Rockwell Automation 1606-XLS180B User Manual

Rockwell Automation

1606-XLS180B 12V, 15A; Single Phase Input

1606-XLS180B

12V,15A Single Phase Input

POWER SUPPLY

¾ Ultra-small size
¾ Extra-low inrush current
¾ Active power factor correction
¾ Wide range AC/DC input
¾ Superior reserve power (can support 150% rated power for five seconds)
¾ Superior efficiency and temperature rating
¾ DC-OK and overload LED

1. GENERAL DESCRIPTION

The most outstanding features of this 1606-XLS DIN-rail power supply are the high efficiency and the small size, which are achieved by a synchronous rectification and
further novel design details.

With short-term peak power capability of 150% and built-in large sized output capacitors, these features help start motors, charge capacitors and absorb reverse energy and
often allow a unit of a lower wattage class to be used.

High immunity to transients and power surges as well as low electromagnetic emission makes usage in nearly every environment possible.
The integrated output power manager, a wide range input voltage design and virtually no input inrush current make installation and usage simple. Diagnostics are easy due

to the dry DC-ok contact, a green DC-ok LED and red overload LED.

Unique quick-connect spring-clamp terminals allow a safe and fast installation and a large international approval package for a variety of applications makes this unit
suitable for nearly every situation.

2. SPECIFICATION QUICK REFERENCE

Output voltage DC 12V
Adjustment range 12-15V
Output current 15A continuous, 12V

22.5A for typ. 4s, 12V
Output power 180W continuous, 12V
270W for typ. 4s, 12V
Output ripple < 50mVpp 20Hz to 20MHz
Input voltage AC 100-240V ±15%
Line frequency 50-60Hz ±6%
AC Input current 1.65 / 0.93A at 120 / 230Vac
Power factor 0.98 / 0.92 at 120 / 230Vac
AC Inrush current typ. 4 / 7A peak at 120 / 230Vac
DC Input voltage DC 110-300V
DC Input current 1.78 / 0.65A at 110 / 300Vdc
Efficiency 91.5 / 91.8% at 120 / 230Vac
Losses 16.7 / 16.1W at 120 / 230Vac
Temperature range -25°C to +70°C operational
Derating 5W/°C +60 to +70°C
Hold-up time typ. 32 / 32ms at 120 / 230Vac
Dimensions 60x124x117mm WxHxD

-

-20%/+25%

3. AGENCY APPROVALS

IND. CONT. EQ.

UL 508

Class I Div 2

GL

Marine

UL 60950-1

EMC, LVD

4. RELATED PRODUCTS

1606-XLB Wall mount bracket
1606-XLSRED Redundancy Module
1606-XLBUFFER Buffer unit

INDEX PAGE INDEX PAGE

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Rockwell Automation

1606-XLS180B 12V, 15A; Single Phase Input

1. General Description................................................................1

2. Specification Quick reference.................................................1

3. Agency Approvals...................................................................1

4. Related Products....................................................................1

5. AC-Input..................................................................................3

6. Input Inrush Current................................................................4

7. DC-Input.................................................................................4

8. Output.....................................................................................5

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

10. DC-OK Relay Contact............................................................7

11. Efficiency and Power Losses..................................................8

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

13. Product Face label..................................................................9

14. Terminals and Wiring............................................................10

15. Reliability..............................................................................10

16. EMC......................................................................................11

17. Environment .........................................................................12

18. Protection Features..............................................................13

19. Safety....................................................................................13

20. Dielectric Strength................................................................13

21. Approvals..............................................................................14

22. Fulfilled Standards................................................................14

23. Used Substances..................................................................14

24. Physical Dimensions and Weight .........................................15

25. Installation and Operation Instructions .................................15

26. Accessories...........................................................................16

27. Application Notes..................................................................17

27.1. Repetitive Pulse Loading..........................................17

27.2. Peak Current Capability ...........................................18

27.3. Back-feeding Loads..................................................18

27.4. Charging of Batteries................................................18

27.5. Output Circuit Breakers............................................19

27.6. External Input Protection..........................................19

27.7. Parallel Use to Increase Output Power....................20

27.8. Parallel Use for Redundancy ...................................20

27.9. Daisy Chaining of Outputs........................................20

27.10. Series Operation ......................................................20

27.11. Inductive and Capacitive Loads ...............................21

27.12. Operation on Two Phas es........................................21

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

27.14. Mounting Orientations..............................................21

INTENDED USE

Those responsible for the applicati on and use of the products must satisfy themselves th at all necessary steps have b een taken to assure that each
application and use meets all performance and safety requirements, including and applicable laws, regulation , codes, and standards.

TERMINOLOGY AND ABBREVIATIONS

PE and

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

230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.

PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage

symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol

±20%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
As long as not otherwise stated, AC 100V and AC 230V parameters are valid at 50Hz and AC 120V parameters are
valid at 60Hz mains frequency.

.

DISCLAIMER

The information presented in this document is believed to be accurate and reliable and may change without notice.

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

5. AC-INPUT

AC input
AC input range
min. 60-85Vac full power for 200ms, no damage between 0 and 85Vac

Input frequency
Turn-on voltage typ. 81Vac steady-state value, see Fig. 5-1
Shut-down voltage typ. 63Vac steady-state value, see Fig. 5-1

AC 100V AC 120V AC 230V

Input current
Power factor * typ. 0.99 0.98 0.92 at 12V, 15A, see Fig. 5-4
Crest factor ** typ. 1.65 1.67 1.85 at 12V, 15A
Start-up delay typ. 800ms 650ms 340ms see Fig. 5-2
Rise time typ. 8ms 8ms 8ms 0mF, 12V, 15A, see Fig. 5-2

Turn-on overshoot

* 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. 5-1 Input vol tage range Fig. 5-2 Turn-on behavior, definitions

P

OUT

full

power

for

200ms

Shut-down

60V 300Vac

input range

Tur n-o n

85V

Ra t e d

Fig. 5-3 Input current vs. output load at 12V Fig. 5-4 Power factor vs. output load

Input Current, typ.

2.0A

1.5

1.0

0.5

0

135791113

nom. AC 100-240V wide-range input, see Fig. 5-1
min. 85-276Vac continuous operation

min. 276-300Vac < 500ms
nom. 50 – 60Hz ±6%

typ. 55Vac dynamical value

typ. 1.98A 1.65A 0.93A at 12V, 15A, see Fig. 5-3

typ. 15ms 15ms 15ms 15mF, 12V, 15A, see Fig. 5-2
max. 20mV 20mV 20mV see Fig. 5-2

max.

500ms

276V

c

a

V

0

0

c

1

a

V

0

2

1

c

a

V

0

3

2

Output Current

15A

V

IN

Intput
Vol tag e

Output
Vol tag e

Power Factor, typ.

1.0

0.95

0.9

0.85

0.8

0.75
135791113

- 5%

St a r t - u p

delay

Ri se

Ti me

100Vac

120Vac

a

V

0

3

2

Output Current

c

15A

Overshoot

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

6. INPUT INRUSH CURRENT

An active inrush limitation circuitry 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 milliseconds after switch-on.

AC 100V AC 120V AC 230V
Inrush current
typ. 5A
Inrush energy
Inrush delay

Fig. 6-1 Input inrush current, typical beh avior

A

B

max. 10A

peak

peak

10A

4A

peak

peak

10A

7A

peak

peak

-25°C to +70°C

-25°C to +70°C
max. 1A2s 1A2s 1A2s -25°C to +70°C
typ. 650ms 520ms 250ms

Input Current

A: Inrush delay
B: Start-up delay

Input: 230Vac
Output: 12V, 15A
Ambient: 25°C

Input Voltage

Upper curve: Input current 2A / DIV
Medium curve: Input voltage 500V / DIV
Lower curve: Output voltage 10V / DIV

Output Voltage

Time basis: 100ms / DIV

7. DC-INPUT

DC input nom. DC 110-300V
DC input range min. 88-375Vdc continuous operation
DC input current typ. 1.78A / 0.65A 110Vdc / 300Vdc, 12V, 15A
Turn-on voltage typ. 80Vdc steady state value
Shut-down voltage typ. 55Vdc steady state value

Fig. 7-1 Wiring for DC Input

Battery

+

-

Fu se

Power Supply

AC

internal

fused

L

N

PE

DC

Instructions for DC use:

a) Use a battery or similar DC source.

+

Lo ad

-

b) Connect +pole to L and –pole to N.
c) Connect the PE terminal to a earth wire or to the machine

ground.

When the –pole of the battery is not connected to earth, use an
appropriate fuse to protect the N terminal.

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1606- XLS180B 12V, 15A; Single Phase Input

8. OUTPUT

Output voltage
Adjustment range
max. 16.5V at clockwise end position of potentiometer
Factory setting
Line regulation
Load regulation max. 100mV static value, 0A Æ 15A Æ 0A
Ripple and noise voltage
Output capacitance typ. 7 000µF

Continuous power capability

Output current

Output power
nom. 203W 15V, continuous
Short-circuit current
max. 18A load impedance 50mOhm, see Error! Reference source not found.

Power Boost, short term power capability (up to typ. 4s)

The power supply is designed to support loads with a high er short-term power requirement without damage or shutdown. The short- term duration is
hardware controlled by an output power manager. The Power Boost is repeatedly available. Detailed information can be found in chapter 27.1 .

Once Power Boost has been stopped by the output pow er limi ter, a tim er disables the next Power Boost capability. The recovery timer will start as soon
as the output voltage reaches the adjusted value again, which usually happens after the load has been reduced.

Output current

Output power
nom. 305W 15V, short term
Short-circuit current
max. 35A load impedance 100mOhm, see Error! Reference source not found.
Boost time
min 3s see Error! Reference source not found.

Power Boost recovery time

Peak current capability (up to several ms)

The power supply can deliver a peak current which is hig her than the specified short term current. This helps to start current demandi ng 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 chapter 27.2.

Peak current voltage dips
typ. from 12V to 7.5V at 60A for 2ms

nom. 12V
min. 12-15V guaranteed, multi turn potentiometer

max. 10mV 60 to 300Vac

max. 50mVpp 20Hz to 20MHz, 50Ohm

nom. 15A at 12V, see Error! Reference source not found.
nom. 13.5A at 15V, see Error! Reference source not found.
nom. 180W 12V, continuous

min. 12A load impedance 50mOhm, see Error! Reference source not found.

nom. 22.5A at 12V, see Error! Reference source not found.
nom. 20.3A at 15V, see Error! Reference source not found.
nom. 270W 12V, short term

min. 15A load impedance 100mOhm, see Error! Reference source not found.

typ. 4s at 12V, 22.5A, duration until the output voltage dips,

max. 5s
typ. 7s overload free time to reset power manager, see Fig. 8-3

typ. from 12V to 10V at 30A for 20ms

typ. from 12V to 5.2V at 60A for 5ms

12.0V

±0.2%, at full load, cold unit

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

Fig. 8-1 Output voltage vs. output current, typ. Fig. 8-2 Bonus time vs. output power

Output Voltage

16V

14
12
10

8
6
4
2
0

0 5 10 20 25

Adjustment

Range

s

c
o

n
t

i

n
u
o
u
s

Output Current

h

o

r

t

-

t

e

r

m

35A15 30

Fig. 8-3 Power-Boost recovery time

Bonus Time

10s

9
8
7
6
5
4
3
2
1
0

110 120 130 140 150

m

a

x

m

i

n

Output Power

160%

Limitation by
Po w e r M a n ag er

100%

Reco ve ry Ti m e

Bonus Power disabled

Po w e r
Demand

Output
Vol tag e

<150%

Bonus

Ti me

Power Boost

is available as soon as power comes on and immediately after the end of an output short circuit.

Fig. 8-4 Power-Boost after input turn-on Fig. 8-5 Power-Boost after output short

100%

Short of

Out put

150%

Bonus

Boost
Power

Po w e r

Intput
Vol tag e

Output
Vol tag e

Output
Po w e r

100%

150%

Boost

Bonus

Power

Output
Vol tag e

ePo w r

Output
Po w e r

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

9. HOLD-UP TIME

AC 100V AC 120V AC 230V
Hold-up Time typ. 31ms 32ms 32ms 15A, 12V, see
typ. 72ms 72ms 73ms 7.5A, 12V, see Fig. 9-1

Fig. 9-1 Hold-up time vs. input voltage Fig. 9-2 Shut-down behavior, de finitions

Hold-up Time

75ms

60

45

30

15

0

85 120 155 190 230Vac

12V, 7.5A, t yp.

,

m

,

7

.

5

A

1

2

V

y

t

,

A

5

1

,

V

2

1

i

A

m

,

1

,

5

1

2

V

Input Voltage

Zer o Tr ansit io n

.

i

n

.

p

.

n

Intput
Vol tag e

Output
Vol tag e

Hold-up Time

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

Fig. 9-1

- 5%

10. DC-OK RELAY CONTACT

This feature monitors the output volt age, which is produced by the power supply itself. It is independent of a back-fed volt age from a unit which is
connected in parallel to the power supply output.

Contact closes As soon as the output voltage reaches the adjusted output voltage.

Contact opens As soon as the output voltage dips more than 10% below the adjusted output voltage.

Contact re-closes As soon as the output voltage exceeds 90% of the adjusted voltage.
Contact ratings max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
min 1mA at 5Vdc min. permissible load
Isolation voltage See dielectric strength table in section 20

F ig. 10-1 DC-ok relay contact behavior

V

=

V

OUT

ADJ

90%
V

ADJ

open

<

1ms

Short dips will be extended to a signal length of 250ms. Dips shorter than 1ms will be ignored.

Note:

The DC-ok feature requires that the output voltag e reaches the nominal

10%

(=adjusted) level after turn-on in order to function according to
specification. If this level cannot be achiev ed, the overload lamp will be
on and the DC-ok contact will be open. The overload signal wil l only

>

1ms

250ms

shut off as soon as the adjusted voltage is re ached. T his is an import ant
condition to consider particularly, if the load is a battery, the power
supply is used in parallel or the power supply is used for N+1 redundan t
systems.

opencl osed clo sed

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A

1606- XLS180B 12V, 15A; Single Phase Input

11. EFFICIENCY AND POWER LOSSES

AC 100V AC 120V AC 230V
Efficiency typ. 90.7% 91.5% 91.8% 15A, 12V
Power losses typ. 18.5W 16.7W 16.1W 15A, 12V
typ. 3.8W 3.9W 4.9W 0A, 12V

Fig. 11-1 Efficiency vs. output current at 12V Fig. 11-2 Losses vs. output current at 12V

Eff ici ency

93%

92
91
90
89
88
87
86
85

3

511

Output Current

79 13

100Vac

230Vac

120Vac

15

Fig. 11-3 Effici ency vs. input voltage, 12V, 15A Fig. 11-4 Losses vs. input voltage, 12V, 15A

Eff ici ency

94%

93

92

91

90

89

88

85 120 155 190 225 260

Input Voltage

Vac

Power Losses

19W

17
15
13
11

9
7
5
3

03691215A

Power Losses

24W

20

16

12

8

85 120 155 190 225 260

100Vac

120Vac

230Vac

Output Current

Input Voltage

Vac

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

12. FUNCTIONAL DIAGRAM

Fig. 12-1 Functional diagram

L

N

Input Fuse
Input Filter
Input Rectifier
Active Transient Filter &
Inrush Current Limiter

Temper-

ature
Shut­down

Output
Power

Manager

PFC

Converter

Output

Over-

Voltage

Protection

Converter

Output
Voltage
Monitor

Power

Output

Voltage

Regulator

Output

Filter

DC-ok
Relay

V

OUT

+
+

-

-

Overload
lamp

DC-ok
lamp

DC-ok
contact

13. PRODUCT FACE LABEL

Output Terminals

Quick-connect spring-clamp
terminals, no tools required

+ Positive output

- Negative (return) output

Dual pins per pole
DC ok Relay contact
(NO-contact)

180W Continuous power /
270W Peak power

Input Terminals

Quick-connect spring-clamp
terminals, no tools required

N … Neutral input
L … Line (hot) input

... PE (Protective Earth) input

See chapter 14 “Terminals and
Wiring” to choose appropriate wire
gauges

Fig. 13-1 Front side

Output voltage potentiometer

(multi turn potentiometer)
Open the flap to tune the output voltage.
Factory setting: 12.0V

DC-ok lamp (green)
Overload lamp (red)

Normal mode OFF ON Closed
Power Boost

mode
Overload

< 90%)

(V

OUT

Short-circuit

= ca. 0V)

(V

OUT

Over- temperature Intermitted OFF Open

No input power OFF OFF Open

Overload

lamp

OFF ON Closed

ON OFF Open

ON OFF Open

DC-ok lamp and DC-ok contact
function synchronized

DC-ok

lamp

DC-ok

contact

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

14. TERMINALS AND WIRING

Type Bi-stable, quick-connect spring clamp terminals. IP20 Finger safe construction.

Suitable for field- and factory installation. Shipped in open position.
Solid wire 0.5-6mm
Stranded wire 0.5-4mm
American wire gauge 20-10 AWG
Ferrules allowed, but not required
Wire stripping length 10mm / 0.4inch
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)

Fig. 14-1 Connecting a wire

1.

Insert the wire

To disconnect wire: same procedure
vice versa

2.

Snap t he lever

2
2

Instructions:

a) Use appropriate copper cables that are designed for an

operating temperature of:
60°C for ambient up to 45°C and

75°C for ambient up to 60°C minimum.
b) Follow national installation codes and installation regulations!
c) Ensure that all strands of a stranded wire enter the terminal

connection!
d) Up to two stranded wires with the same cross section are

permitted in one connection point (except PE wire).

e) Do not use the unit without PE connection.

15. RELIABILITY

AC 100V AC 120V AC 230V

Lifetime expectancy min. 61 000h 65 000h 76 000h 40°C, 12V, 15A
min. 111 000h 117 000h 112 000h 40°C, 12V, 7.5A
min. 172 000h 15 years 15 years 25°C, 12V, 15A
MTBF SN 29500, IEC 61709 577 000h 582 000h 631 000h 40°C, 12V, 15A
998 000h 1 006 000h 1 091 000h 25°C, 12V, 15A
MTBF MIL HDBK 217F 361 000h 362 000h 370 000h 40°C, 12V, 15A, Ground Ben ign GB40
495 000h 496 000h 507 000h 25°C, 12V, 15A, Ground Benign GB25

The Lifetime expectancy shown in the ta ble indicates the operating hours (servic e life) and is determined by the lifetime expectancy of the built-in
electrolytic capacitors.

Lifetime expectancy is specified in operational hours. Lifetime expectancy is c alculated according to the capacitor’s manufactu rer specification. The
prediction model allows a calculation of up to 15 years from date of shipment.

MTBF stands for Mean Time Between Failure, whic h is calculated according to statis tical device failures, and indic ates reliability of a device. It is the
statistical representation of the likelihood of the unit to fail and does not necessarily represent the life of a product.

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1606- XLS180B 12V, 15A; Single Phase Input

16. EMC

The power supply is suitable for applications in ind ustrial environment as well as in residential, commercial and l ight industry environ ment without any
restrictions. CE mark is in conformance with EMC guideline 89/336/EEC and 93/68/EEC and the low-voltage directive (LVD) 73/23/EWG.

EMC Immunity EN 61000-6-1 EN 61000-6-2 Generic standards

Electrostatic discharge EN 61000-4-2 Contact discharge

Electromagnetic RF field EN 61000-4-3 80MHz-1GHz 10V/m Criterion A

Fast transients (Burst) EN 61000-4-4 Input lines

Surge voltage on input EN 61000-4-5 L Æ N

Surge voltage on output EN 61000-4-5 + Æ -

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

Line voltage dips EN 61000-4-11 70% of 100Vac

Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C

Voltage sags SEMI F47 0200

Input voltage swells RA internal standard 300Vac, 500ms Criterion A
Powerful transients VDE 0160 over entire load range 750V, 1.3ms Criterion A

Criterions:
A: Power supply shows normal operation behavior within the defined limits.

C: Temporary loss of function is possible. Power supply might shut-down and restarts by itself. No damages or hazards for the power supply occur.

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
EN 55022 Class B, output lines
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 Fulfilled, active PFC
Voltage fluctuations, flicker EN 61000-3-3 Fulfilled

This device complies with FCC Part 15 rules.
Operation is subjected to following tw o conditions: (1) this device may not cause harmful interferenc e, and (2) this device mus t accept any interf erence
received, including interference that may cause undesired operation.

Switching Frequencies The power supply has three converters with three different switching frequencies included. Two are nearly

Switching frequency 1 35kHz nearly constant
Switching frequency 2 105kHz nearly constant
Switching frequency 3 40kHz to 220kHz input voltage and load dependent

constant. The other one is input voltage and load dependent.

Air discharge

Output lines

N / L Æ PE

+ / - Æ PE

40% of 100Vac
40% of 100Vac

8kV
15kV

4kV
2kV

2kV
4kV

500V
500V

70Vac, 10ms
40Vac, 100ms
40Vac, 1000ms

96Vac, 1000ms
84Vac, 500ms
60Vac, 200ms

Criterion A
Criterion A

Criterion A
Criterion A

Criterion A
Criterion A

Criterion A
Criterion A

Criterion A
Criterion C
Criterion C

Criterion A
Criterion A
Criterion A

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C

1606- XLS180B 12V, 15A; Single Phase Input

17. ENVIRONMENT

Operational temperature -25°C to +70°C (-13°F to 158°F) reduce output power above +60°C
Output de-rating 5W/°C 60-70°C (140°F to 158°F), see
Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation

Humidity 5 to 95% r.H. IEC 60068-2-30

Vibration sinusoidal 2-17.8Hz: ±1.6mm;

17.8-500Hz: 2g

Do not energize while condensation is present
IEC 60068-2-6

2 hours / axis

2(s3

)

Vibration random

0.5m
2 hours / axis

Shock 30g 6ms, 20g 11ms

3 bumps / direction,

IEC 60068-2-64

IEC 60068-2-27

18 bumps in total

Altitude 0 to 6000m (0 to 20 000ft) Reduce output power or ambient temperature above 2000m

sea level.
Output de-rating (for altitude) 15W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 17-2
Over-voltage category III EN 50178, altitudes up to 2000m
II Altitudes from 2000m to 6000m
Degree of pollution 2 EN 50178, not conductive

Fig. 17-1 Output current vs. ambient temp., Fig. 17-2 Output current vs. altitude

Max. Output
Current at 12V

22.5A

f

r

o

t

p

y

4

.

s

Allowed Output
Current at 12V

22.5A

f

r

o

t

p

y

4

.

s

Fig. 17-1

15

7.5

0

-25 0 20 40

Ambient Temperature

o

c

i

t

n

u

n

s

u

o

70°

60

The ambient temperature is defined as the air temperature 2cm below the unit.

15

c

o

t

n

i

u

n

s

u

o

5

.

A

.

.

m

a

T

b

<

B

.

.

C

.

0

.

0 2000 4000

.

m

a

T

<

b

.

T

m

a

<

b

C

B

A

6

0

C

°

5

°

0

C

4

°

0

C

Altitude

6000m

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

18. PROTECTION FEATURES

Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 35Vdc

max. 39Vdc

Output over-current protection Electronically limited See Error! Reference source not found.
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 Oxide Varistor) and active transient filter
Internal input fuse T6.3A H.B.C. not user replaceable

Note: In case of a protection event, audible noise may occur.

19. SAFETY

Input / output separation SELV IEC/EN 60950-1
PELV EN 60204-1, EN 50178, IEC 60364-4-41
double or reinforced insulation
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. 0.19mA 100Vac, 50Hz, TN mains
typ. 0.29mA 120Vac, 60Hz, TN mains
typ. 0.53mA 230Vac, 50Hz, TN mains
< 0.25mA 110Vac, 50Hz, TN mains
< 0.38mA 132Vac, 60Hz, TN mains
< 0.74mA 264Vac, 50Hz, TN mains

In case of an internal power supply defect, a redundant circuitry limits
the maximum output voltage. The output shuts-down and automatically
attempts to restart.

20. DIELECTRIC STRENGTH

To fulfill the PELV requirements acc ording t o EN6020 4-1 § 6.4.1 , we rec omme nd th at eit her the + pole, the – pol e or any ot her part of the outp ut circuit
shall be connected to the protective earth system. This helps to avoid situations i n wh ich a load starts unexpectedly or can not be switched off any more
when unnoticed earth faults occur.

Fig. 20-1 Dielectric strength

Input DC-ok

L

N

The output voltage is floating and has no ohmic connection to ground.

10000052966 (Version 00)

AD

Earth

B

B

Output

C

+

-

A B C D
Type test 60s 2500Vac 3000Vac 500Vac 500Vac

Factory test 5s 2500Vac 2500Vac 500Vac 500Vac
Field test 5s 2000Vac 2000Vac 500Vac 500Vac

Type tests and factory tests:
Conducted by the manufacturer. Do not repeat test in field!
Rules for field test:
Use appropriate test equipment which applies the voltage with a slow ramp!
Connect L and N together as well as all output poles.

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

21. APPROVALS

IEC 60950-1

IECEE

CB SCHEME

UL 508

IND. CONT. EQ.

UL 60950-1

UL 1604

The unit is suitable for us e in Clas s I Divis ion 2 Grou p s A, B, C, D loc at ions as well as for Class I Zone 2 Groups IIA, IIB

Marine

SEMI F47

and IIC locations. Substitution of components may impair suitability for Class I Division 2 environment. Do not
disconnect equipment unless power has b een sw itch ed off. Wiring mus t be i n accord ance with C lass I, Div is ion 2 wir ing
methods of the National Electrical Code, NFPA 70, and in accordance with other local or national codes.

GL

ABS

CB Scheme,
Information Technology Equipment

LISTED E198865 listed for use in U.S.A. (UL 508) and Canada (C22.2 No. 14-95)
Industrial Control Equipment

RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-1) and Canada
(C22.2 No. 60950)
Information Technology Equipment, Level 3

RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and Canada (C22.2
No. 213-M1987)
Hazardous Location Class I Div 2 T3C Groups A,B,C,D and
Class I Zone 2 Groups IIA, IIB and IIC

GL (Germanischer Lloyd) classified and ABS (American Bureau for Shipping) PDA for
marine and offshore applications.

Environmental category: C, EMC2
SEMI F47-0200 Power Quality Star

Ride-through compliance for semiconductor industry.
Full SEMI range compliance (Input: 120Vac or 208Vac, output: 180W)

22. FULFILLED STANDARDS

EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN/IEC 61131-2 Programmable Controllers
EN 50178 Electronic Equipment in Power Installations

23. USED SUBSTANCES

The unit does not release any silicone and is suitable for the 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, wires and cables are not PVC insulated.

The production material within our production does not include following toxic chemicals:
Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCT), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrom Biphenyll (PBB),
Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO),
Cadmium, Asbest, Mercury, Silicia

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

24. PHYSICAL DIMENSIONS AND WEIGHT

Weight 900g / 1.98lb
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 (117mm) to calculate the total required installation depth.

Fig. 24-1 Front view Fig. 24-2 Side view

25. INSTALLATION AND OPERATION INSTRUCTIONS

Hazardous voltage inside device. Risk of electric shock, severe burns, or death.

• Do not use the unit without pr oper earth c onnection (P rotective Eart h). Us e the pin on th e terminal block for earth c onnecti on a nd not on e of
the screws on the housing.

• Turn power off 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 into the housing.

• Do not use in wet locations or in areas where moisture or condensation can be expected.

Mounting Orientation:

Output terminal must be located on top and input terminal on the bottom. For other orientat i ons see section 27.14.

Cooling:

Convection cooled, no forced cooling required. Do not cover ventilation grid (e.g. cable conduits) by more than 30%!

Installation clearances:

40mm on top, 20mm on the bottom, 5mm on the left and ri ght side are recommended when loade d permanently with full pow er. In case the adjacent
device is a heat source, 15mm clearance is recommended.

Service parts:
The unit does not contain any serviceable parts. The tripping of an internal fuse is caused by an internal defect.

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

26. ACCESSORIES

1606-XLB Wall mounting bracket
This bracket is used to mount 1606 units onto a flat surfac e without utilizing a DIN-Rail. The two alumi num brackets and the blac k plastic slider of the

unit have to be detached, so that the two steel brackets can be mounted.

Fig. 26-1 1606-XLB Wall Mounting Bracket Fig. 26-2 Assembled Wall Mounting Bracket

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

27. APPLICATION NOTES

27.1. REPETITIVE PULSE LOADING

Typically, a load current is not constant. It varies over time. For pulse load compatibility, following rules must be met:
a) The pulse power demand must be below 150% of the nominal power.

b) The duration of the pulse power must be shorter than the allowed Power Boost . (see output section)
c) The average (R.M.S.) output current must be below the specified continuous output current.

If the R.M.S. current is higher, the unit will respond with a thermal shut-down after a while. Use the max. duty cycle curve (
average output current is below the nominal current.

d) For altitudes higher than 2000m reduce the pulse loading (15W/1000m) or the ambient temperature (5°C/1000m)

Fig. 27-1 Repetitive pulse loads, definitions Fig. 27-2 Max. Duty Cycle Curve

0

utyCycle

)

=

T

0

DutyCycle

P0

=

1

110 120 130 140

T

peak

=

T

peak + T0

T

peak -

(D

utyCycle

x T

peak

D

utyCycle

:

0

1s

-

(0.37 x 1s)

0.37

=1.7s

2.7s

T

PEAK

0

P
P
P

0

0

%

)

= 50% curve

0

1.0

P

max.

150%
100%

PEA KTPEA K

P

0

T

0

0.8

0.6

0.4

0.2

Base load (W)

P

0

Pulse load (above 100%)

P

PEAK

Duration between pulses (s)

T

0

Pulse duration (s)

T

PEAK

D

T0 =

Utilizing the Max. Duty Cycle Curve:

Example to determine the repetition rate of pulses without dipping of the output voltage:
Parameters of application:

Pulse length is T

PEAK = 1s

RATED

0=120W

)

Steady state load P
(= 50% of I

Peak load P
(= 150% of I

PEAK = 360W

)

RATED

Determining the repetition rate:

1) make a vertical line at P

PEAK

= 150%

2) make a horizontal line where the vertical line crosses the P

3) Read the Max. Duty Cycle from the Duty Cycle-axis (= 0.37)

4) Calc ulat e the min. pause (base load) length T

T

peak -

(D

utyCycle

x T

T0 =

D

utyCycle

peak

5) Pulse length = 1s, min. pause length = 1.7s

6) Max. repetition rate = pulse length +pause length =

More examples for pulse load compatibility:

P

P

PEAK

T

0

PEAK

T

0

P

P

PEAK

270W 180W 1s >25s 270W 90W 0.1s >0.16s
270W 0W 1s >1.3s 270W 90W 1s >1.6s
225W 90W 1s > 0,75s 270W 90W 3s >4.9s

Fig. 27-2) to check if the

=

0

1

%

0

=

5

%

0

0

=

%

5

7

0

P

PEAK

150%100

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

27.2. PEAK CURRENT CAPABILITY

Solenoids, contactors and pneumatic mod ules often have a steady state coil a nd a pic k - up c oil. Th e i nrus h c u rrent d em an d of the pick-up coil is several
times higher than the steady state current and usually exceeds the nominal output current (including the Power Boost) The same situation applies,
when starting a capacitive load.

Branch circuits are often protected with circuit br eak ers or fus es . In c ase of a short or an overload in the branch c irc uit, the fuse needs a certain amount
of over-current to trip or to blow. The peak current capability ensures the safe operation of subsequent circuit breakers.

Assuming the input voltage is turned on before such an event, the built-in large sized outp ut capacitors inside the power supply can deliver extra
current. Discharging this capacitor causes a voltage dip on the output. The following two examples show typical voltage dips:

Fig. 27-3 Peak load 30A for 50ms, typ. Fig. 27-4 Peak load 60A for 5ms, typ.

12V

Output
Vol tag e

10V

12V

Output
Vol tag e

30A

Output

0A

10ms/DIV

Peak load 30A (resistive) for 50ms

Output voltage dips from 12V to

Please note: The DC-OK relay triggers when the voltage dips more than 10% for longer than 1ms.

Current

10V.

Peak load 60A (resistive) for 5ms

60A

0A

Output voltage dips from 12V to

5.2V

Output
Current

1ms/DIV

5.2V.

27.3. BACK-FEEDING LOADS

Loads such as decelerating motors and inductors can feed voltage back to the power supply . This feature is also called return volt age immunity or
resistance against Back- E.M.F. (

This power supply is resistant and does not sh ow malfunctioning whe n a load feeds back v oltage to the power supply . It does not m atter, whether the
power supply is on or off.

The maximum allowed feed back volt age is 18V dc. The abs orbing e nergy c an be calcu lated ac cording t o the bui lt-in large s ized ou tpu t capacit or which
is specified in chapter 8.

Electro Magnetic Force).

27.4. CHARGING OF BATTERIES

The power supply can be used for float-charging of lead-acid or maintenance free 12V VRLA batteries.

Instructions for charging batteries:

a) Set the output voltage, at disconnected load, very precisely to the end-of-charge voltage according to the expected battery temperature.

End-of-charge voltage 13.9V 13.75V 13.6V 13.4V
Battery temperature 10°C 20°C 30°C 40°C

b) Use a 20A circuit breaker (or blocking diode ) between the power supply and the battery.
c) Ensure that the output current of the power supply is below the allowed charging current of the battery.
d) The return current to the power supply is typ. 5mA at 13.8Vdc when the power supply is switched off (except in case a blocking diode is utilized).

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

27.5. OUTPUT CIRCUIT BREAKERS

Standard miniature circuit breakers (MCBs) can be used for branch protection. Ensure that the MCB is rated for DC voltage, too. The following tests
show which circuit breakers the power supply typically trips.

Circuit breakers have huge tolerances in their trip ping beh avior. Ther efore, t hese ty pical te sts c an only be us ed as a recom men dation or for c omparin g
two different power supplies. Furthermore, the loop impe dance has a major influence on whether a breaker trips or not. Tw o 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. 27-5 Branch protectors, test circuit 1

Ci r c u i t

Po w e r

Supply

AC

DC

Breaker

I

+

S1

-

+

Lo ad

-

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

Fig. 27-6 Branch protectors, test circuit 2

Ci r c u i t

Po w e r

Supply

AC

DC

Breaker

I

+

-

R

+

S1 Lo ad

-

0.5mm
180mOhm 5.0m 7.0m 10.0m 15.0m 25.1m 40.1m

Example:

Which wire gauge must be used to trip a B-Characteristic circuit breaker with a rating of 6A? The load wire length is 21m.
Answer: A 6A B-Characteristic circuit breaker requires a loop impedance of less than 180mOhm (test results). The wire le ngth table shows that up to

25.1m wire with a cross section of 2.5mm

2

are below 180mOhm. A wire not smaller than 2.5mm2 shall be used.

Parameters:
Input voltage: 230Vac, load current: 0A

Tripping time shorter than 5s.
The following circuit breaker tripped during the test:

A- or Z- Characteristic:: equal or smaller 10A
B- Characteristic: equal or smaller 6A
C- Characteristic: equal or smaller 6A

Parameters:
Input voltage: 230Vac, load current: 0A

Tripping time shorter than 5s.
The following circuit breaker tripped during the test:

A- or Z- Characteristic:: ≤ 6A and R< 180mOhm
B- Characteristic: ≤ 6A and R< 180mOhm
C- Characteristic: ≤ 6A and R< 180mOhm

What does this resistance mean in wire length?

2

0.7mm

2

1.0mm21.5mm

2

2.5mm

2

4.0mm

2

27.6. EXTERNAL INPUT PROTECTION

The unit is tested and approved for branc h circuits up to 20A. Ex ternal protection is only required, if t he supplying branc h has an ampacity greater than
this. In some countries local regulations might apply. Check also local codes and local requirements.

If an external fuse is necessary or utilized, a minimum value is required to avoid undesired tripping of the fuse.

B-Characteristic C-Characteristic
Ampacity max. 20A 20A
min. 6A 4A

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Rockwell Automation

1606- XLS180B 12V, 15A; Single Phase Input

27.7. PARALLEL USE TO INCREASE OUTPUT POWER

Power supplies can be paralleled to increase the output power.

Fig. 27-7 Schematic for parallel operation

Uni t A

AC

Uni t B

AC

DC

DC

+

­+

+

-

Load

-

27.8. PARALLEL USE FOR REDUNDANCY

Power supplies can be paralleled for redundancy to gain a higher system availability. Redundant systems require a certain amount of extra power to
support the load in case one power s upply unit f ails. T he s implest way is t o put two XLS p ower s upplies in p aralle l. T his is called a 1+1 redundancy. In
case one power supply unit fails, the other one is aut omatically able to support the load current without any interruption. Re dundant systems for a
higher power demand are usually built in a N+1 method. E.g. Five power supplies, each rated for 10A are paralleled to build a 40A redundant system.

Please note: This simple way to build a redundant system does not cover failures such as an internal short circuit in the secondary side of t he power
supply. In such a - virtually nearly impossible - c ase, the defect unit becomes a load for the ot her power supplies and the output voltag e can not be
maintained any more. This can only be avoided by utilizing decoupling diodes which are included in the decoupling module 1606-XLSRED.

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 lamp and a DC-ok contact is already included in the units This feature reports a faulty unit.
c) When possible, connect each power supply to different phases or circuits.
d) It is desirable to set the output voltages of all power supplies to the same value to avoid a false DC-ok signal.

Instructions for parallel use:

a) Use only power supplies from the same series (XLS).
b) Adjust the output voltages of all power supplies to approximately the same

value (±500mV).
Otherwise, the DC-ok signal might not work properly.

c) A fuse (or diode) on the output is only required if more than three units are

connected in parallel.

d) Do not load terminals with more than 25A. Follow wiring instructions according

to chapter 27.9

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

and avoid installing the power supplies on top of each other.

27.9. DAISY CHAINING OF OUTPUTS

Daisy chaining (jumping from one power supply output to the next) is allowed as long as the maximum current through one terminal pin does not
exceed 25A. If the current is higher, use a separate distribution terminal block.

Fig. 27-8 Daisy chaining of outputs Fig. 27-9 Using distribution terminals

max 25A!

+

-

+ +

- -

Po w e r

Supply

Input

+ +

- -

Po w e r

Supply

Input

Load

+

+ +

- -

+ +

- -

Po w e r

Supply

L N PE

Po w e r

Supply

L N PE

Dist ribut io n
Ter mi nal s

-

Lo ad

27.10. SERIES OPERATION

The power supply can be put in series to increase the output voltage.

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Rockwell Automation

y

1606- XLS180B 12V, 15A; Single Phase Input

Fig. 27-10 Schematic for series operation

Uni t A

AC

Uni t B

AC

DC

DC

+

-

+

-

Ea r t h

+

Load

-

Instructions for use in series:

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) Warning ! Voltages with a potential above 60Vdc are not SELV any more and

can be dangerous. Such voltages must be installed with a protection against

touching.
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.

27.11. INDUCTIVE AND CAPACITIVE LOADS

The unit is designed to supply any kind of load, including unlimited capacitive and inductive loads.

27.12. OPERATION ON TWO PHASES

Fig. 27-11 Schematic for two phase operation

L1

L3

L2

max.

+15%

240V

Po w er Su p p l

Fuse

PE

L

N

AC

internal

fused

DC

Instructions for two phase operation:
a) A phase to phase connection is allowed as long as the supplying voltage is

below 240V(+15%).
b) Use a fuse or a circuit breaker to protect the N input. The N input is

internally not protected and is in this case connected to a hot wire.
Appropriate fuses or circuit breakers are specified in section 27.6 “External Input

Protection”.

27.13. 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 defines 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 producer inside the box
Enclosure: Typ IP66 Box PK 9519 100, plastic, 180x180x165mm

Load: 12V, 12A; (=80%) load is placed outside the box
Input: 230Vac
Temperature inside enclosure: 46°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 27°C
Temperature rise: 19°C

27.14. 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
max. allowed ambient temperature. The amo unt of reduction influences the l ifetime expectancy of the powe r supply. Therefore, two different derating
curves for continuous operation can be found below:

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Rockwell Automation

C

C

C

C

C

1606- XLS180B 12V, 15A; Single Phase Input

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

Fig. 27-12 Mounting
Orientation A

Standard Orientation

Fig. 27-13

Mounting Orientation
B
(Upside down)

OUTPUT

Power

Supply

INPUT

INPUT

Supply

Power

OUTPUT

Fig. 27-14 Mounting
Orientation C

(Table-top mounting)

Fig. 27-15 Mounting

Orientation D

(Horizontal cw)

Supply

INPUT

OUTPUT

Power

Fig. 27-16 Mounting
Orientation E

(Horizontal ccw)

OUTPUT

Power

INPUT

Supply

Output Current

15A

12

9
6
3
0

Ambient Temperature

10 20 30 40

Output Current

15A

12

9
6
3
0

Ambient Temperature

10 20 30 40

Output Current

15A

12

9
6
3
0

Ambient Temperature

10 20 30 40

Output Current

15A

12

9
6
3
0

Ambient Temperature

10 20 30 40

Output Current

15A

12

9
6
3
0

Ambient Temperature

10 20 30 40

A

1

60°

50

A

2

A

1

50

A

2

A

1

50

A

2

A

1

50

A

2

A

1

50

60°

60°

60°

60°

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