Rockwell Automation 1606-XLS240F, 1606-XLS240F-D User Manual

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Numbers: 1606-XLS240F & 1606-XLS240F-D

Index

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

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

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

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

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

Output .................................................................7

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

DC-OK Relay Contact ..........................................9

Efciency and Power Losses ..............................10

Reliability ...........................................................11

10.

11. Functional Diagram ...........................................12

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

13. Front Side and User Elements ...........................13

14. EMC ....................................................................14

15. Environment ......................................................15

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

17. Safety Features ..................................................16

18. Dielectric Strength ............................................16

19. Certications

20. Environmental Compliance ..............................18

21. Physical Dimensions and Weight ......................18

.....................................................17

22. Accessories ........................................................ 19

22.1. 1606-XLB Wall Mounting Bracket .......19

22.2. 1606-XLSBUFFER48 Module ....................20

22.3. 1606-XLSRED Redundancy Module.............20

23. Application Notes............................................. 21

23.1. Repetitive Pulse Loading .......................... 21

23.2. Peak Current Capability ...........................22

23.3. Back-feeding Loads ..................................22

23.4. External Input Protection .........................22

23.5. Charging Batteries ...............................23

23.6. Output Circuit Breakers ............................23

23.7. Parallel Use to Increase Output Power ....24

23.8. Parallel Use for Redundancy ....................24

23.9. Daisy Chaining

23.10. Series Operation .......................................25

23.11. Inductive and Capacitive Loads................25

23.12. Operation on Two Phases ........................26

23.13. Use in a Tightly Sealed Enclosure ............26

23.14. Mounting Orientations ............................ 27

egaP egaP

of Outputs .......................25

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.

• 3AC 400V—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 whether it is charged (13.7V) or discharged (10V).

• 230Vac—Afigure with the unit (Vac) at the end is a momentary figure without any additional tolerance included.

• 50Hz vs. 60Hz—Unless 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

AC 100-240V Wide-range Input Width only 60mm Efciency up to 92% 150% (360W) Peak Load Capability Easy Fuse Tripping due to High Overload Current Active Power Factor Correction (PFC) Negligible low Inrush Current Surge Short-term Operation down to 60Vac and up to 300Vac Full Power Between -25°C and +60°C DC-OK Relay Contact Quick-connect Spring-clamp Terminals 3 Year Warranty

Description

The most outstanding features of this 1606-XLS series DIN rail power supply are its high efciency and small size, which are achieved by a synchronous rectication 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.

Specication Quick Reference

Output voltage DC 48V Adjustment range 48 – 56V Output current 5 – 4.3A continuous

7.5 – 6.5A for typ. 4s Output power 240W continuous 360W for typ. 4s Output ripple < 100mVpp 20Hz to 20MHz Input voltage AC 100-240V ±15% Mains frequency 50-60Hz ±6% AC Input current 2.22 / 1.22A at 120 / 230Vac Power factor 0.98 / 0.92 at 120 / 230Vac AC Inrush current typ. 4 / 7A peak at 120 / 230Vac Efciency 91.2 / 92.0% at 120 / 230Vac Losses 23.2 / 20.9W at 120 / 230Vac Temperature range -25°C to +70°C operational Derating 6W/°C +60 to +70°C Hold-up time typ. 27 / 28ms at 120 / 230Vac Dimensions 60x124x117mm WxHxD

Catalog Numbers

Power Supply

1606-XLS240F

48-56V Power supply Extended DC Input

Accessories 1606-XLB Wall mount bracket

1606-XLSRED Redundancy module 1606-XLSBUFFER48 Buffer unit

Certication Marks

IND. CONT. EQ.

UL 508

UL 60950-1

Class I Div 2

Marine

EMC, LVD

1606-XLS240F-D

Gost R C-Tick

Marine RINA

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2 Rockwell Automation Publication 1606-RM045A-EN-P — March 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.

• Should damage or malfunction occur during installation or operation, turn power immediately 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 derating

requirements in this document. Please refer to section 24.14.

• 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 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM045A-EN-P — March 2014 3

Bulletin 1606 Switched Mode Power Supplies

3. AC-Input

AC input nom. AC 100-240V suitable for TN-, TT- and IT mains networks AC input range min. 85-276Vac continuous operation min. 60-85Vac full power for 200ms, no damage between 0 and 85Vac min. 276-300Vac < 500ms Allowed voltage L or N to earth max. 276Vac continuous, IEC 62103 Input frequency nom. 50–60Hz ±6% Turn-on voltage typ. 81Vac steady-state value, see Fig. 3-1 Shut-down voltage typ. 63Vac steady-state value, see Fig. 3-1 typ. 55Vac dynamic value

AC 100V AC 120V AC 230V Input current typ. 2.65A 2.22A 1.22A at 48V, 5A, see Fig. 3-3 Power factor *) typ. 0.99 0.98 0.92 at 48V, 5A, see Fig. 3-4 Crest factor **) typ. 1.65 1.67 1.85 at 48V, 5A Start-up delay typ. 800ms 650ms 340ms see Fig. 3-2 Rise time typ. 8ms 8ms 8ms 0mF, 48V, 5A, see Fig. 3-2 typ. 15ms 15ms 15ms 5mF, 48V, 5A, 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

60V 300Vac276V

Shut-down

full

power

for

200ms

Start-up

delay

Rise

Time

Overshoot

- 5%

Output Voltage

Input Voltage

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

0.5 1 1.5 2 2.5 3 3.5 4 4.5

0.4

0.8

1.2

1.6

2.0

2.4

2.8A

Output Current

Input Current, typ.

Power Factor, typ.

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5A

0.75

0.8

0.85

0.9

0.95

1.0

Output Current

100Vac

120Vac

4 Rockwell Automation Publication 1606-RM045A-EN-P — March 2014

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

4. DC-Input

1606-XLS240F:

DC input nom. DC 110-150V -20%/+25% DC input range min. 88-187Vdc continuous operation DC input current typ. 2.37A 110Vdc, at 24V, 10A

1606-XLS240F-D:

DC input nom. DC 110-300V -20%/+25% DC input range min. 88-375Vdc continuous operation DC input current typ. 2.37/ 0.85A 110/300Vdc, at 24V, 10A

All units:

Allowed Voltage L/N to Earth max. 375Vdc continuous, IEC 62103 Turn-on voltage typ. 80Vdc steady state value Shut-down voltage typ. 55Vdc steady state value

Fig. 4-1 Wiring for DC Input

Instructions for DC use:

Load

Power Supply

Battery

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 a earth wire or to the machine

ground.

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM045A-EN-P — March 2014 5

Bulletin 1606 Switched Mode Power Supplies

5. Input Inrush Current

An active inrush limitation circuit limits the input inrush current after turn-on of the input voltage and after short input voltage interruptions.

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

AC 100V AC 120V AC 230V

Inrush current max. 10A

peak

10A

peak

10A

peak

over entire temperature range

typ. 5A

peak

over entire temperature range

Inrush energy max. 4A

s 4A2s 4A2s over entire temperature range

Inrush delay (A) typ. 650ms 520ms 250ms see (A) in Fig. 5-1

Fig. 5-1 Input inrush current, typical behavior

Input Current

Input Voltage

Output Voltage

A…. Inrush delay

Input: 230Vac Output: 48V, 5A Ambient: 25°C

Upper curve: Input current 2A / DIV Middle curve: Input voltage 500V / DIV Lower curve: Output voltage 40V / DIV Time basis: 100ms / DIV

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

6 Rockwell Automation Publication 1606-RM045A-EN-P — March 2014

Bulletin 1606 Switched Mode Power Supplies

6. Output

Output voltage nom. 48V Adjustment range min. 48-56V guaranteed max. 58V Factory setting typ. 48.0V ±0.2%, at full load, cold unit Line regulation max. 10mV 60-300Vac Load regulation max. 100mV static value, 0A 5A Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm Output current nom. 5A continuously available at 48V, see Fig. 6-1 nom. 4.3A continuously available at 56V, see Fig. 6-1

nom. 7.5A

nom. 6.5A

Output power nom. 240W continuously available nom. 360W BonusPower

time typ. 4s duration until the output voltage dips, see Fig. 6-2 min. 3s max. 5s

BonusPower

recovery time typ. 7s overload free time to reset power manager, see Fig. 6-3 Overload behaviour cont. current Short-circuit current min. 3A max. 7A min. 5A max. 15A max. 7.5A Output capacitance typ. 3 000μF included inside the power supply

*) BonusPower, short term power capability (up to typ. 4s)

The power supply is designed to support loads with a higher short-term power requirement without damage or shutdown. The shortterm duration is hardware controlled by an output power manager. BonusPower is available repeatedly. Detailed information can be found in chapter 23.1. If the power supply is loaded longer with the BonusPower than shown in the Bonus-time diagram (see Fig. 6-2), the max. output power is automatically reduced to 240W.

**) Discharge current of output capacitors is not included.

***) This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. It is not

guaranteed value which can be achieved. The typical value is about 56.8V.

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 chapter 23.2.

Peak current voltage dips typ. from 48V to 42V at 10A for 50ms, resistive load typ. from 48V to 42V at 20A for 2ms, resistive load typ. from 48V to 36V at 20A for 5ms, resistive load

***)

at clockwise end position of potentiometer

short term available BonusPower

at 48V, for typical 4s, see Fig. 6-1

short term available BonusPower

at 56V, for typical 4s, see Fig. 6-1

short term available BonusPower

**)

continuous, load impedance 200mOhm, see Fig. 6-1

**)

continuous, load impedance 200mOhm, see Fig. 6-1

**)

during BonusPower

**)

during BonusPower

**)

continuous, load impedance <10mOhm, see Fig. 6-1

, load impedance 200mOhm

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM045A-EN-P — March 2014 7

Bulletin 1606 Switched Mode Power Supplies

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

Output Voltage

60V

56V

48V

typ.

c o

n t

n u o u s

Adjustment

Range

02 6810

Output Current

12A

Fig. 6-2 Bonus time vs. output power

Bonus Time

10s

9 8 7 6 5 4 3 2 1 0

110 120 130 140 150

Fig. 6-3 BonusPower recovery time

Limitation by

Power Demand

100%

Output Voltage

Bonus

Time

Power Manager

Recovery Time

Bonus Power disabled

Output Power

typ

160%

The BonusPower

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

output overload.

Fig. 6-4 BonusPower after input turn-on Fig. 6-5 BonusPower after output short

Input Voltage

Short of

Output

Output Voltage

Output Power

100%

150%

Bonus Power

Output Power

150%

100%

Bonus Power

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

8 Rockwell Automation Publication 1606-RM045A-EN-P — March 2014

Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time

AC 100V AC 120V AC 230V Hold-up Time typ. 51ms 53ms 55ms at 48V, 2.5A, see Fig. 7-1 typ. 26ms 27ms 28ms at 48V, 5A, see Fig. 7-1

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

50ms

85 120 155 190 230Vac

Input Voltage

Hold-up Time

- 5%

Hold-up Time

Zero Transition

Output Voltage

Input Voltage

8. DC-OK Relay Contact

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

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

Short dips will be extended to a signal length of 250ms. Dips shorter than 1ms will be ignored. 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 18.

Fig. 8-1 DC-ok relay contact behavior

250ms

0.9* V

ADJ

1ms

10%

OUT

= V

ADJ

1ms

open openclosed closed

Note: The DC-ok feature requires that the output voltage reaches the nominal (=adjusted) level after turn-on in order to function according

to specication. If this level cannot be achieved, the overload lamp will be on and the DC-ok contact will be open. The overload signal will only shut off as soon as the adjusted voltage is reached. This is an important condition to consider particularly if the load is a battery, if the power supply is used in parallel or if the power supply is used for N+1 redundant systems.

All parameters are specified at 48V, 5A, 230Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM045A-EN-P — March 2014 9

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