A shut-down
can be expected within 10 minutes, if
the ambient temperature or the load
current stays constant.

E. Shut-down LED (red) and reset button F.

The red LED ashes when the device has
shut down. Pressing the reset button or
cycling the input power (10s required)
initiates a restart. If the fault has been
cleared the device will operate normally.

A

B

C

D

E

F

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 9

Bulletin 1606 Switched Mode Power Supplies

12. Terminals and Wiring

Use appropriate copper cables that are designed for a minimum operating temperatures of 60°C (for ambient up to
45°C) and 75°C (for ambient up to 60°C). Follow national installation codes and regulations! Ensure that all strands of
a stranded wire enter the terminal connection! Do not use the power supply without PE (Ground) connection! Up to
two stranded wires with the same cross section are permitted in one connection point (except PE wire). Ferrules are
allowed, but not required.

Output

Input

lanimret wercS lanimret wercS epyT

mm6-5.0 eriw diloS

2

mm61-5.0

2

mm4-5.0 eriw dednartS

2

mm01-5.0

2

GWA 8-22 GWA 01-02 eguag eriw naciremA
Wire stripping length 7mm / 0.26inch 12mm / 0.5inch
Recommended tightening torque 0.8Nm / 7lb.inch 1.2Nm / 10.6lb.inch

13. Reliability

Lifetime expectancy min. 51 000h 40°C, 24.1V, 40A

A04 ,V1.42 ,C°52 h000 241 .nim
A04 ,V1.42 ,C°04 h000 925 90716 CEI ,00592 NS FBTM
A04 ,V1.42 ,C°52 h000 959

°

04

h000 602

F712 KBDH LIM FBTM

C, 24.1V, 40A, Ground Benign GB40

276 000h 25°C, 24.1V, 40A, Ground Benign GB25

The Lifetime expectancy shown in the table above indicates the operating hours (service life) and is determined by
the lifetime expectancy of the built-in electrolytic capacitors.

Lifetime expectancy is specied in operational hours and is calculated according to specications from the
manufacturer of the capacitor. The prediction model allows a calculation up to 15 years from the shipping date.

MTBF stands for Mean Times Between Failures which is calculated according to statistical device failures, and indicates
reliability of a device. It is the statistical representation of the likelihood of failure of the unit, and does not necessarily
represent the life of a product.

10 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.

Bulletin 1606 Switched Mode Power Supplies

14. EMC

The power supply is suitable for applications in industrial environments as well as in residential, commercial and light
industry environment without any restriction. The CE Mark indicates conformance with EMC guideline 89/336/EC,
93/68/EC and the low-voltage directive (LVD) 73/23/EC, 93/68/EC and 2006/95/EC.

A detailed EMC Report is available upon request.

EMC Immunity

EN 61000-6-1, EN 61000-6-2 Generic standards

Electrostatic discharge EN 61000-4-2 Contact discharge

Air discharge

8kV
15kV

Criterion A

Criterion A
Electromagnetic RF eld EN 61000-4-3 80MHz-1GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines

Output lines

4kV
4kV

Criterion A

Criterion A

Surge voltage on input

EN 61000-4-5 L1
L1 / L2 / L3

+ -

2kV
4kV

500V

Criterion A

Criterion A

Criterion A

-

+

PE

Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A

EMC Emission

EN 61000-6-3 and EN 61000-6-4 Generic standards

Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B, input lines

Class B, output lines

Radiated emission EN 55011, EN 55022 Class B

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.

Switching frequency

Switching frequency 36kHz Nearly constant

EN 55022

L2, L2 L3, L1 L3

PE

Surge voltage on output EN 61000-4-5

500V

Criterion A

Mains voltage dips EN 61000-4-11 0% of 400Vac 20ms Criterion B
40% of 400Vac 200ms Criterion C
70% of 100Vac 500ms Criterion C
0% of 480Vac 20ms Criterion B
40% of 480Vac 200ms Criterion C
70% of 480Vac 500ms Criterion C

Power transients VDE 0160 over entire load range 1300V, 1.3ms Criterion D

Criteria:

A: Power supply shows normal behavior within the dened limits.
B: During the mains voltage dip, the output voltage will decrease according to curves in the Hold-up Time section. Unit works in normal

mode after the voltage dip. If criterion A is required, use one or two buffer modules in addition to the 1606-XLE960DX-3N supply.

C: Temporary loss of function is possible. Power supply may shutdown and restart by itself. No damage or hazard to the power supply occurs.
D: The input transient blocker opens and the main converter is without input power during such transients. The output voltage decreases as

well, as described in the Hold-up Time section, during such an event.

Harmonic input current EN 61000-3-2 Fullled, active PFC

Voltage uctuations, icker EN 61000-3-3 Fullled

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 11

Bulletin 1606 Switched Mode Power Supplies

15. Environment

Operational temperature -25°C to +70°C (-13°F to 158°F) Reduce output power above +60°C

ees ,)F°851 ot F°041( C°07-06 24W/°C Output derating Fig. 15-1

Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation

.H.r %59 ot 5 ytidimuH

no condensation allowed

Vibration sinusoidal

2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis

IEC 60068-2-6

Vibration random

0.5m

2(s3

)

2 hours / axis

IEC 60068-2-64

Shock

15g 6ms, 10g 11ms
3 bumps / direction, 18 bumps in total

IEC 60068-2-27

tneibma ro rewop tuptuo ecudeR )tf000 02 ot 0( m0006 ot 0 edutitlA

temperature above 2000m sea level.

Output derating (for altitude) 60W/1000m or 5°C/1000m above 2000m, see Fig. 15-2.

NE III Over-voltage category

50178, altitudes up to 2000m

m0006 ot m0002 morf sedutitlA II

evitcudnoc non ,87105 NE 2 noitullop fo eergeD

Fig. 15-1 Output current vs. ambient temp., Fig. 15-2 Output current vs. altitude

Allowed
Output Current

0

-25 0 20 40

70°

10

20

30

40A

60

Ambient Temperature

Allowed Output
Current

0

0 2000 4000

6000m

10

20

30

40A

Altitude

A

.

.

.

T

a

m

b

<

6

0

°

C

B

.

.

.

T

a

m

b

<

5

0

°

C

C

.

.

.

T

a

m

b

<

4

0

°

C

A

B

C

The ambient temperature is dened 2cm below the unit.

C

12 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.

Bulletin 1606 Switched Mode Power Supplies

16. Protection Features

Output protection Electronically protected against overload, no-load and short-circuits

*)

Output overvoltage protection max. 29.9Vdc in case of an internal power supply defect, a redundant

circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.

Input overvoltage shutdown typ. 3x 560Vac 1606-XLE960DX-3N

Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm e.g. screws, small parts
Over-temperature protection yes output shut-down with automatic restart
Input transient protection MOV (Metal Oxyde Varistor) and active transient blocker
Internal input fuse not included see section 25.4

*) An audible noise may be heard during a no-load, overload or short circuit event.

17. Safety

Input/output separation SELV IEC/EN 60950-1

PELV
double or reinforced insulation

EN 60204-1, EN 50178, IEC 60364-4-41

Class of protection I PE (Protective Earth) connection required

Isolation resistance > 5MOhm input to output, 500Vdc
PE resistance < 0.1Ohm between housing and PE terminal
Touch current (leakage current) typ. 0.40mA 13x480V, 60Hz, TN mains

< 0.45mA 3x524V, 60 Hz, TN mains

18. Dielectric Strength

Fig. 18-1 Dielectric strength

A B C

Type test 60s 2500Vac 3000Vac 500Vac
Factory test 5s 2500Vac 2500Vac 500Vac
Field test 5s 2000Vac 2000Vac 500Vac

A

C

B

L1

Input

Earth

Output

-

+

L3

L2

Type tests and factory tests:

Conducted by the manufacturer. Do not repeat these tests in
the eld!

Rules for eld test:

Use appropriate test equipment which applies the voltage
with a slow ramp! Connect L1, L2 and L3 together as well as
all output poles.

The output voltage is oating and has no ohmic connection to ground. Grounding of output is allowed.
To fulll the PELV requirements according to EN60204-1, paragraph 6.4.1, we recommend that either + pole or

the – pole be connected to the protective earth system. This helps avoid situations in which a load starts
unexpectedly or cannot be switched o when an unnoticed ground fault occurs.

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 13

Bulletin 1606 Switched Mode Power Supplies

19. Certications

UL 508

IND. CONT. EQ.

18WM
LISTED

LISTED E56639 for use in the U.S.A. (UL 508) and Canada
(C22.2 No. 14-95)

UL 60950

RECOGNIZED E1168663 for use in the U.S.A. (UL 60950-1)
and Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3

EN 60950-1, EN 61204-3 Complies with CE EMC and CE Low Voltage Directives

Marine RINA

RINA (Registro Italiano Navale) certied. See below for link
to the Certicate.

GOST R

GOST R certication is applicable for products intended for sale and use
within Russia. See below for link to the Certicate.

C-TICK C-Tick compliance is for products intended for sale and use within

the Australian market. See below for link to the C-Tick Declarations
of Conformity.

20. Environmental Compliance

The unit does not release any silicone and is suitable for use in paint shops.

Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.

Plastic housings and other molded plastic materials are free of halogens.

The materials used in our production process do not include the following toxic chemicals:
Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated
Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated
Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica

Product certification information (including Certificates and Declarations of Conformity) can be found at www.ab.com/certifications.

14 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.

Bulletin 1606 Switched Mode Power Supplies

21. Physical Dimensions and Weight

Weight 1400g / 3.09lb
DIN Rail Use 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 depth (157mm) to calculate the total required
installation depth.

Fig. 21-1 Front view

Side view

22. Installation and Operating Instructions

Mounting and installation:

Output terminal must be located on top and input terminal on the bottom. For other orientations see section 25.12.
An appropriate electrical and re end-product enclosure needs to be considered in the end use application.

Cooling:

Convection cooled, no forced air cooling required. Do not block ventilation grille by more than 30%!

Installation clearances:

40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently
with full power. If the adjacent device is a heat source, 15mm clearance are recommended.

Risk of electrical shock, re, personal injury or death!

Do not use the unit without proper earth connection (Protective Earth). Use the pin on the terminal block for earth
connection and not one of the screws on the housing.
Turn power o before working on the power supply. Protect against inadvertent re-powering.
Make sure the wiring is correct by following all local and national codes.
Do not open, modify or repair the unit.
Use caution to prevent any foreign objects from entering the housing.
Do not use in wet locations or in areas where moisture and/or condensation are likely to occur.

Service parts:

The unit does not contain any eld replaceable parts. In case of damage or malfunction, turn power o immediately
and return the unit to the manufacturer for inspection.

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 15

Bulletin 1606 Switched Mode Power Supplies

23. Accessories

Buer Module 1606-XLSBUFFER24

This buer unit is a supplementary device for DC24V power supplies. It delivers power to bridge typical mains failures
or extends the hold-up time after turn-o of the AC power. At times when the power supply provides sucient
voltages, the buer unit stores energy in integrated electrolytic capacitors. In case of mains voltage fault, this energy
is released again in a regulated process.

Fig. 23-1 Buer module 1606-XLSBUFFER24

Fig. 23-2

Wiring diagram:
1606-XLSBUFFER24

The buer unit does not require any
control wiring. It can be added in parallel
to the load circuit at any given point.
Buer units can be added in parallel to
increase the output ampacity or the hold­up time.

Do not use the buer module to bridge mains interruptions which are longer than typ. 350ms. Once the mains is o
for longer than typ. 350ms, the power supply needs an additional 1s to restart.

24. Comparison between the 1606-XLE960DX-3N, a Transformer and a
Traditional Switched-mode Power Supply

1606-XLE960DX-3N

semi-regulated

power supply

Traditional

switched-mode

power supply

Transformer

power supply

Input voltage range

+ ++ -

Inrush current surge

++ + -

Hold-up time

- + -

Phase-loss operation

- + -

Eciency

+++ ++ -

Output voltage regulation

+ ++ -

Output adjustment range

- ++ -

Ripple & noise voltage

- ++ -

Error diagnostics

++ ++ -

Harmonic distortion (PFC)

+ + -

EMC

++ ++ +

Ease of installation

++ ++ -

Size

+++ ++ -

Weight

+++ + -

+++ …very, very good ++…very good +…good -…poor

DC

Buer

Unit(s)

Power

Supply

Load

AC

+

-

16 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.

Bulletin 1606 Switched Mode Power Supplies

25. Application Notes

25.1. Periodic Peak Power Capability

Fig. 26 Periodic peak power capability

The short term power can be used
periodically.

The duration of the peak power (Tp)
must be shorter than 15s.

The time between two peak power
pulses must be three times longer than
the duration of the preceding pulse
length.

t

T

100%

125%

P

OUT

P

NOM

TP> 3x T

P

25.2. Charging Batteries

Do not use this power supply to charge batteries.

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 17

Bulletin 1606 Switched Mode Power Supplies

25.3. Output Circuit Breakers

Standard miniature circuit breakers (MCBs or UL 1077 supplementary breakers) can be used for branch protection
but make sure that the MCB is rated for DC voltage as well. The following tests show which circuit breakers the power
supply will typically trip.

Circuit breakers have huge tolerances in their tripping behavior. These typical tests can therefore be used only as a
recommendation or for comparing two dierent power supplies. Furthermore, the loop impedance has a major
inuence on whether a breaker trips or not. Two tests were performed, representing typical situations:

Test 1: Short circuit with S1 on the power supply end of the cable (loop impedance approx. 20mOhm)

Fig. 25-1 Branch protectors, test circuit 1

Circuit

Breaker

Power

Supply

AC

DC

+

-

I

Load

+

-

S1

Parameters:

Input voltage: 3x400Vac, load current: 0A

The following circuit breaker tripped during the test:
A- or

Z -Characteristic: equal or smaller 25A *)

B- Characteristic: equal or smaller 32A *)

C- Characteristic: equal or smaller 20A *)

Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).

Fig. 25-2 Branch protectors, test circuit 2

R

Circuit

Breaker

Power

Supply

AC

DC

+

-

I

S1 Load

+

-

Parameters:

Input voltage: 3x400Vac, load current: 0A

The following circuit breaker tripped during the test:
A- or

Z -Characteristic: ≤ 25A and R= 50mOhm *)

B- Characteristic: ≤ 25A and R= 50mOhm *)
C- Characteristic: ≤ 20A and R= 82mOhm *)

What does this resistance mean in wire length?

1.0mm

2

1.5mm2 2.5mm2 4.0mm2 6.0mm2 10mm

2

50mOhm

2.8m 4.2m 7.0m 11.1m 16.7m 27.9m

82mOhm

4.6m 6.9m 11.4m 18.3m

27.4m 45.7m

*) A list of the circuit breakers under test is available upon request.

Example:

Which wire gauge must be used at a length of 10m before a B-Characteristic circuit breaker with 25A trips?
Answer: A 25A B-Characteristic circuit breaker requires a loop impedance of less than 50mOhm based on the test

results. The wire length table shows that a length of 11.1m with a cross-section of 4.0mm has an impedance of
50mOhm. A wire not smaller than 4.0mm

2

shall be used.

2

18 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.

Bulletin 1606 Switched Mode Power Supplies

25.4. External Input Protection

The power supply has no internal input fuses included. The unit is tested and approved for branch circuits up to 16A
(U.S.A. 15A). External protection is required only if the supplying branch has an ampacity greater than this. In some
countries local regulations may apply; do check all local codes and requirements. If an external fuse is necessary or
utilized, minimum requirements need to be considered to avoid nuisance tripping of the fuse.

citsiretcarahC-C citsiretcarahC-B

Ampacity max.

20A 20A

min.

6A 3A

25.5. 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-EMF (Electro Magnetic Force).

This power supply is resistant and does not show adverse eects when a load feeds back voltage to the power supply.
It does not matter whether the power supply is on or o.

If the power supply is fully loaded after a return-feeding event, the output voltage can dip to 21V for approx. 20ms.
The maximum allowed feed back voltage is 28.9Vdc. The absorbing energy can be calculated according to the built-in

large sized output capacitor which is specied in section 7.

25.6. Parallel Use to Increase Output Power

The 1606-XLE960DX-3N power supply shall not be used in parallel to increase output power.

25.7. Parallel Use for Redundancy

Power supplies can be paralleled for a 1+1 redundancy to gain a higher system availability and reliability. 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 1606-XLE power supplies in parallel (a method called 1+1 redundancy). In case one power supply fails,
the second is automatically able to support the load current without any interruption.

Please note: This simple way to build a redundant system does not cover failures such as an internal short circuit on
the secondary side of the power supply. In such a condition, the shorted unit becomes a load for the other power
supplies and the output voltage can not be maintained. This can be avoided by using decoupling diodes wich are
included in some redundancy modules.

Recommendations for building redundant power systems:
a) Use separate input fuses for each

power supply.

b) Monitor the individual power supply units. A DC-ok LED and a DC-ok contact are included in some redundancy

modules and are able to report a faulty unit.

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 19

Bulletin 1606 Switched Mode Power Supplies

25.8. Series Operation

Power supplies from the 1606-XLE family can be used in series to increase output voltage.

Fig. 25-3 Schematic for series operation

Installation notes for use in series:

Unit B

-

+

Load

+

-

AC

DC

AC

DC

-

+

Unit A

Earth
(see notes)

a) It is possible to connect as many units in series as needed,

providing the sum of the output voltage does not exceed
150Vdc.

b) Voltages with a potential above 60Vdc are no longer rated SELV

and can be hazardous in some situations. Such voltages must be

installed with a protection to make the unit touch-safe.
c) For serial operation use power supplies of the same type.
d) Earthing of the output is required when the sum of the output

voltage is above 60Vdc.

e) Keep an installation clearance of 15mm (left/right) between two

power supplies and avoid installing the power supplies on top of

each other.

Note:

Avoid return voltage (e.g. from a decelerating motor or

battery) which is applied to the output terminals.

25.9. Inductive and Capacitive Loads

The unit is designed to supply any kind of loads, including inductive loads or capacitive loads with a capacity of up
to160mF.

25.10. Loss of One Input Phase

The unit protects itself against a loss of one input phase and does not require an external protection device.
A phase-loss operation is possible for output currents below 8A. Above this level, the yellow LED indicates an

impending shut-down. If the missing phase does not recover, the unit switches o after 3.5s. Pressing the reset
button or cycling the input power (10s required) initiates a restart.

Please note that the input current and the output ripple are higher when one phase is missing.

25.11. 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. The inside temperature denes the ambient temperature for the power supply.

Results from such an installation:
Power supply is placed in the middle of the box, no other heat producing equipment is inside the box.
Enclosure: Rittal Typ IP66 Box PK 9519 100, plastic, 180x180x165mm

Load: 24V, 32A (=80% of the rated current); load is placed outside the box.
Input: 3x400Vac
Temperature inside the box: 54.9°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside the box: 25.7°C
Temperature rise: 29.7K

20 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.

Bulletin 1606 Switched Mode Power Supplies

25.13. Mounting Orientations

Mounting orientations other than input terminals on the bottom and output on the top require a reduction in
continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction
inuences the lifetime expectancy of the power supply. Therefore, two different derating curves for continuous
operation can be found below:

Curve A1 Recommended output current.
Curve A2 Max allowed output current (results in approximately half the lifetime expectancy of A1).

Fig. 25-4
Mounting
Orientation A

(Standard
orientation)

Power
Supply

OUTPUT

INPUT

Output Power

0

10 20 30 40

60°C

12

36

48

60W

50

A

1

24

Ambient Temperature

Fig. 25-5
Mounting
Orientation B

(Upside down)

Power

Supply

OUTPUT

INPUT

Output Power

0

10 20 30 40

60°C

12

36

48

60W

50

24

A

1

A

2

Ambient Temperature

Fig. 25-6
Mounting
Orientation C

(Table-top
mounting)

Output Power

0

10 20 30 40

60°C

12

36

48

60W

50

24

A

1

A

2

Ambient Temperature

Fig. 25-7
Mounting
Orientation D

(Horizontal cw)

Power

Supply

OUTPUT

INPUT

Output Power

0

10 20 30 40

60°C

12

36

48

60W

50

24

A

1

A

2

Ambient Temperature

Fig. 25-8
Mounting
Orientation E

(Horizontal ccw)

Power

Supply

OUTPUT

INPUT

Output Power

0

10 20 30 40

60°C

12

36

48

60W

50

24

A

1

A

2

Ambient Temperature

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 21

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support
notes, sample code and links to software service packs, and a MySupport feature that you can customize to
make the best use of these tools. You can also visit our Knowledgebase at http://

www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums,

software updates, and to sign up for product notification updates.

, you can find technical manuals, technical and application

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConne ct
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 Canada 1.440.646.3434

Outside United States or Canada Use the Wor ldwi de Lo cato r at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local

Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from
the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these
procedures.

United States Contact your distributor. You must provide a Customer Support c ase number (call the phone number above to obtain one) to your

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

distributor to complete the return process.

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improve this document, complete this form, publication RA-DU002

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