Rockwell Automation 1606-XLP15A User Manual

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLP15A

Index

Intended Use .......................................................3

2. Installation Requirements...................................3

3. AC-Input...............................................................4

4. DC-Input...............................................................5

5. Input Inrush Current ...........................................5

6. Output .................................................................6

7. Hold-up Time.......................................................7

8. Efciency and Power Losses................................8

9. Functional Diagram.............................................9

10. Front Side and User Elements.............................9

11. Terminals and Wiring........................................10

12. Lifetime Expectancy and MTBF.........................10

13. EMC ....................................................................11

14. Environment ......................................................12

15. Protection Features ...........................................13

16. Safety Features ..................................................13

17. Dielectric Strength ............................................14

Certications ................................................... 15

18.

19. Physical Dimensions and Weight ..................... 16

20. Application Notes............................................. 17

20.1. Peak Current Capability ...........................17

20.2. Back-feeding Loads ..................................17

20.3. External Input Protection .........................18

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

20.5. Parallel Use for Redundancy ....................19

20.6. Series Operation ....................................... 19

20.7. Inductive and Capacitive Loads ................ 19

20.8. Operation on Two Phases ........................20

20.9. Use Without PE on the Input ...................20

20.10. Use in a Tightly Sealed Enclosure ............ 21

20.11. Mounting Orientations ............................ 22

egaP egaP

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

Power Supply

100-240V Wide Range Input NEC Class 2 Compliant Adjustable Output Voltage Efciency up to 77.2% Compact Design, Width only 22.5mm Full Output Power Between -10°C and +60°C Large International Approval Package

3 Year Warranty

Description

Compact size, light weight, simple installation onto the DIN rail and the integration of only the highest quality components are the factors that make the XLP family of power supplies so easy to deploy and use within seconds.

A rugged electrical and mechanical design as well as high immunity against electrical disturbances on the mains provide reliable output power. This power supply offers superior protection for equipment connected to the public mains network or exposed to a critical industrial environment.

The XLP family of power supplies offers output voltages from 5 to 56Vdc and power ratings from 15W to 120W.

Specication Quick Reference

Output voltage DC 5V Adjustment range 5 – 5.5V Output current 3A at 5V Output power 15W Output ripple < 50mVpp 20Hz to 20MHz Input voltage AC 100-240V -15% / +10% Mains frequency 50-60Hz ±6% AC Input current 0.28 / 0.17A at 120 / 230Vac Power factor 0.51 / 0.44 at 120 / 230Vac AC Inrush current typ. 16 /31A peak value at

120/230Vac, 40°C

and cold start DC Input 88-375Vdc Efciency 76.8 / 77.2% at 120 / 230Vac Losses 4.6 / 4.5W at 120 / 230Vac Temperature range -10°C to +70°C operational Derating 0.4W/°C +60 to +70°C Hold-up time typ. 45 / 186ms at 120 / 230Vac Dimensions 22.5x75x91mm WxHxD Weight 130g / 0.29lb

Catalog Numbers

Power Supply 1606-XLP15A 5V Standard unit

Certications

UL 508

UL 60950-1 NEC Class 2

Class I Div 2

CSA 22.2 No107.1

Marine

EMC, LVD

Marine RINA

GOST R

C-Tick

All parameters are specified at 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

2 Rockwell Automation Publication 1606-RM019A-EN-P — March 2014

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.

• Should damage or malfunction 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.

• 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 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM019A-EN-P — March 2014 3

Bulletin 1606 Switched Mode Power Supplies

3. AC Input

AC input nom. AC 100-240V -15% / +10%, TN/TT/IT-mains AC input range 85-264Vac continuous operation 264–300Vac < 0.5s Allowed voltage L or N to earth max. 300Vac Input frequency nom. 50–60Hz ±6% Turn-on voltage typ. 59Vac steady-state value, see Fig. 3-1 Shut-down voltage typ. 54Vac steady-state value, see Fig. 3-1

AC 100V AC 120V AC 230V Input current (rms) typ. 0.34A 0.28A 0.17A at 5V, 3A see Fig. 3-3 Power factor *) typ. 0.52 0.51 0.44 at 5V, 3A see Fig. 3-4 Crest factor **) typ. 3.45 3.53 3.94 at 5V, 3A Start-up delay typ. 630ms 630ms 630ms see Fig. 5 2 Rise time typ. 10ms 10ms 10ms at 5V, 3A, see Fig. 3-2 Turn-on overshoot max. 100mV 100mV 100mV see Fig. 3-2

*) The power factor 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.

Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, denitions

Turn-on

85V

Rated

input range

max.

500ms

OUT

54V 300Vac264V

Shut-down

59V

Start-up

delay

Rise

Time

Overshoot

- 5%

Output Voltage

Intput Voltage

Fig. 3-3 Input current vs. output load Fig. 3-4 Power factor vs. output load

3.0A

0.5

1.0

2.00

0.10

0.4A

Input Current, typ.

2.5

0.20

1.5

0.25

0.15

0.05

0.30

0.35

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

Output Current

3.0A

0.5 1.0

1.5 2.5

0.30

0.35

0.40

0.45

0.50

0.55

Power Factor, typ.

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

2.0

Output Current

4 Rockwell Automation Publication 1606-RM019A-EN-P — March 2014

All parameters are specified at 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

4. DC Input

DC input nom. DC 110-300V -20%/+25%

DC input range min. 88-375Vdc continuous operation

DC input current typ. 0.16A / 0.057A 110Vdc / 300Vdc, at 5V, 3A Turn-on voltage typ. 80Vdc steady state value Shut-down voltage typ. 60Vdc steady state value

Fig. 4-1 Wiring for DC Input

Instructions for DC use:

Load

Power Supply

Battery

internal

fused

a) Use a battery or similar DC source.

For other sources, please contact Rockwell Automation. b) Connect +pole to L and –pole to N. c) Connect the PE terminal to an earth wire or to the

machine ground.

5. Input Inrush Current

A NTC limits the input inrush current after turn-on of the input voltage. The inrush current is input voltage and ambient temperature dependent.

The charging current into EMI suppression capacitors is disregarded in the rst microseconds after switch-on.

AC 100V AC 120V AC 230V

Inrush current max. 13A

peak

16A

peak

31A

peak

40°C ambient, cold start

typ. 11A

peak

13A

peak

26A

peak

40°C ambient, cold start

Inrush energy max. 0.1A

s 0.1A2s 0.4A2s 40°C ambient, cold start

Fig. 5-1 Input inrush current, typical behavior

Fig. 5-2 Input inrush current, zoom into rst peak

Input: 230Vac Output: 5V, 3A Ambient: 25°C Upper curve: Input current 5A/DIV Lower curve: Input voltage 500V/DIV Time basis: 10ms / DIV

Output: 5V, 3A Ambient: 25°C Input current curve: 5A/DIV, 500μs / DIV

Ipeak 23A

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM019A-EN-P — March 2014 5

Bulletin 1606 Switched Mode Power Supplies

6. Output

Output voltage nom. 5V Adjustment range min. 5-5.5V guaranteed max. 6V *) at clockwise end position of potentiometer Factory setting 5.1V ±0.2%, at full load, cold unit Line regulation max. 10mV 85-264Vac Load regulation max. 100mV static value, 0A 3A Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm Output capacitance typ. 4 800μF Output current nom. 3A at 5V, see Fig. 6-1 nom. 2.72A at 5.5V, see Fig. 6-1 Output power nom. 15W Short-circuit current min. hiccup mode see Fig. 6-2

max. 3A rms-current short circuit impedance <10mOhm, unit makes start-up

attempts at short-circuit (hiccup mode)

*) This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. There is no

guarantee this value can be achieved. The typical value achievable by turning the potentiometer to the clockwise end position is 5.8V.

Fig. 6-1 Output voltage vs. output current,

typ.

Fig. 6-2 Hiccup mode; output current at

shorted output, 230Vac, typ.

Output Voltage

3.5

2.51.50.5 2.01.0 3.0

Adjustment

Range

Output Current

Continuous Hiccup Mode

Output Current

3.3A

45ms

235ms 235ms

Peak current capability (up to several milliseconds)

The power supply can deliver a peak current which is higher than the specied short term current. This helps to start current demanding loads or to safely operate subsequent circuit breakers.

The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be discharged and causes a voltage dip on the output. Detailed curves can be found in section 20.1.

Peak current voltage dips typ. from 5V to 2.4V at 6A for 50ms, resistive load typ. from 5V to 1.0V at 15A for 2ms, resistive load typ. from 5V to 0.8V at 15A for 5ms, resistive load

6 Rockwell Automation Publication 1606-RM019A-EN-P — March 2014

All parameters are specified at 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time

AC 100V AC 120V AC 230V Hold-up Time typ. 61ms 93ms 340ms at 5V, 1.5A, see Fig. 7-1 typ. 29.5ms 45ms 186ms at 5V, 3A, see Fig. 7-1

Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on at this time.

Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, denitions

125

150ms

85 120 155 190 230Vac

Input Voltage

Hold-up Time

100

a) 5V 1.5A typ. b) 5V 1.5Amin. c) 5V 3A typ. d) 5V 3A min.

a b c d

- 5%

Hold-up Time

Zero Transition

Output Voltage

Input Voltage

All parameters are specified at 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM019A-EN-P — March 2014 7

Bulletin 1606 Switched Mode Power Supplies

8. Efciency and Power Losses

AC 100V AC 120V AC 230V Efciency typ. 75.8% 76.8% 77.2% at 5V, 3A (full load) Power losses typ. 0.2W 0.3W 0.6W at 0A typ. 2.3W 2.3W 2.4W at 5V, 1.5A (half load) typ. 4.9W 4.6W 4.5W at 5V, 3A (full load)

Fig. 8-1 Efciency vs. output current at 5V,

typ.

Fig. 8-2 Losses vs. output current at 5V,

typ.

Efciency

78%

3.0A1.0 1.5 2.5

Output Current

0.5 2.0

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

Power Losses

0 0.5 3.0A

1.0 1.5 2.0

Output Current

2.5

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

b c

c b a

Fig. 8-3 Efciency vs. input voltage at 5V, 3A,

typ.

Fig. 8-4 Losses vs. input voltage at 5V, 3A,

typ.

Efciency

85 120

155

190 225 260Vac

78%

Input Voltage

Power Losses

3.75

4.25

4.50

4.75

85 120

155

190 225 260Vac

Input Voltage

4.00

8 Rockwell Automation Publication 1606-RM019A-EN-P — March 2014

All parameters are specified at 5V, 3A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.

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