Rockwell Automation 1606-XLS960FE User Manual
Reference Manual
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1.
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. Efciency and Power Losses..............................11
13. Lifetime Expectancy and MTBF.........................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. Certications ................................................... 18
23. Physical Dimensions and Weight ..................... 19
24. Accessories ........................................................ 20
24.1. 1606-XLC Wall Mounting Bracket ............ 20
24.2. 1606-XLSBUFFER48 Module ..................... 20
25. Application Notes ............................................. 22
25.1. Repetitive Pulse Loading .......................... 22
25.2. Peak Current Capability ...........................23
25.3. External Input Protection ......................... 23
25.4. Charging of Batteries ...............................24
25.5. Output Circuit Breakers ............................24
25.6. Parallel Use to Increase Output Power ....25
25.7. Parallel Use for Redundancy ....................25
25.8. Series Operation .......................................26
25.9. Inductive and Capacitive Loads ................26
25.10. Back-feeding Loads ..................................26
25.11. Operation on Two Phases ........................ 27
25.12. Use in a Tightly Sealed Enclosure ............ 27
25.13. Mounting Orientations ............................ 28
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLS960FE
Index
Terminology and Abbreviations
•PE and symbol—PE is the abbreviation for Protective Earth and has the same meaning as the symbol .
•Earth, Ground—This document uses the term “earth” which is the same as the U.S. term “ground”.
• T.b.d.—To be defined, value or description will follow later.
• AC 230V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)
included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
• 230Vac—A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.
• 50Hz vs. 60Hz—As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.
•may—A key word indicating flexibility of choice with no implied preference.
•shall—A key word indicating a mandatory requirement.
•should—A key word indicating flexibility of choice
Bulletin 1606 Switched Mode Power Supplies
Power Supply
AC 200-240V Input
Width only 125mm, Weight only 1.8kg
95.0% Full Load and Excellent Partial Load Efciencies
50% BonusPower
, 1440W for up to 4s
55A High Peak Current for 25ms for Easy Fuse
Tripping
Safe Hiccup
PLUS
Overload Mode
Active PFC (Power Factor Correction)
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.
DC-OK Relay Contact
Shut-down Input
3 Year Warranty
Description
The most outstanding features of our family of DIN rail
power supplies are their extremely high efciency and
their small footprint, which are achieved by a
synchronous rectication and other technological
innovations.
The 1606-XLS960FE is a device for 200-240V mains
voltages. 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 make usage in nearly
every environment possible.
The integrated output power manager and input fuses
as well as the 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.
Specication Quick Reference
Output voltage DC 48V nominal
Adjustment range 48 - 54V
Output current 20 – 17.8A continuous
30 – 26.7A short term (4s)
Output power 960W continuous
1440W short term (4s)
Output ripple < 150mVpp 20Hz to 20MHz
Input voltage AC 200-240V -15%/+10%
Mains frequency 50-60Hz ±6%
AC Input current 4.6A at 230Vac
Power factor 0.96 at 230Vac
AC Inrush current typ. 14A peak at 230Vac
Efciency 95.0% at 230Vac
Losses 50.5W at 230Vac
Temperature range -25°C to +70°C operational
Derating 24W/°C +60 to +70°C
Hold-up time typ. 30ms at 230Vac
Dimensions 125x124x127mm WxHxD
Weight 1800g / 3.97lb
Catalog Numbers
Power Supply 1606-XLS960FE 48-54V Standard unit
Accessories 16060-XLC Wall mount bracket
1606-XLSBUFFER48 Buffer unit
Certications
IND. CONT. E
Q.
UL 508
UL 60950-1
EMC, LVD, RoHS
Marine
Marine RINA
GOST R C-TICK
2 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
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 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.
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 terminals are located on the bottom of the unit. For other mounting orientations, refer to Mounting.
• This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid
(e.g. cable conduits) by more than 15%!
• 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, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM018A-EN-P — February 2014 3
Bulletin 1606 Switched Mode Power Supplies
3. AC Input
AC input nom. AC 200-240V suitable for TN, TT and IT mains networks
AC input range min. 170-264Vac continuous operation
min. 110-170Vac full power for up to 200ms
min. 0-170Vac no damage to the unit
264-300Vac < 500ms
Allowed voltage L or N to earth max. 300Vac continuous, IEC 62103
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 164Vac steady-state value, load independent, see Fig. 3-1
Shut-down voltage typ. 151Vac steady-state value, load independent, see Fig. 3-1
Input current typ. 4.6A at 48V, 20A, see Fig. 3-3
Power factor*) typ. 0.96 at 48V, 20A, see Fig. 3-4
Crest factor
**)
typ. 1.65 at 48V, 20A
Start-up delay typ. 750ms see Fig. 3-2
Rise time typ. 18ms at 48V, 20A, resistive load, 0mF see Fig. 3-2
typ. 35ms at 48V, 20A, resistive load, 20mF see Fig. 3-2
Turn-on overshoot max. 200mV 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, denitions
Turn-on
170V
Rated input range
V
IN
P
OUT
151V 264Vac
Shut-down
164V
Start-up
delay
Rise
Time
Overshoot
- 5%
Output
Voltage
Input
Voltage
Fig. 3-3 Input current vs. output load at 48V Fig. 3-4 Power factor vs. output load at 48V
20A
2 4 6 8 10 12 14 16 18
0
1
2
3
4
5
6A
Input Current, typ.
Output Current
Power Factor, typ.
2 4 6 8 10 12 14 16 18 20
A
0.75
0.80
0.85
0.90
0.95
1.00
Output Current
4 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
All parameters are specified at 48V, 20A, 230Vac, 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.
Inrush current
*)
max. 18A
peak
over entire temperature range
typ. 14A
peak
over entire temperature range
Inrush energy max. 4A
2
s over entire temperature range
Inrush delay typ. 750ms
*) The charging current into EMI suppression capacitors is disregarded in the rst microseconds after switch-on.
Fig. 4-1 Typical turn-on behavior at nominal
load and 25°C ambient temperature
Output
50mS/DIV
Input 230Vac
48Vdc
Input Current 5A / DIV
5. DC Input
Do not operate this power supply with DC input voltage. Check the 1606-XLE480FP-D instead.
Two 1606-XLE480FP-D units in parallel may be necessary.
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM018A-EN-P — February 2014 5
Bulletin 1606 Switched Mode Power Supplies
6. Output
Output voltage nom. 48V
Adjustment range min. 48-54V guaranteed
max. 56V
Factory setting typ. 48.0V ±0.2%, at full load, cold unit, in “single use” mode
typ. 46.0V ±0.2%, at full load, cold unit, in “parallel use” mode
typ. 48.0V at no load, cold unit, in “parallel use” mode
Line regulation max. 10mV 170-264Vac
Load regulation max. 50mV in “single use” mode: static value, 0A 20A, see Fig. 6-1
typ. 2000mV in “parallel use” mode: static value, 0A
Ripple and noise voltage max. 150mVpp 20Hz to 20MHz, 50Ohm
Output current nom. 20A continuously available at 48V, see Fig. 6-1 and Fig. 6-2
nom. 17.8A continuously available at 54V, see Fig. 6-1 and Fig. 6-2
nom. 30A short term available BonusPower
nom. 26.7A short term available BonusPower
typ. 55A up to 25ms, output voltage stays above 40V, see Fig.
Output power nom. 960W continuously available at 48-54V
nom. 1440W*) short term available BonusPower*) at 48-54V
BonusPower
time typ. 4s duration until the output voltage dips, see Fig. 6-5
BonusPower recovery time typ. 7s overload free time to reset power manager, see Fig. 6-6
Overload behavior cont. current output voltage > 40Vdc, see Fig. 6-1
Hiccup
Short-circuit current min. 30A
max. 35A
max. 11.5A average (R.M.S.) current, load impedance 50mOhm, see
min. 55A up to 25ms, load impedance <10mOhm, see Fig. 6-4
typ. 63A up to 25ms, load impedance <10mOhm, see Fig. 6-4
Output capacitance typ. 3 700μF 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 with the BonusPower longer than shown in the Bonus-time diagram (see
Fig. 6-5), the max. output power is automatically reduced to 960W. If the power requirement is continuously above 960W and the
voltage falls below approx. 40V (due to the current regulating mode at overload), the unit shuts-off and makes periodical restart
attempts. This behavior is called hiccup mode which is described below. If the voltage is above 40V, the unit continuously delivers
current.
PLUS
**) Hiccup
Up to 4s of overloading, the power supply delivers continuous output current. After this, the output power is reduced to nearly zero
for approx. 17s before a new start attempt is automatically performed. If the overload has been cleared, the device will operate
normally. If the overload still exists, the output current will be delivered for 2 to 4s (depending on the overload) again followed by a
17s rest time. This cycle is repeated as long as the overload exists. See Fig. 6-3. During the off-period a small rest voltage and rest
current is present on the output.
***) 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 this value can be achieved. The typical value is about 55V.
Mode
****)
at clockwise end position of potentiometer
see Fig. 6-2
®*)
, at 48V
for typical 4s, see Fig. 6-1 and Fig. 6-2
®*)
, at 54V
for typical 4s, see Fig. 6-1 and Fig. 6-2
6-4, This peak current is available once every second.
See section 25.2 for more peak current measurements.
PLUS
***)
load impedance 50mOhm, see Fig. 6-3
***)
load impedance 50mOhm, see Fig. 6-3
mode
**)
output voltage < 40Vdc, see Fig. 6-1
Fig. 6-3
20A,
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
6 Rockwell Automation Publication 1606-RM018A-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
0
0 5 10 15 20
8
16
24
56V
32
40
48
3025 35A
Output Current
Adjustment Range
Hiccup
mode
A
B
A
B
Short-term (4s)
then switching
to curve
Continuously
available
A
A B
Output Voltage
(Parallel Use, typ.)
42V
01020
44V
46V
48V
56V
50V
52V
54V
30A25155
Adjustment Range
Factory
setting
Continuously
allowed
Bonus
Power
Output Current
Fig. 6-3 Short-circuit on output, Hiccup
PLUS
mode, typ. Fig. 6-4 Dynamic overcurrent capability, typ.
Output
Current
0
35A
17s
17s
17s
2s
2s
2s
t
Short -circuit
Normal
operation
Normal
operation
Output Voltage
(dynamic behavior, < 25ms)
0
0
8
16
24
54V
32
40
48
70A30 6010 20 40 50
Adjustment
Range
Output Current
Fig. 6-5 Bonus time vs. output power Fig. 6-6 BonusPower recovery time
ma
x
.
Bonus Time
0
100 120 130 140 150
170%
1
2
3
4
5s
110 160
Output Power
m
i
n
.
Power
Demand
100%
t
t
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 output
overload.
Fig. 6-7 BonusPower after input turn-on Fig. 6-8 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 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM018A-EN-P — February 2014 7
Bulletin 1606 Switched Mode Power Supplies
7. Hold-up Time
AC 230V
Hold-up Time typ. 58ms at 48V, 10A, see Fig. 7-1
min. 47ms at 48V, 10A, see Fig. 7-1
typ. 30ms at 48V, 20A, see Fig. 7-1
min. 24ms at 48V, 20A, see Fig. 7-1
Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, denitions
0
10
20
30
40
60ms
170 190 210 230 250Vac
Input Voltage
Hold-up Time
48V, 10A, typ.
4
8
V
,
2
0
A
,
t
y
p
.
48V, 10A, min.
50
4
8
V
,
2
0
A
,
m
i
n
.
- 5%
Hold-up Time
Zero Transition
Output
Voltage
Input
Voltage
8 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
All parameters are specified at 48V, 20A, 230Vac, 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
= V
OUT
ADJ
10%
<
1ms
>
1ms
250ms
0.9* V
ADJ
open
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 <4V 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-
15
down
Input
OFF: linked
ON : open
16
Option B:
(via open
collector)
OFF: I > 0.3mA
ON : I < 0.1mA
n.c.
I
15
16
-
Shutdown
Input
Option C:
(via external
voltage
OFF: U < 1V
ON : U = 4 -29V
n.c.
+
U
16
-
down
Input
Shut-
15
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM018A-EN-P — February 2014 9
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