Rockwell Automation 1606-XLS960E-3 User Manual

Reference Manual

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

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

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

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

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

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

7. Hold-up Time.......................................................8

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

9. Shut-down Input .................................................9

10. Remote Control of Output Voltage .................10

11. Internal Data Logging.......................................10

12. Efciency and Power Losses..............................11

13. Reliability...........................................................12

14. Functional Diagram...........................................12

15. Terminals and Wiring........................................13

16. Front Side and User Elements...........................14

17. EMC....................................................................15

18. Environment......................................................16

19. Protection Features...........................................17

20. Safety Features..................................................17

21. Dielectric Strength ............................................18

22. Certications

.................................................. 18

23. Physical Dimensions and Weight.................... 19

24. Accessories....................................................... 20

24.1. Wall mounting bracket - 1606-XLC......... 20

24.2. Buffer module - 1606-XLSBUFFER24........ 20

24.3. 1606-XLSRED80 - Redundancy Modules... 20

25. Application Notes.............................................

25.1. Repetitive Pulse Loading..........................21

25.2. Peak Current Capability ...........................22

25.3. External Input Protection.........................22

25.4. Using only 2 Legs of a 3-Phase System .... 23

25.5. Charging Batteries ...............................24

25.6. Output Circuit Breakers............................24

25.7. Parallel Use to Increase Output Power.... 25

25.8. Parallel Use for Redundancy .................... 25

25.9. Series Operation ....................................... 26

25.10. Inductive and Capacitive Loads................26

25.11. Back-feeding Loads ..................................26

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

25.13. Mounting Orientations ............................27

Bulletin 1606 Switched Mode Power Supplies

Catalog Number:

Index

1606-XLS960E-3

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 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 full (13.7V) or flat (10V)

• 400Vac—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

3AC 380-480V Wide-range Input

Three Input Fuses Included

Width only 110mm, Weight only 1.5kg

95.3% Full Load and Excellent Partial Load Efciencies 50% BonusPower

, 1440W for up to 4s 110A Peak Current for 25ms for Easy Fuse Tripping Active PFC (Power Factor Correction) Active Filtering of Input Transients Negligible Lo

w Input Inrush Current Surge Full Power Between -25°C and +60°C Current Sharing Feature for Parallel Use Internal Data Logging for Troubleshooting Included. Remote Control of Output Voltage DC-OK Relay Contact Shut-down Input 3 Year Warranty

Description

The most outstanding features of the 1606-XLS960E-3 DIN rail power supply are its extremely high efciencies and its small size, which are achieved by a synchronous rectication and other technological breakthroughs.

Large power reserves of 150% support the starting of heavy loads such as DC motors or capacitive loads. In many cases this allows the use of a unit from a lower wattage class which saves space and money.

High immunity to transients and power surges as well as low electromagnetic emission allow the use of these power supplies in nearly every environment.

The integrated output power manager, the three input fuses and near zero input inrush current make installation and usage simple. Diagnostics are easy due to the DC-ok relay, a green DC-OK LED and the red overload LED.

A large international approval package for a variety of applications makes this unit suitable for nearly every application.

Specication Quick Reference

Output voltage DC 24V nominal Adjustment range 24 - 28V Output current 40 – 34.3A continuous 60 – 51.5A short term (4s) Output power 960W continuous 1440W short term (4s) Output ripple < 100mVpp 20Hz to 20MHz Input voltage 3AC 380-480V -15%/+20% Mains frequency 50-60Hz ±6% AC Input current 1.65 / 1.35A at 3x400 / 480Vac Power factor 0.88 / 0.90 at 3x400 / 480Vac AC Inrush current typ. 4.5A peak Efciency 95.3 / 95.2% at 3x400 / 480Vac Losses 47.3 / 48.4W at 3x400 / 480Vac Temperature range -25°C to +70°C operational Derating 24W/°C +60 to +70°C Hold-up time typ. 25 / 25ms at 3x400 / 480Vac Dimensions 110x124x127mm WxHxD

Catalog Numbers

Power Supply 1606-XLS960E-3 24-28V Standard unit

Accessories 1606-XLC Wall mount bracket 1606-XLSBUFFER24 Buffer unit 1606-XLSRED80 Redundancy module

Certications

IND. CONT. E

UL 508

UL 60950-1

Marine

EMC, LVD, RoHS

Weight 1500g / 3.3 lb

C-Tick

GOST R

Marine RINA

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2 Rockwell Automation Publication 1606-RM005A-EN-P - February 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.

• 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 output and input terminals are located on the bottom of the unit. For other mounting orientations, see

derating requirements in this document. Refer to section 25.13.

• 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, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 3

Bulletin 1606 Switched Mode Power Supplies

3. AC-Input

AC input nom. 3AC 380-480V suitable for TN, TT and IT mains networks,

grounding of one phase is allowed except in UL 508

applications AC input range min. 3x 323-576Vac continuous operation Allowed voltage L to earth max. 576Vac continuous, IEC 60664-1 Input frequency nom. 50–60Hz ±6% Turn-on voltage typ. 3x 305Vac steady-state value, load independent, see Fig. 3-1 Shut-down voltage typ. 3x 275Vac steady-state value, load independent, see Fig. 3-1

3AC 400V 3AC 480V

Input current typ. 1.65A 1.35A at 24V, 40A, symmetrical phase voltages,

see Fig. 3-3 Power factor*) typ. 0.88 0.90 at 24V, 40A, see Fig. 3-4 Start-up delay typ. 500ms 600ms see Fig. 3-2 Rise time typ. 35ms 35ms at 24V, 40A, resistive load, 0mF see Fig. 3-2 typ. 40ms 40ms at 24V, 40A, resistive load, 40mF see Fig. 3-2 Turn-on overshoot max. 500mV 500mV see Fig. 3-2

*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.

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

Turn-on

323V

Rated input range

OUT

275V 576Vac

Shut-down

305V

Start-up

delay

Rise

Time

Overshoot

- 5%

Output Voltage

Input Voltage

L1 L2 L3

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

40A

4 8 12 16 20 24 28 32 36

0.2

0.4

0.6

0.8

1.0

1.2

1.6A

Input Current, typ.

1.4

Output Current

A: 3x 400Vac B: 3x 480Vac

Power Factor, typ.

4 8 12 16 20 24 28 32 36 40A

0.70

0.75

0.80

0.85

0.90

0.95

Output Current

A: 3x 400Vac B: 3x 480Vac

4 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

4. Input Inrush Current

The power supply is equipped with an active inrush current limitation circuit, which limits the input inrush current after turn-on to a negligible low value. The input current is usually smaller than the steady state input current.

3AC 400V 3AC 480V

Inrush current

max. 6A

peak

over entire temperature range

typ. 4.5A

peak

4.5A

peak

over entire temperature range

Inrush energy max. 1.5A

s 1.5A2s over entire temperature range

Inrush delay typ. 500ms 600ms

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

Fig. 4-1 Typical turn-on behaviour at nominal

load and 25°C ambient temperature

Input

Output

Input Current 2A/DIV

3x400Vac

24Vdc

100ms/DIV

5. DC-Input

Do not operate this power supply with DC input voltage.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 5

Bulletin 1606 Switched Mode Power Supplies

6. Output

Output voltage nom. 24V Adjustment range min. 24-28V guaranteed max. 30V

***)

at clockwise end position of potentiometer Factory setting typ. 24.1V ±0.2%, at full load, cold unit, in “single use” mode typ. 24.1V ±0.2%, at full load, cold unit, in “parallel use” mode typ. 25.1V at no load, cold unit, in “parallel use” mode Line regulation max. 10mV 3x323-576Vac Load regulation max. 50mV in “single use” mode: static value, 0A 40A, see Fig. 6-1

typ. 1000mV in “parallel use” mode: static value, 0A

40A,

see Fig. 6-2 Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm Output current nom. 40A continuously available at 24V, see Fig. 6-1 and Fig. 6-2 nom. 34.3A continuously available at 28V, see Fig. 6-1 and Fig. 6-2 nom. 60A short term (4s) available BonusPower*), at 24V,

see Fig. 6-1, Fig. 6-2 and Fig. 6-4 nom. 51.5A short term (4s) available BonusPower

, at 28V,

see Fig. 6-1, Fig. 6-2 and Fig. 6-4 typ. 110A up to 25ms, output voltage stays above 20V, see Fig.

6-4. This peak current is available once every second.

See section 25.2 for more peak current measurements. Output power nom. 960W continuously available at 24-28V nom. 1440W*) short term available BonusPower*) at 24-28V BonusPower

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

BonusPower recovery time typ. 7s overload free time to reset power manager, see Fig. 6-5 Overload behavior cont. current see Fig. 6-1 Short-circuit current

**)

min. 40A continuous, load impedance 25mOhm, see Fig. 6-1 max. 44A continuous, load impedance 25mOhm, see Fig. 6-1 min. 60A short-term (4s), load impedance 25mOhm, see Fig. 6-1 max. 68A short-term (4s), load impedance 25mOhm, see Fig. 6-1 typ. 46A continuous, load impedance <10mOhm max. 51A continuous, load impedance <10mOhm Output capacitance typ. 10 200μF included in 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 repeatedly available. Detailed information can be found in section 25.1. If the power supply is loaded longer with the BonusPower than shown in the bonus-time diagram (see Fig. 6-3), the max. output power is automatically reduced to 960W.

**) 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. There is no

guarantee that this value can be achieved. The typical value is about 28.5V.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

6 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

Bulletin 1606 Switched Mode Power Supplies

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

“single use” mode, typ.

Fig. 6-2 Output voltage vs. output current in

“parallel use” mode, typ.

Output Voltage

010203040

28V

6050 70A

Output Current

Adjustment Range

A B

Short-term (4s) BonusPower

Continuously available

Output Voltage

(Parallel Use, typ.)

22V

02040

23V

24V

25V

29V

26V

27V

28V

60A503010

Adjustment Range

Output Current

Factory setting

Short-term (4s) BonusPower

Continuously available

Fig. 6-3 Bonus time vs. output power Fig. 6-4 Dynamic overcurrent capability, typ.

Bonus Time

100 120 130 140 150

170%

110 160

Output Power

Output Voltage

(dynamic behavior, < 25ms)

28V

150

6030 90 12015 45 75 105 135

Adjustment

Range

Output Current

Fig. 6-5 BonusPower recovery time

Power Demand

100%

Limitation by Power Manager

Output Voltage

Bonus Power disabled

Bonus

Time

Recovery Time

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

Fig. 6-6 BonusPower after input turn-on Fig. 6-7 BonusPower after output short

100%

Output Voltage

Input Voltage

Bonus Power

Output Power

150%

Short of

Output

100%

Output Voltage

Bonus Power

Output Power

150%

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 7

Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time

3AC 400V

3AC 480V*) Hold-up Time typ. 50ms 50ms at 24V, 20A, see Fig. 7-1 min. 40ms 40ms at 24V, 20A, see Fig. 7-1 typ. 25ms 25ms at 24V, 40A, see Fig. 7-1 min. 20ms 20ms at 24V, 40A, see Fig. 7-1

*) Curves and gures for operation on only 2 legs of a 3-phase system can be found in section 25-4.

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

50ms

320 360 400 440 3x480Vac

Input Voltage

Hold-up Time

24V, 20A, typ.

24V, 20A, min.

- 5%

Hold-up Time

Output Voltage

Input Voltage

L1 L2 L3

8 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

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 90% of the adjusted output voltage. 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 21.

Fig. 8-1 DC-ok relay contact behavior

= V

OUT

ADJ

10%

0.9* V

ADJ

open

1ms

250ms

openclosed closed

9. Shut-down Input

This feature allows a switch-off of the output of the power supply with a signal switch or an external voltage. The shut-down function ramps down and has no safety feature included. The shut-down occurs immediately while the turn-on is delayed up to 350ms. In a shut-down condition, the output voltage is <2V and the output power is <0.5W.

The voltage between different minus pole output terminals must be below 1V when units are connected in parallel. In a series operation of multiple power supplies only wiring option “A” with individual signal switches is allowed.

Please note that option C requires a current sink capability of the voltage source. Do not use a blocking diode.

Fig. 9-1 Activation of the shut-down input

Option A:

Shut-

down Input

OFF: linked ON : open

Option B:

(via open collector)

OFF: I > 0.3mA ON : I < 0.1mA

n.c.

Option C:

(via external voltage

OFF: U < 1V ON : U = 4 -29V

n.c.

down Input

Shut-

down Input

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 9

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