Allen-Bradley 1606-XLS960E-3 User manual

Reference Manual
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLS960E-3
Index
•PEand 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.
Terminology and Abbreviations
egaPegaP
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. 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 mountingbracket - 1606-XLC......... 20
24.2. Buffer module - 1606-XLSBUFFER24........20
24.3. 1606-XLSRED80 - Redundancy Modules...20
25. Application Notes.............................................21
25.1. Repetitive Pulse Loading..........................21
25.2. Peak Current Capability ...........................22
25.3. External Input Protection.........................22
25.4. Usingonly 2 Legs of a 3-Phase System ....23
25.5. ChargingBatteries ...............................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-feedingLoads ..................................26
25.12. Use in a Tightly Sealed Enclosure ............26
25.13. MountingOrientations ............................27

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
2Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
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 Filteringof Input Transients
Negligible Low Input Inrush Current Surge
Full Power Between -25°C and +60°C
Current SharingFeature for Parallel Use
Internal Data Loggingfor TroubleshootingIncluded.
Remote Control of Output Voltage
DC-OK Relay Contact
Shut-down Input
3 Year Warranty
Description
The most outstandingfeatures 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 startingof
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
Derating24W/°C +60 to +70°C
Hold-up time typ. 25 / 25ms at 3x400 / 480Vac
Dimensions 110x124x127mm WxHxD
CatalogNumbers
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
Q.
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.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 3
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.
4Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
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
V
IN
P
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
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
A
B
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
B
A: 3x 400Vac
B: 3x 480Vac

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
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 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.
6Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
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.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 7
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
010203040
4
8
12
28V
16
20
24
6050 70A
Output Current
Adjustment Range
A B
A B
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
AB
AB
A
B
Short-term (4s)
BonusPower
Continuously
available
Fig. 6-3 Bonus time vs. output power Fig. 6-4 Dynamic overcurrent capability, typ.
max.
Bonus Time
0
100 120 130 140 150 170%
1
2
3
4
5s
110 160
Output Power
min.
Output Voltage (dynamic behavior, < 25ms)
0
0
4
8
12
28V
16
20
24
150
A
6030 90 12015 45 75 105 135
Adjustment
Range
Output Current
Fig. 6-5 BonusPower recovery time
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 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.
8Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
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
0
10
20
30
40
50ms
320 360 400 440 3x480Vac
Input Voltage
Hold-up Time
24V, 20A, typ.
24V,40A,typ.
24V, 20A, min.
24V,40A,min.
- 5%
Hold-up Time
Output
Voltage
Input
Voltage
L1 L2 L3

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
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
250ms
0.9* V
ADJ
<
1ms
10%
open
V
OUT
= V
ADJ
openclosed closed
>
1ms
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
15
16
OFF: linked
ON : open
Shut-
down
Input
Option A:
15
16
OFF: I > 0.3mA
ON : I < 0.1mA
Shut-
down
Input
Option B:
-
(via open
collector) I
n.c.
15
16
OFF: U < 1V
ON : U = 4 -29V
Shut-
down
Input
Option C:
-
(via external
voltage
+
U
n.c.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
10 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
Bulletin 1606 Switched Mode Power Supplies
10. Remote Control of Output Voltage
The shut-down input can also be used to remotely adjust the output voltage between typically 14Vdc and 28Vdc. All
other functions of shut-down input remain the same.
The control voltage is referenced to the main ground (negative output voltage).
Fig. 10-1 Remote control of the output
voltage
Fig. 10-2 Applying the control voltage
Output Voltage
12V
0V 5V 15V
14V
16V
18V
28V
20V
22V
26V
Control Voltage
24V
10V 20V
Potentiometer:
set to 28V
set to 24V
15
16
Control
Voltage
Shut-
down
Input
-
+
n.c.
Instructions:
1. Set the unit into “Single Use” mode.
2. Set the output voltage adjustment (24-28V) to the maximum desired voltage.
3. Apply a control voltage to reduce the output voltage.
11. Internal Data Logging
A protected microcontroller inside the power supply acquires and stores operating data during the life of the unit. The
data can be downloaded with a small tool and special software by Rockwell Automation service and repair personnel,
even if the unit is faulty. Having the data facilitates troubleshooting. Knowledge of the events occuring just before a
failure allows for a more accurate analysis of the problem.
The data will be acquired with a xed sampling rate unless the peak detectors trigger due to an abnormal condition.
In such cases, the abnormal condition is properly captured.
Acquired data:
- Family name of unit (1606-XLS), revision of rmware
- Operational hours and expired portion of lifetime
- Operational data; latest 60 values with timestamps of the last 158 minutes of:
Number of over-voltage transients,
Average input voltage,
Peak input voltage,
Inside temperature,
Overloads > 2s,
Missing of one input phase (minimum output load required)
- Failure data; various errors such as:
Internal errors,
Over-temperature shut-down,
OVP,
Long-term overloads,
Remarkable temperatures inside the unit,
….
- Number of turn-on sequences and overvoltage transients

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 11
Bulletin 1606 Switched Mode Power Supplies
12. Efciency and Power Losses
Efciencies for 3-Phase operation:
3AC 400V 3AC 480V
Efciency typ. 95.3% 95.2% at 24V, 40A
Average efciency*) typ. 94.7% 94.6% 25% at 10A, 25% at 20A, 25% at 30A. 25%
at 40A
Power losses typ. 1.5W 1.5W with activated shut-down
typ. 9.5W 9.8W at 24V, 0A (no load)
typ. 24.1W 25.0W at 24V, 20A (half load)
typ. 47.3W 48.4W at 24V, 40A (full load)
*) The average efciency is an assumption for a typical application where the power supply is loaded with 25% of the nominal load for 25%
of the time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of the time and with 100%
of the nominal load for the rest of the time.
Efciencies when using only 2 legs of a 3-phase system:
2AC 400V 2AC 480V
Efciency typ. 94.4%**) 94.7%**) at 24V, 40A
Power losses typ. 56.9W**) 53.7W**) at 24V, 40A (full load)
**) Curves can be found in section 25.4.
Fig. 12-1 Efciency vs. output current at 24V,
typ.
Fig. 12-2 Losses vs. output current at 24V,
typ.
Efciency
8 1216202428323640A
92
93
94
Output Current
95
96%
3x480Vac
3x400Vac
Power Losses
0 4 8 1216202428 40A
10
0
30
40
50
60W
32 36
20
3x400Vac
3x480Vac
Output Current
Fig. 12-3 Efciency vs. input voltage at 24V,
40A, typ.
Fig. 12-4 Losses vs. input voltage at 24V, 40A,
typ.
Efciency
350 400 450 500 3x550Vac
94.9
95.0
95.1
95.2
Input Voltage
95.3
95.4
95.5%
Power Losses
350 400 450 500 3x550Vac
44
45
46
47
Input Voltage
48
49
50W

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
12 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
Bulletin 1606 Switched Mode Power Supplies
13. Reliability
3AC 400V 3AC 480V
Calculated lifetime expectancy*) 314 000h*) 294 000h*) at 24V, 20A and 25°C
111 000h 104 000h at 24V, 20A and 40°C
179 000h*) 174 000h*) at 24V, 40A and 25°C
63 000h 62 000h at 24V, 40A and 40°C
MTBF**) SN 29500, IEC 61709 375 000h 369 000h at 24V, 40A and 40°C
685 000h 678 000h at 24V, 40A and 25°C
MTBF**) MIL HDBK 217F 158 000h 157 000h at 24V, 40A and 40°C; Ground Benign GB40
211 000h 210 000h at 24V, 40A and 25°C; Ground Benign GB25
*) The calculated lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the
lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specied in operational hours and is calculated according
to the capacitor’s manufacturer specication. The manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15
years (131 400h). Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices.
**) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a
device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.
The MTBF gure is a statistical representation of the likelihood of a device to fail. A MTBF gure of e.g. 1 000 000h means that
statistically one unit will fail every 100 hours if 10 000 units are installed in the eld. However, it’s impossible to determine if the failing
unit has been running for 50 000h or only for 100h.
14. Functional Diagram
Fig. 14-1 Functional diagram
+
+
-
-
V
OUT
DC-ok
Contact
Output
Over-
Voltage
Protection
PFC
Converter
Input Fuses
Input Filter
Input Rectier
Inrush Limiter
Transient Filter
Output
Voltage
Regulator
Power
Converter
Output
Filter
DC ok
Relay
Output
Voltage
Monitor
Output
Power
Manager
Temper-
ature
Shut-
down
Overload
LED
DC-ok
LED
L2
L3
L1
Single /
Parallel
Shut-
down
Input
Shut-
down
13
14
15
16
Event Datalogger

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 13
Bulletin 1606 Switched Mode Power Supplies
15. Terminals and Wiring
The terminals are IP20, finger safe, constructed and suitable for eld and factory wiring.
Input Output DC-OK, Shut-down
Type screw termination screw termination spring-clamp termination
Solid wire 0.5-6mm20.5-16mm20.15-1.5mm2
Stranded wire 0.5-4mm20.5-10mm20.15-1.5mm2
American Wire Gauge AWG 20-10 AWG 22-8 AWG 26-14
Max. wire diameter 2.8mm
(including ferrules)
5.2mm
(including ferrules)
1.5mm
(including ferrules)
Wire stripping length 7mm / 0.28inch 12mm / 0. 5inch 7mm / 0.28inch
Screwdriver 3.5mm slotted or cross-
head No 2
3.5mm or 5mm slotted
or cross-head No 2
3mm slotted
(to open the spring)
Recommended tightening torque 1Nm, 9lb.in 2.3Nm, 20.5lb.in Not applicable
Instructions:
a) Use appropriate copper cables that are designed for minimum operating temperatures of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum
90°C for ambient up to 70°C minimum.
b) Follow national installation codes and installation regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Do not use the unit without PE connection.
e) Unused terminal compartments should be securely tightened.
f) Ferrules are allowed.
Daisy chaining:
Daisy chaining (jumping from one power supply output to the next) is allowed as long as the average output current
through one terminal pin does not exceed 54A. If the current is higher, use a separate distribution terminal block as
shown in Fig. 15-2.
Fig. 15-1 Daisy chaining of outputs Fig. 15-2 Using distribution terminals
Load
+ -
Power
Supply
+ +
- -
Output
Power
Supply
+ +
- -
Output
max 54A!
Distribution
Terminals
Load
+ -
Power
Supply
+ +
- -
Output
Power
Supply
+ +
- -
Output

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
14 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
Bulletin 1606 Switched Mode Power Supplies
16. Front Side and User Elements
Fig. 16-1 Front side
AInput Terminals (Screw terminals)
L1, L2, L3 Line input
...PE (Protective Earth) input
BOutput Terminals (Screw terminals, two pins per pole)
+ Positive output
–Negative (return) output
C“Parallel Use” “Single Use” Selector
Set jumper to “Parallel Use” when power supplies are connected
in parallel to increase the output power. In order to achieve a
sharing of the load current between the individual power
supplies, the “parallel use” regulates the output voltage in such a
manner that the voltage at no load is approx. 4% higher than at
nominal load. See also section 25.7. A missing jumper is equal to
a “Single Use” mode.
DOutput Voltage Potentiometer
Multi turn potentiometer;
Open the ap to set the output voltage.
Factory set: 24.1V at full output current, “Single Use” mode.
EDC-OK LED (green)
On, when the voltage on the output terminals is >90% of the
adjusted output voltage
FOverload LED (red)
- On, when the voltage on the output terminals is <90% of the
adjusted output voltage, or in case of a short circuit in the output.
- Flashing, when the shut-down has been activated or the unit has
switched off due to over-temperature.
- Input voltage is required
GDC-OK Relay Contact
The DC-OK relay contact is synchronized with the DC-OK LED.
See section 8 for details.
HShut-down and Remote Control Input
Allows the power supply to be shut down. Can be activated with
a switch contact or an external voltage.
The remote control input allows adjusting the output voltage
between 14V and 28V. See sections 9 and 10 for details.
Indicators, LEDs
Overload LED DC-OK LED DC-OK Contact
Normal mode OFF ON Closed
During BonusPower OFF ON Closed
Overload (Vout < 90%) ON OFF Open
Output short circuit ON OFF Open
Temperature Shut-down ashing OFF Open
Active Shut-down input ashing OFF Open
No input power OFF OFF Open
AB
CD
E
F
G
H

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 15
Bulletin 1606 Switched Mode Power Supplies
17. EMC
The power supply is suitable for applications in industrial environment as well as in residential, commercial and light
industry environment without any restrictions. A detailed EMC report is available on request.
EMC Immunity According generic standards: EN 61000-6-1 and EN 61000-6-2
Electrostatic discharge EN 61000-4-2 contact discharge
air discharge
8kV
15kV
Criterion A
Criterion A
Electromagnetic RF eld EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 input lines
output lines
DC-OK signal (coupling clamp)
4kV
2kV
2kV
Criterion A
Criterion A
Criterion A
Surge voltage on input EN 61000-4-5 L1 L2, L2 L3, L1 L3
L1 / L2 / L3 PE
2kV
4kV
Criterion A
Criterion A
Surge voltage on output EN 61000-4-5 + -
+ / - PE
1kV
1kV
Criterion A
Criterion A
Surge voltage on DC-OK EN 61000-4-5 DC-OK signal PE 1kV Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips
(Dips on three phases)
EN 61000-4-11 0% of 380Vac (0Vac)
0% of 480Vac (0Vac)
0Vac, 20ms
0Vac, 20ms
Criterion A,
Criterion A
Mains voltage dips
(Dips on two phases)
EN 61000-4-11 40% of 380Vac (152Vac)
40% of 480Vac (192Vac)
70% of 380Vac (266Vac)
70% of 480Vac (336Vac)
200ms
200ms
500ms
500ms
Criterion A
Criterion A
Criterion A
Criterion A
Voltage interruptions EN 61000-4-11 0Vac 5000ms Criterion C
Voltage sags SEMI F47 0706 dips on two phases according to section 7.2. of the SEMI F47 standard
80% of 380Vac (304Vac)
70% of 380Vac (266Vac)
50% of 380Vac (160Vac)
1000ms
500ms
200ms
Criterion A
Criterion A
Criterion A
Powerful transients VDE 0160 over entire load range 1550V, 1.3ms Criterion A
Criteria:
A: Power supply shows normal operation behavior within the dened limits.
C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. The power supply will incur neither damage
nor hazard.
EMC Emission According generic standards: EN 61000-6-3 and EN 61000-6-4
Conducted emission
input lines
EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B
Conducted emission
output lines
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 5dB higher than average limits
for DC power port according EN
61000-6-3
**)
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 fullled for class A equipment
Voltage uctuations, icker EN 61000-3-3 fullled
*)
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.
*) Tested with constant current loads, non pulsing
**) Restrictions apply for applications in residential, commercial and light-industrial environments, where local DC power networks according
to EN 61000-6-3 are involved. No restrictions for all kinds of industrial applications.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
16 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
Bulletin 1606 Switched Mode Power Supplies
Switching Frequencies The power supply has three converters with three different switching frequencies
included. One is nearly constant. The others are variable.
Switching frequency 1 105kHz Resonant converter, nearly constant
Switching frequency 2 1kHz to 150kHz Boost converter, load dependent
Switching frequency 3 40kHz to 300kHz PFC converter, input voltage and load dependent
18. Environment
Operational temperature
*)
-25°C to +70°C (-13°F to 158°F) reduce output power according Fig. 18-1
Storage temperature -40 to +85°C (-40°F to 185°F) for storage and transportation
Output de-rating 24W/°C 60-70°C (140°F to 158°F)
Humidity**) 5 to 95% r.H. IEC 60068-2-30
Vibration, sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 1g
***)
2 hours / axis
IEC 60068-2-6
Shock 15g 6ms, 10g 11ms
***)
3 bumps / direction, 18 bumps in total
IEC 60068-2-27
Altitude 0 to 2000m (0 to 6 560ft) no restrictions
2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature,
see Fig. 18-2
IEC 62103, EN 50178, overvoltage category II
Altitude de-rating 60W/1000m or 5°C/1000m > 2000m (6500ft), see Fig. 18-2
Over-voltage category III IEC 62103, EN 50178, altitudes up to 2000m
II altitudes from 2000m to 6000m
Degree of pollution 2 IEC 62103, EN 50178, not conductive
LABS compatibility The unit does not release any silicone or other LABS-critical substances and is suitable for
use in paint shops.
*) Operational temperature is the same as the ambient temperature and is dened as the air temperature 2cm below the unit. Curves and
gures for operation on only 2 legs of a 3-phase system can be found in section 25.4.
**) Do not energize in the presence of condensation.
***) Higher levels allowed when using the 1606-XLC wall mounting bracket.
Fig. 18-1 Output current vs. ambient temp. Fig. 18-2 Output current vs. altitude
Allowed Output Current at 24V
0-25 0 20 40 70°C
10
20
30
40
50
60A
continuous
60
Ambient Temperature
short-term(4s)
Allowed Output Current at 24V
00 2000 4000
10
20
30
40
50
60A
continuous
6000m
Altitude
short-term(4s)
AC
A... Tamb < 60°C
B... Tamb < 50°C
C... Tamb < 40°C
B

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 17
Bulletin 1606 Switched Mode Power Supplies
19. Protection Features
Output protection Electronically protected against overload, no-load and short-circuits*)
Output over-voltage protection typ. 30Vdc
max. 32Vdc
In case of an internal power supply defect, a redundant
circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 5mm e.g. screws, small parts
Over-temperature protection yes Output shut-down with automatic restart
Input transient protection MOV (Metal Oxide Varistor)
Internal input fuse included not user replaceable
*) In case of a protection event, audible noise may occur.
20. Safety Features
Input / output separation*) SELV IEC/EN 60950-1
PELV IEC/EN 60204-1, EN 50178, IEC 62103, 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
Touch current (leakage current) typ. 0.35mA / 0.64mA 3x400Vac, 50Hz, TN-,TT-mains / IT-mains
typ. 0.45mA / 0.91mA 3x480Vac, 60Hz, TN-,TT-mains / IT-mains
max. 0.45mA / 0.78mA 3x440Vac, 50Hz, TN-,TT-mains / IT-mains
max. 0.60mA / 1.20mA 3x528Vac, 60Hz, TN-,TT-mains / IT-mains
*) double or reinforced insulation

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
18 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
Bulletin 1606 Switched Mode Power Supplies
Product certification information (including Certificates and Declarations of Conformity) can be found at www.ab.com/certifications.
21. Dielectric Strength
The output voltage is oating and has no ohmic connection to the ground. Type and factory tests are conducted by
the manufacturer. Field tests may be conducted in the eld using the appropriate test equipment which applies the
voltage with a slow ramp (2s up and 2s down). Connect all phase terminals together as well as all output poles before
conducting the test. When testing, set the cut-off current settings to the value in the table below.
Fig. 21-1 Dielectric strength
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
Cut-off current setting > 10mA > 10mA > 40mA > 1mA
AD
C
B
B
*)
L1
Input
Earth
L3
L2
DC-ok
13
14
Output
15/16
+/-
Shut-down
To full the PELV requirements according to EN 60204-1 § 6.4.1, we
recommend that either the + pole, the – pole or any other part of
the output circuit shall be connected to the protective earth
system. This helps to avoid situations in which a load starts
unexpectedly or can not be switched off when unnoticed earth
faults occur.
B*) When testing input to DC-OK ensure that the max. voltage between DC-OK and the output is not exceeded (column D). We recommend
connecting DC-OK pins and the output pins together when performing the test.
22. Certications
EC Declaration of Conformity Complies with CE EMC and CE Low Voltage Directives
UL 508
IND. CONT. EQ.
LISTED E56639 for use in the U.S.A. (UL 508) and Canada
(C22.2 No. 14-95)
Industrial Control Equipment
UL 60950-1
RECOGNIZED E168663 for use in the U.S.A. (UL 60950-1) and
Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3
SEMI F47
SEMI F47-0706 Voltage Sag Immunity Compliance. See below
for link to the Certicate.
Marine GL
GL (Germanischer Lloyd) classied for marine and offshore
applications. Environmental category: C, EMC2. See below
for link to the Certicate.
GOST R
Certicate of Conformity for Russia and other GUS countries
Marine RINA RINA (Registro Italiano Navale) certied. See below for link to
Certicate.
C-Tick C-tick compliance is for products intended for sale and use
within the Australian market. See below for link to the C-tick
Declarations of Conformity.

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 19
Bulletin 1606 Switched Mode Power Supplies
23. Physical Dimensions and Weight
Weight 1500g / 3.3lb
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 unit depth (127mm) to calculate the total required
installation depth.
Installation Clearances See Section 2.
Fig. 23-1 Front view Fig 23-2 Side view

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
20 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
Bulletin 1606 Switched Mode Power Supplies
24. Accessories
24.1. 1606-XLC Wall Mounting Bracket
This bracket is used to mount specic
units onto a at surface without a DIN rail.
24.2. 1606-XLSBUFFER24 Buffer Module
This buffer unit is a supplementary device for DC 24V power supplies. It delivers
power to bridge typical mains failures or
extends the hold-up time after turn-off of
the AC power. In times when the power
supply provides sufcient voltages, the
buffer unit stores energy in integrated
electrolytic capacitors. In case of mains
voltage fault, this energy is released again in a regulated process. One buffer
module can deliver 20A. To buffer the full output current of 40A, two buffer
modules are needed in parallel.
DC
Buffer
Unit(s)
Power
Supply Load
AC
+
-
The buffer unit does not require any control wiring. It can be added in parallel to
the load circuit at any given point. Buffer units can be added in parallel to increase
the output ampacity or the hold-up time.
1606-XLSRED80
Redundancy
Module
+ - + -
Input
1
Input
2
Output
24V
40A
Load
Failure
Monitor
L1 L2 L3 PE
+ +
- -
24V, 40A
Parallel Use
Single Use
DC-
OK
1606-XLS960E-3
24-28V 960W
Power Supply
L1 L2 L3 PE
+ +
- -
24V, 40A
Parallel Use
Single Use
DC-
OK
1606-XLS960E-3
24-28V 960W
Power Supply
L1
L2
PE
I I II I I
L3
24.3. 1606-XLSRED80 Redundancy Modules
The 1606-XLSRED80 redundancy module is a unit in the 1606-XLS
series that is also suitable in combination with power supplies;
the latter have a continuous current overload behavior.
The 1606-XLSRED80 is the preferred redundancy module for the
1606-XLS960E-3 power supply. It is equipped with two input
channels that are individually decoupled by using mosfet
technology. Using mosfets instead of diodes reduces the heat
generation and the voltage drop between input and output.
The 1606-XLSRED80 unit does not require additional auxiliary
voltage and is self-powered even in case of a short circuit
across the output.
Due to the low power losses, the unit is very slender and only
requires 46mm width on the DIN rail. No space is needed
between the 1606-XLS power supply and the redundancy module.