Rockwell Automation 1606-XLE96B-2 User manual

Reference Manual
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLE96B-2
Index
egaPegaP
1. Intended Use .......................................................3
2. Installation Requirements ...................................3
3. AC-Input...............................................................4
4. DC-Input...............................................................5
5. Input Inrush Current ...........................................5
6. Output .................................................................6
7. Hold-up Time .......................................................7
8. Efciency and Power Losses................................8
9. Functional Diagram.............................................9
10. Front Side and User Elements.............................9
11. Terminals and Wiring........................................10
12. Reliability ...........................................................10
13. EMC ....................................................................11
14. Environment ......................................................12
15. Protection Features ...........................................13
16. Safety Features ..................................................13
17. Dielectric Strength ............................................13
18. Certications .....................................................14
19. Environmental Compliance ............................. 14
20. Physical Dimensions and Weight ..................... 15
21. Accessories ........................................................ 16
22. Application Notes ............................................. 17
22.1. Peak Current Capability ...........................17
22.2. Back-feedingLoads ..................................17
22.3. ChargingBatteries ...............................18
22.4. External Input Protection .........................18
22.5. Inductive and Capacitive Loads ................18
22.6. Parallel Use to Increase Output Power ....19
22.7. Parallel Use for Redundancy ....................19
22.8. Daisy Chainingof Outputs .......................20
22.9. Series Operation .......................................20
22.10. Use in a Tightly Sealed Enclosure ............20
22.11. MountingOrientations ............................21
•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 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 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 with a strongly preferred implementation.
Terminology and Abbreviations

2Rockwell Automation Publication 1606-RM030A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
Power Supply
AC 380-480V Wide-range Input
Input Fuses Already Included
Requires only Two Legs of a 3-Phase System
Width only 40mm
Efciency up to 85.8%
Input -Transient BlankingCircuit Included
Minimal Inrush Current Surge
Full Power Between -25°C and +60°C
3 Year Warranty
Description
Our power supplies are cost optimized without
compromisingquality, reliability or performance. The
most outstandingfeatures of the 1606-XLE96B-2 are its
high efciency, electronic inrush current limitation, active
input transient lter and wide operational temperature
range. It distinguishes itself by its small size and other
technological design breakthroughs.
The 1606-XLE96B-2 includes all the essential basic functions.
It utilizes only two legs of a three-phase system which saves
on wiringand installation costs. Furthermore, this concept
allows you to use a smaller unit without compromisingthe
size of the terminals. Due to the low power consumption,
an unbalancingof the individual phases is not expected.
Specication Quick Reference
Output voltage DC 12V
Adjustment range 12-15V
Output current 8 – 6.4A
Output power 96W
Output ripple < 100mVpp 20Hz to 20MHz
Input voltage AC 380-480V -15%/+20%
Mains frequency 50-60Hz ±6%
AC Input current 0.64 / 0.56A at 400 / 480Vac
Power factor 0.44 / 0.42 at 400 / 480Vac
AC Inrush current typ. 4A peak
Efciency 85.4 / 85.8% at 400 / 480Vac
Losses 16.4 / 15.9W at 400 / 480Vac
Temperature range -25°C to +70°C operational
Derating2.5W/°C +60 to +70°C
Hold-up time typ. 33 / 58ms at 400 / 480Vac
Dimensions 40x124x117mm WxHxD
CatalogNumbers
Power Supply 1606-XLE96B-2 12-15V Standard unit
Accessories 1606-XLB Wall mount bracket
1606-XLSRED Decouplingmodule
Certication Marks
IND. CONT. EQ.
UL 508
UL 60950-1
Marine
EMC, LVD
Marine RINA
GOST R C-Tick

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM030A-EN-P — April 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 terminals are located on the bottom of the unit. For other mounting orientations, refer to derating
requirements in this document.
•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 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
4Rockwell Automation Publication 1606-RM030A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
3. AC Input
AC input nom. AC 380-480V TN, TT, IT-mains networks,
grounding of one phase is allowed except for UL508
applications
AC input range 323-576Vac continuous operation,
no damage between 0 and 323Vac
576-700Vac for max. 1 second, occasional (not periodical)
Allowed Voltage Phase to Earth 500Vac IEC 62103
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 270Vac load independent, see Fig. 3-1
Shut-down voltage typ. 185Vac at 12V, 0A, see Fig. 3-1
typ. 215Vac at 12V, 4A
typ. 225Vac at 12V, 8A
AC 400V AC 480V
Input current typ. 0.64A 0.56A at 12V, 8A, see Fig. 3-3
Power factor *) typ. 0.44 0.42 at 12V, 8A, see Fig. 3-4
Start-up delay typ. 75ms 75ms see Fig. 3-2
Rise time typ. 50ms 50ms 0mF, 12V, 8A, see Fig. 3-2
typ. 85ms 85ms 8mF, 12V, 8A, see Fig. 3-2
Turn-on overshoot max. 100mV 100mV 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
185V 576V
Shut-down
260V 700Vac
< 1s
Start-up
delay Rise Time
Overshoot
- 5%
Output
Voltage
Input
Voltage
Fig. 3-3 Input current vs. output load at 12V Fig. 3-4 Power factor vs. output load
8A
01 34
0
0.1
0.2
0.4
0.5
0.6
0.8A
Input Current, typ.
Output Current
25
0.3
0.7
6 7
400Vac
480Vac
8A
01 34
0.30
0.35
0.40
0.45
0.50
Power Factor, typ.
Output Current
25
480Vac
400Vac
7
6

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM030A-EN-P — April 2014 5
Bulletin 1606 Switched Mode Power Supplies
4. DC Input
DC input nom. DC 600V
DC input range 450-780Vdc continuous operation
Allowed Voltage Line to Earth max. 820Vdc IEC 62103
DC input current typ. 0.24A / 0.14A 450Vdc / 780Vdc, 12V, 8A
Turn-on voltage typ. 370Vdc steady state value
Shut-down voltage typ. 260Vdc steady state value
Fig. 4-1 Wiring for DC Input Instructions for DC use:
+
-
Load
L1
PE
+
-
Power Supply
AC
DC
Battery
L2
FUSE
FUSE
a) Use a battery or similar DC source.
For other sources, contact Rockwell Automation.
b) Connect +pole to L1 and –pole to L2.
c) Use appropriate external fuses in the + and – lines which
are suitable for the DC-voltage.
d) Connect the PE terminal to a earth wire or to the machine
ground.
e) Operation with DC is not included in the UL approval.
Additional testing might be necessary.
5. Input Inrush Current
An active inrush limitation circuit limits the input inrush current after turn-on of the input voltage and after short
input voltage interruptions.
The charging current into EMI suppression capacitors is disregarded in the rst microseconds after switch-on.
AC 400V AC 480V
Inrush current max. 10Apeak 10Apeak -25°C to +70°C
typ. 4Apeak 4Apeak -25°C to +70°C
Inrush energy max. 0.5A2s 0.5A2s -25°C to +70°C
Fig. 5-1 Input inrush current, typical behavior
1 >
2
2 >
3 >
Output Voltage
Input Voltage
Input Current
20ms / DIV
Input: 400Vac
Output: 12V, 8A
Ambient: 25°C
Upper curve: Input current 2A / DIV
Middle curve: Input voltage 500V / DIV
Lower curve: Output voltage 5V / DIV
Time basis: 20ms / DIV

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
6Rockwell Automation Publication 1606-RM030A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
6. Output
Output voltage nom. 12V
Adjustment range min. 12-15V guaranteed
max. 16.0V at clockwise end position of potentiometer
Factory setting 12.0V ±0.2%, at full load, cold unit
Line regulation max. 10mV 323-576Vac
Load regulation max. 100mV static value, 0A 8A
Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 5 200μF
Output current nom. 8A at 12V, see Fig. 6-1
nom. 6.4A at 15V, see Fig. 6-1
Output power nom. 96W
Short-circuit current min. 12A continuous current, short circuit impedance 100mOhm
max. 15A continuous current, short circuit impedance 100mOhm
Fig. 6-1 Output voltage vs. output current,
typ.
Output Voltage
0
048
3
6
15V
9
12
012162 14
A
Adjustment
Range
Output Current
Peak current capability (up to several milliseconds)
The power supply can deliver a peak current which is higher than the specied short term current. This helps to start
current demanding loads or to safely operate subsequent circuit breakers.
The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be
discharged and causes a voltage dip on the output. Detailed curves can be found in section 23.1.
Peak current voltage dips typ. from 12V to 7V at 16A for 50ms, resistive load
typ. from 12V to 7V at 40A for 2ms, resistive load
typ. from 12V to 3.7V at 40A for 5ms, resistive load

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM030A-EN-P — April 2014 7
Bulletin 1606 Switched Mode Power Supplies
7. Hold-up Time
AC 400V AC 480V
Hold-up Time typ. 33ms 58ms at 12V, 8A, see Fig. 7-1
typ. 63ms 110ms at 12V, 4A, see Fig. 7-1
Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, denitions
0
25
50
75
100ms
320 360 400 440 480Vac
Input Voltage
Hold-up Time at 12Vdc
4A,typ.
8A,min.
8A,typ.
4A,min.
- 5%
Hold-up Time
Zero Transition
Output
Voltage
Input
Voltage

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
8Rockwell Automation Publication 1606-RM030A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
8. Efciency and Power Losses
AC 400V AC 480V
Efciency typ. 85.4% 85.8% at 12V, 8A
Average efciency *) typ. 84.7% 84.1% 25% at 2A, 25% at 4A, 25% at 6A. 25% at 8A
Power losses typ. 1.5W 1.6W at 0A
8.4W 9.1W at 12V, 4A
typ. 16.4W 15.9W at 12V, 8A
*) 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.
Fig. 8-1 Efciency vs. output current at 12V,
typ.
Fig. 8-2 Losses vs. output current at 12V,
typ.
Efciency
1
82
84
86
81
87%
8
A
245
Output Current
3
83
85
400Vac
480Vac
67
Power Losses
012 45 8A
0
3
9
15
18W
6
3
12
Output Current
67
400Vac
480Vac
Fig. 8-3 Efciency vs. input voltage at 12V,
8A, typ.
Fig. 8-4 Losses vs. input voltage at 12V, 8A,
typ.
Efciency
320 360 400 440 480
87%
84.5
85.5
86.5
86.0
85.0
84.0
520 560
Input Voltage Vac
Power Losses
320 360 400 440 480
18W
3
9
15
12
6
o
520 560
Input Voltage Vac

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM030A-EN-P — April 2014 9
Bulletin 1606 Switched Mode Power Supplies
9. Functional Diagram
Fig. 9-1 Functional diagram
+
+
-
-
V
OUT
Output
Over-
Voltage
Protection
PFC
Inductor
Inrush
Limiter
Transient
Filter
Input Fuses
Input Filter
Input
Rectier
Output
Voltage
Regulator
Power
Converter Output
Filter
Output
Power
Manager
Temper-
ature
Shut-
down DC-ok LED
L2
L1
10. Front Side and User Elements
Fig. 10-1 Front side
AOutput Terminals
Screw terminals, dual terminals per pole
+ Positive output
-Negative (return) output
BInput Terminals
Screw terminals
L1, L2 Phase input
PE (Protective Earth) input
COutput voltage potentiometer
Open the ap to set the output voltage. Factory set: 12.0V
DDC-OK LED (green)
On when the voltage on the output terminals is > 10.5V
A
B
C
D

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.
10 Rockwell Automation Publication 1606-RM030A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
11. Terminals and Wiring
Input Output
Type screw terminals screw terminals
Solid wire 0.5-6mm20.5-6mm2
Stranded wire 0.5-4mm20.5-4mm2
American Wire Gauge 20-10 AWG 20-10 AWG
Wire stripping length 7mm / 0.275inch 7mm / 0.275inch
Screwdriver 3.5mm slotted or
Pozidrive No 2
3.5mm slotted or
Pozidrive No 2
Recommended tightening torque 0.8Nm, 7lb.in 0.8Nm, 7lb.in
Instructions:
a) Use appropriate copper cables that are designed for an operating temperature of:
60°C for ambient up to 45°C and 75°C for ambient up to 60°C minimum.
b) Follow national installation codes and regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Up to two stranded wires with the same cross section are permitted in one connection point (except PE wire).
e) Do not use the unit without grounding it to the earth (PE).
f) Screws of unused terminal compartments should be securely tightened.
g) Ferrules are allowed, but not required.
12. Reliability
AC 400V AC 480V
Lifetime expectancy *) 51 000h 55 000h at 12V, 8A and 40°C
152 000h 147 000h at 12V, 4A and 40°C
144 000h 156 000h at 12V, 8A and 25°C
MTBF **) SN 29500, IEC 61709 983 000h 967 000h at 12V, 8A and 40°C
1 799 000h 1 769 000h at 12V, 8A and 25°C
MTBF **) MIL HDBK 217F 484 000h 455 000h at 12V, 8A and 40°C; Ground Benign GB40
636 000h 600 000h at 12V, 8A and 25°C; Ground Benign GB25
*) The 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 prediction model allows only a calculation of up to 15 years from date of shipment.
**) 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.