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