Rockwell Automation 1606-XLS960E-3 User Manual

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Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLS960E-3

Index

		Page			Page
1.	Intended Use .......................................................	3	22. Certifications ..................................................		18
2.	Installation Requirements...................................	3	23. Physical Dimensions and Weight ....................		19
3.	AC-Input...............................................................	4	24. Accessories .......................................................		20
4.	Input Inrush Current ...........................................	5	24.1.	Wall mounting bracket - 1606-XLC.........	20
5.	DC-Input...............................................................	5	24.2.	Buffer module - 1606-XLSBUFFER24........	20
6.	Output .................................................................	6	24.3.	1606-XLSRED80 - Redundancy Modules...	20
7.	Hold-up Time.......................................................	8	25. Application Notes.............................................		21
8.	DC-OK Relay Contact ..........................................	9	25.1.	Repetitive Pulse Loading..........................	21
9.	Shut-down Input .................................................	9	25.2.	Peak Current Capability ...........................	22
10.	Remote Control of Output Voltage .................	10	25.3.	External Input Protection.........................	22
11.	Internal Data Logging.......................................	10	25.4.	Using only 2 Legs of a 3-Phase System ....	23
12.	Efficiency and Power Losses..............................	11	25.5.	Charging Batteries ...............................	24
13.	Reliability...........................................................	12	25.6.	Output Circuit Breakers............................	24
14.	Functional Diagram...........................................	12	25.7.	Parallel Use to Increase Output Power....	25
15.	Terminals and Wiring........................................	13	25.8.	Parallel Use for Redundancy ....................	25
16. Front Side and User Elements...........................		14	25.9.	Series Operation .......................................	26
17.	EMC....................................................................	15	25.10. Inductive and Capacitive Loads................		26
18.	Environment ......................................................	16	25.11. Back-feeding Loads ..................................		26
19. Protection Features ...........................................		17	25.12. Use in a Tightly Sealed Enclosure ............		26
20.	Safety Features..................................................	17	25.13. Mounting Orientations ............................		27
21.	Dielectric Strength ............................................	18

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

Description

The most outstanding features of the 1606-XLS960E-3 DIN rail power supply are its extremely high efficiencies and its small size, which are achieved by a synchronous rectification 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.

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 Efficiencies

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 Low 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

Specification 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
Efficiency	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
Weight	1500g / 3.3 lb

Catalog Numbers				Certifications
Catalog Numbers				Certifications
Power Supply	1606-XLS960E-3 24-28V Standard unit


Accessories	1606-XLC	Wall mount bracket		IND. CONT. EQ.	UL 60950-1	GOST R
	1606-XLSBUFFER24		Buffer unit	UL 508	UL 60950-1	GOST R
	1606-XLSBUFFER24		Buffer unit	UL 508	Marine RINA
	1606-XLSRED80	Redundancy module
				Marine	EMC, LVD, RoHS	C-Tick

	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, definitions

POUT		Rated input range
Shut-down	Turn-on
			VIN
275V 305V		323V	576Vac

Input
Voltage
L1	L2	L3
Output		- 5%		Overshoot
Output
Voltage
	Start-up		Rise
		delay	Time

Fig. 3-3 Input current vs. output load at 24V									Fig. 3-4 Power factor vs. output load at 24V
Input Current, typ.									Power Factor, typ.
1.6A									0.95
1.6A										A: 3x 400Vac
1.4	A: 3x 400Vac									A: 3x 400Vac
1.4									0.90	B: 3x 480Vac					B
1.2									0.90	B: 3x 480Vac					B	A
1.2	B: 3x 480Vac						A									A
							A
1.0							B		0.85
0.8									0.80
0.6									0.80
0.6
0.4									0.75
0.2									0.75
0.2						Output Current									Output Current
0						Output Current			0.70						Output Current
0									0.70
4	8	12	16	20	24	28	32	36 40A	4	8	12	16	20	24	28	32	36 40A

	All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
4	Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

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.	6Apeak	6Apeak	over entire temperature range
	typ.	4.5Apeak	4.5Apeak	over entire temperature range
Inrush energy	max.	1.5A2s	1.5A2s	over entire temperature range
Inrush delay	typ.	500ms	600ms

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

Fig. 4-1 Typical turn-on behaviour at nominal load and 25°C ambient temperature

Input Current 2A/DIV

Input

3x400Vac

24Vdc

Output 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 short-
	term 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

Rockwell Automation 1606-XLS960E-3 User Manual

Bulletin 1606 Switched Mode Power Supplies

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

“single use” mode, typ.

Output Voltage					Adjustment Range
					Adjustment Range
28V			A			B
24			A			B
24
20
16					A		B
12	A Continuously				A		B
	A Continuously
		available
8	B	Short-term (4s)
		BonusPower
4
0
0		10	20	30	40	50	60	70A
						Output Current

Fig. 6-3 Bonus time vs. output power

Bonus Time
5s
4						max.



3					min.
					min.

2




1




0			Output Power
0
100	110	120	130	140			150	160	170%

Fig. 6-5 BonusPower recovery time

	Limitation by
Power	Power Manager
Demand
100%
	t
Bonus	Recovery Time


	Time	Bonus Power disabled
Output
Voltage

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

“parallel use” mode, typ.

Output Voltage (Parallel Use, typ.)
29V				Adjustment Range
28V
27V					A		B
26V			Factory
25V			setting
25V
24V	A Continuously
23V		available
23V	B	Short-term (4s)			A		B
22V	B	BonusPower
22V
0		10	20	30	40	50	60A

Output Current

Fig. 6-4 Dynamic overcurrent capability, typ.

Output Voltage (dynamic behavior, < 25ms)

28V
24
20	Adjustment
16		Range
16
12
8
4			Output Current
0			Output Current
0
0	15	30	45	60	75	90 105120135 150A

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

Input

Voltage

Output

Voltage

150% Bonus

Power

Output 100%

Power

Fig. 6-7 BonusPower after output short

	Short of
	Output
Output
Voltage
Output	150%	Bonus
Output	100%	Power
Power	100%

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 figures 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, definitions

Hold-up Time			24V, 20A, typ.
50ms			24V, 20A, typ.
50ms
40			24V, 20A, min.
40
30			24V, 40A, typ.
			24V, 40A, typ.
20			24V, 40A, min.
			24V, 40A, min.
10
0		Input Voltage
0
320	360	400	440	3x480Vac

L1 L2 L3

Input

Voltage

Output				- 5%


Voltage

Hold-up Time

	All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
8	Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

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

				VOUT = VADJ
	10%			0.9* VADJ
				0.9* VADJ
	<	>	250ms
	1ms	1ms	250ms
open	closed		open	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:	Option B:	n.c.	15	Shut-	Option C:		15 Shut-
15 Shut-	(via open					n.c.
				down	(via external
	collector)		16				down
down		I		Input	voltage
16 Input						+	16 Input


OFF: linked	OFF: I > 0.3mA		-		OFF: U < 1V U		-
ON : open					ON : U = 4 -29V
	ON : I < 0.1mA

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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