Rockwell Automation 1606-XLS80E User manual

Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
1606-XLS80E
24V,3.4A Single Phase Input
POWER SUPPLY
¾Ultra-small size
¾Extra-low inrush current
¾Active power factor correction
¾Wide range AC/DC input
¾Superior reserve power (can support 150% rated power for five
seconds)
¾Superior efficiency and temperature rating
¾DC-OK and overload LED
1. GENERAL DESCRIPTION
The most outstanding features of this 1606-XLS DIN-rail power supply are the high efficiency and the small size, which are achieved by a
synchronous rectification and further novel design details.
With short-term peak power capability of 150% and built-in large sized output capacitors, these features help start motors, charge capacitors
and absorb reverse energy and often allow a unit of a lower wattage class to be used.
High immunity to transients and power surges as well as low electromagnetic emission makes usage in nearly every environment possible.
The integrated output power manager, a wide range input voltage design and virtually no input inrush current make installation and usage
simple. Diagnostics are easy due to the dry DC-ok contact, a green DC-ok LED and red overload LED.
Unique quick-connect spring-clamp terminals allow a safe and fast installation and a large international approval package for a variety of
applications makes this unit suitable for nearly every situation.
2. SPECIFICATION QUICK REFERENCE
Output voltage DC 24V
Adjustment range 24-28V
Output current 3.4A continuous, 24V
5A for typ. 4s, 24V
Output power 80W continuous, 24V
120W for typ. 4s, 24V
Output ripple < 50mVpp 20Hz to 20MHz
Input voltage AC 100-240V ±15%
Line frequency 50-60Hz ±6%
AC Input current 1.42 / 0.82A at 120 / 230Vac
Power factor 0.53 / 0.47 at 120 / 230Vac
AC Inrush current typ. 5 / 10A peak at 120 / 230Vac
DC Input voltage DC 110-300V --20%/+25%
DC Input current 0.8 / 0.29A at 110 / 300Vdc
Efficiency 88.7 / 90.0% at 120 / 230Vac
Losses 10.4 / 9.1W at 120 / 230Vac
Temperature range -25°C to +70°C operational
Derating 2W/°C +60 to +70°C
Hold-up time typ. 41 / 174ms at 120 / 230Vac
Dimensions 32x124x102mm WxHxD
3. AGENCY APPROVALS
IND. CONT. E
Q
.
UL 508
UL 60950-1
Class I Div 2
EMC, LVD
4. RELATED PRODUCTS
1606-XLB Wall mount
bracket
1606-XLSRED
Redundancy
Module
1606-XLBUFFER Buffer unit
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
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INDEX PAGE INDEX PAGE
1. General Description..............................................1 21. Fulfilled Standards ............................................. 13
2. Specification Quick reference ...............................1 22. Used Substances............................................... 13
3. Agency Approvals.................................................1 23. Physical Dimensions and Weight....................... 14
4. Related Products ..................................................1 24. Installation and Operation Instructions............... 14
5. AC-Input ...............................................................3 25. Accessories ....................................................... 15
6. Input Inrush Current..............................................4 26. Application Notes............................................... 16
7. DC-Input ...............................................................4 26.1. Repetitive Pulse Loading ......................... 16
8. Output...................................................................5 26.2. Peak Current Capability........................... 17
9. Hold-up Time ........................................................7 26.3. Back-feeding Loads ................................. 17
10. Efficiency and Power Losses................................7 26.4. Charging of Batteries............................... 17
11. Functional Diagram ..............................................8 26.5. Output Circuit Breakers ........................... 18
12. Product Face label................................................8 26.6. External Input Protection ......................... 18
13. Terminals and Wiring............................................9 26.7. Parallel Use to Increase Output Power.... 19
14. Reliability ..............................................................9 26.8. Parallel Use for Redundancy ................... 19
15. EMC ...................................................................10 26.9. Daisy Chaining of Outputs ....................... 19
16. Environment .......................................................11 26.10.Series Operation...................................... 20
17. Protection Features ............................................12 26.11.Inductive and Capacitive Loads............... 20
18. Safety .................................................................12 26.12.Operation on Two Phases ....................... 20
19. Dielectric Strength ..............................................12 26.13.Use in a Tightly Sealed Enclosure........... 20
20. Approvals............................................................13 26.14.Mounting Orientations ............................. 21
INTENDED USE
Those responsible for the application and use of the products must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and safety requirements, including and applicable
laws, regulation , codes, and standards.
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 ±20%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
As long as not otherwise stated, AC 100V and AC 230V parameters are valid at 50Hz and AC
120V parameters are valid at 60Hz mains frequency.
230Vac A figure with the unit (Vac) at the end is a value without any additional tolerances included.
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage
DISCLAIMER
The information presented in this document is believed to be accurate and reliable and may change without notice.

Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
5. AC-INPUT
AC input nom. AC 100-240V see Fig. 5-1
AC input range min. 85-276Vac continuous operation
min. 60-85Vac full power for 200ms, no damage between 0 and 85Vac
min. 276-300Vac < 500ms
Input frequency nom. 50 – 60Hz ±6%
Turn-on voltage typ. 61Vac steady-state value, see Fig. 5-1
Shut-down voltage typ. 58Vac steady-state value, see Fig. 5-1
AC 100V AC 120V AC 230V
Input current typ. 1.67A 1.42A 0.82A at 24V, 3.4A, see Fig. 5-3
Power factor * typ. 0.55 0.53 0.47 at 24V, 3.4A, see Fig. 5-4
Crest factor ** typ. 3.33 3.9 3.88 at 24V, 3.4A
Start-up delay typ. 355ms 350ms 330ms see Fig. 5-2
Rise time typ. 6ms 5ms 7ms 0mF, 24V, 3.4A, see Fig. 5-2
typ. 20ms 20ms 22ms 3.4mF, 24V, 3.4A, see Fig. 5-2
Turn-on overshoot max. 50mV 50mV 50mV See Fig. 5-2
* 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. 5-1 Input voltage range Fig. 5-2 Turn-on behavior, definitions
Tu r n -o n
85V
Rat ed
input range max.
500ms
V
IN
P
OUT
60V 300Vac
full
power
for
200ms
276V
Shut-down
St a r t - u p
delay Ri se Ti me
Overshoot
- 5%
Output
Volt age
Intput
Volt age
Fig. 5-3 Input current vs. output load at 24V Fig. 5-4 Power factor vs. output load at 24V
0.5 1.51.0 2.0 2.5 3.0 3.5A
0
0.3
0.6
0.9
1.2
1.5
1.8A
Output Current
Input
Current, typ.
230Vac
120Vac
100Vac
Pow er
Factor, typ.
0.5 1.0 1.5 2.0 3.5
A
0.35
0.4
0.45
0.5
0.55
0.6
Output Current
120Vac
230Vac
2.5 3.0
100Vac
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
6. INPUT INRUSH CURRENT
An active inrush limitation circuitry 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 first milliseconds after switch-on.
AC 100V AC 120V AC 230V
Inrush current max. 6Apeak 7Apeak 13Apeak -25°C to +70°C
typ. 4.5Apeak 5Apeak 10Apeak -25°C to +70°C
Inrush energy max. 2A2s 2A2s 2A2s -25°C to +70°C
Fig. 6-1 Input inrush current, typical behavior
Input Current
Input Voltage
Output Voltage
Input: 230Vac
Output: 24V, 3.4A
Ambient: 25°C
Upper curve: Input current 5A / DIV
Medium curve: Input voltage 500V / DIV
Lower curve: Output voltage 20V / DIV
Time basis: 100ms / DIV
7. DC-INPUT
DC input nom. DC 110-300V
DC input range min. 88-375Vdc continuous operation
DC input current typ. 0.8A / 0.29A 110Vdc / 300Vdc, 24V, 3.4A
Turn-on voltage typ. 61Vdc steady state value
Shut-down voltage typ. 47Vdc steady state value
Fig. 7-1 Wiring for DC Input
Fu se
+
-
Load
L
N
PE
+
-
Power Supply
AC
DC
Battery
internal
fused
Instructions for DC use:
a) Use a battery or similar DC source.
b) Connect +pole to L and –pole to N.
c) Connect the PE terminal to a earth wire or to
the machine ground.
When the –pole of the battery is not connected to
earth, use an appropriate fuse to protect the N
terminal.
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
8. OUTPUT
Output voltage nom. 24V
Adjustment range min. 24-28V guaranteed, multi turn potentiometer
max. 30V at clockwise end position of potentiometer
Factory setting 24.1V ±0.2%, at full load, cold unit
Line regulation max. 10mV 60 to 300Vac
Load regulation max. 100mV static value, 0A Æ3.4A Æ0A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 1 500µF
Continuous power capability
Output current nom. 3.4A at 24V, see Fig. 8-1
nom. 3.0A at 28V, see Fig. 8-1
Output power nom. 80W 24V, continuous
nom. 84W 28V, continuous
Short-circuit current min. 3.5A load impedance 250mOhm, see Fig. 8-1
max. 4.2A load impedance 250mOhm, see Fig. 8-1
Power-Boost , 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. The Power-Boost is repeatedly available.
Detailed information can be found in chapter 26.1 .
Once Power-Boost has been stopped by the output power limiter, a timer disables the next Power-Boost capability. The
recovery timer will start as soon as the output voltage reaches the adjusted value again, which usually happens after the
load has been reduced.
Output current nom. 5A at 24V, see Fig. 8-1
nom. 4.5A at 28V, see Fig. 8-1
Output power nom. 120W 24V, short term
nom. 126W 28V, short term
Short-circuit current min. 5.2A load impedance 250mOhm, see Fig. 8-1
max. 6.0A load impedance 250mOhm, see Fig. 8-1
Power-Boost time typ. 4s at 24V, 5A, duration until the output voltage dips,
min 3s see Fig. 8-2
max. 5s
Power-Boost recovery time typ. 7s overload free time to reset power manager, see Fig. 8-3
Peak current capability (up to several ms)
The power supply can deliver a peak current which is higher than the specified 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 chapter 26.1.
Peak current voltage dips typ. from 24V to 20V at 6.8A for 10ms
typ. from 24V to 12.5V at 13.5A for 2ms
typ. from 24V to 7.5V at 13.5A for 5ms
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
Fig. 8-1 Output voltage vs. output current, typ. Fig. 8-2 Power-Boost time vs. output power
Output Voltage
0
01 34 6A
4
8
12
28V
16
20
24
2
Output Current
5
upto4s
Adjustment
Range
continuous
max
BonusTime
0
110 120 130 140 150 160%
Output Power
1
2
3
7
4
5
6
8
9
10s
min
Boost Time
Fig. 8-3 Power-Boost recovery time
Po w er
Demand
Output
Volt age
Limitation by
Power Manager
BonusPower disabled
Re co v e r y Ti m e
100%
<150%
Bonus
Ti me
Boost
Boost
Power-Boost is available as soon as power comes on and immediately after the end of an output short circuit.
Fig. 8-4 Power-Boost after input turn-on Fig. 8-5 Power-Boost after output short
100%
Output
Volt age
Intput
Volt age
Bonus
Po w e r
Output
Po w er
150%
Short of
Output
100%
Output
Volt age
Bonus
Po w e r
Output
Po w er
150%
Boost
Pow Boost
Power
er
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
9. HOLD-UP TIME
AC 100V AC 120V AC 230V
Hold-up Time typ. 28ms 41ms 174ms 3.4A, 24V, see Fig. 9-1
typ. 58ms 88ms 347ms 1.7A, 24V, see Fig. 9-1
Fig. 9-1 Hold-up time vs. input voltage Fig. 9-2 Shut-down behavior, definitions
10
30
50
70
90
190ms
85 120 155 190 230Vac
Input Voltage
110
130
150
Hold-up
Time
170
24V, 3.4A, t yp.
24V, 3.4A, min.
24V, 1.7A, t yp.
24V, 1.7A, min.
- 5%
Hold-up Time
Zer o Tr an si t i o n
Output
Volt age
Intput
Volt age
Note: At no load, the hold-up time can be up to one minute. The green DC-ok lamp is on during this time.
10. EFFICIENCY AND POWER LOSSES
AC 100V AC 120V AC 230V
Efficiency typ. 91.2% 92.3% 93.0% 10A, 24V
Power losses typ. 23.1W 20.0W 18.1W 10A, 24V
typ. 5.6W 5.7W 5.9W 0A
Fig. 10-1 Efficiency vs. output current at 24V Fig. 10-2 Losses vs. output current at 24V
Efficiency
2345678910A
86
87
88
89
90
91
Output Current
92
93
94%
120Vac
100Vac
230Vac
Power Losses
01234567 10A
6
9
12
15
18
Output Current
21
24W
120Vac
100Vac
230Vac
89
Fig. 10-3 Efficiency vs. input voltage, 24V, 10A Fig. 10-4 Losses vs. input voltage, 24V, 10A
Efficiency
85 120 155 190 225 260 Vac
88
89
90
91
Input Voltage
92
93
94%
Power Losses
9
12
15
18
21
Input Voltage
24
27W
85 120 155 190 225 260 Vac
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
11. FUNCTIONAL DIAGRAM
Fig. 11-1 Functional diagram
+
+
-
-
V
OUT
Input Fuse
Input Filter
Input Rectifier
Inrush Limiter
Transient Filter
Output
Voltage
Regulator
Power
Converter
Output
Filter
Output
Voltage
Monitor
Output
Power
Manager
Temper-
ature
Shut-
down
Over-
load
DC
ok
Output
Over-
Voltage
Protection
L
N
12. PRODUCT FACE LABEL
Fig. 12-1 Front side
Output voltage potentiometer
(multi turn potentiometer)
Open the flap to tune the output voltage.
Factory setting: 24.1V
Output Terminals
Quick-connect spring-clamp
terminals, no tools required
+Positive output
- Negative (return) output
Dual pins per pole
DC-ok lamp (green)
Overload lamp (red)
Overload
LED DC-ok LED
Normal mode OFF ON
80W Continuous power /
120W Peak power Power-Boost mode OFF ON
Overload
(VOUT < 90%, > 80%) ON ON
Overload
(VOUT < 80%) ON OFF
Short-circuit
(VOUT = ca. 0V) ON OFF
Over- temperature Intermitted Intermitted
Input Terminals
Quick-connect spring-clamp
terminals, no tools required
N… Neutral input
L… Line (hot) input
... PE (Protective Earth) input No input power OFF OFF
Voltage fed back to
the output
terminals
OFF ON
See chapter 13 “Terminals and
Wiring” to choose appropriate
wire gauges
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
13. TERMINALS AND WIRING
Type Bi-stable, quick-connect spring clamp terminals. IP20 Finger safe construction.
Suitable for field- and factory installation. Shipped in open position.
Ferrules allowed, but not required
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)
Input terminals Output terminals
Solid wire 0.5-6mm20.3-4mm2
Stranded wire 0.5-4mm20.3-2.5mm2
American wire gauge 20-10 AWG 26-12 AWG
Wire stripping length 10mm / 0.4inch 6mm / 0.25inch
Fig. 13-1 Connecting a wire
1. Insert the wire 2. Snap t he lever
To disconnect wire: same procedure
vice versa
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 installation
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 PE connection.
14. RELIABILITY
AC 100V AC 120V AC 230V
Lifetime expectancy min. 48 000h 62 000h 79 000h 40°C, 24V, 3.4A
min. 117 000h 126 000h 114 000h 40°C, 24V, 1.7A
min. 136 000h 15 years 15 years 25°C, 24V, 3.4A
MTBF SN 29500, IEC 61709 1 191 000h 1 265 000h 1 451 000h 40°C, 24V, 3.4A
2 061 000h 2 155 000h 2 436 000h 25°C, 24V, 3.4A
MTBF MIL HDBK 217F 581 000h 631 000h 643 000h 40°C, 24V, 3.4A, Ground Benign GB40
812 000h 889 000h 912 000h 25°C, 24V, 3.4A, Ground Benign GB25
The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime
expectancy of the built-in electrolytic capacitors.
Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s
manufacturer specification. The prediction model allows 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 the unit to fail and does not necessarily represent
the life of a product.
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
15. EMC
The power supply is suitable for applications in industrial environment as well as in residential, commercial and light industry
environment without any restrictions. CE mark is in conformance with EMC guideline 89/336/EEC and 93/68/EEC and the
low-voltage directive (LVD) 73/23/EWG.
EMC Immunity EN 61000-6-1 EN 61000-6-2 Generic standards
Electrostatic discharge EN 61000-4-2 Contact discharge
Air discharge
8kV
15kV
Criterion A
Criterion A
Electromagnetic RF field EN 61000-4-3 80MHz-1GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Output lines
4kV
2kV
Criterion A
Criterion A
Surge voltage on input EN 61000-4-5 L ÆN
N / L ÆPE
2kV
4kV
Criterion A
Criterion A
Surge voltage on output EN 61000-4-5 + Æ-
+ / - ÆPE
500V
500V
Criterion A
Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 70% of 100Vac
40% of 100Vac
40% of 100Vac
70Vac, 10ms
40Vac, 100ms
40Vac, 1000ms
Criterion A
Criterion C
Criterion C
Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C
Voltage sags SEMI F47 0200
96Vac, 1000ms
84Vac, 500ms
60Vac, 200ms
Criterion A
Criterion A
Criterion A
Input voltage swells RA internal standard 300Vac, 500ms Criterion A
Powerful transients VDE 0160 over entire load range 750V, 1.3ms Criterion A
Criterions:
A: Power supply shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. Power supply might shut-down and restarts by itself. No damages or hazards for the power supply occur.
EMC Emission EN 61000-6-3 and EN 61000-6-4 Generic standards
Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR
22 Class B, input lines
EN 55022 Class A, output lines
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 Fulfilled, active PFC
Voltage fluctuations, flicker EN 61000-3-3 Fulfilled
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.
Switching Frequency 65 to 270kHz load and input voltage dependent
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
16. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) reduce output power above +60°C
Output de-rating 2W/°C 60-70°C (140°F to 158°F), see Fig. 16-1
Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation
Humidity 5 to 95% r.H. IEC 60068-2-30
Do not energize while condensation is present
Vibration sinusoidal 2-17.8Hz: ±1.6mm;
17.8-500Hz: 2g
2 hours / axis
IEC 60068-2-6
Vibration random 0.5m2(s3)
2 hours / axis
IEC 60068-2-64
Shock 30g 6ms, 20g 11ms
3 bumps / direction,
18 bumps in total
IEC 60068-2-27
Altitude 0 to 6000m (0 to 20 000ft) Reduce output power or ambient temperature
above 2000m sea level.
Output de-rating (for altitude) 5W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 16-2
Over-voltage category III EN 50178, altitudes up to 2000m
II Altitudes from 2000m to 6000m
Degree of pollution 2 EN 50178, not conductive
Fig. 16-1 Output wattage vs. ambient temp., Fig. 16-2 Output wattage vs. altitude
Allowed Output
Wattage at 24V
0
-25 0 20 40 70°
C
20
40
60
80
100
120W
continuous
60
Ambient Temperature
fortyp.4s
Allowed Output
Wattage at 24V
0
0 2000 4000 6000m
20
40
60
80
100
120W
continuous
Altitude
fortyp.4s
A...Tamb<60°C
B...Tamb<50°C
C
...Tamb<40°C
ABC
The ambient temperature is defined as the air temperature 2cm below the unit.
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
17. PROTECTION FEATURES
Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 34Vdc
max. 36Vdc
In case of an internal power supply defect, a redundant
circuitry limits the maximum output voltage. The output
shuts-down and automatically attempts to restart.
Output over-current protection Electronically limited See Fig. 8-1
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm e.g. screws, small parts
Over-temperature protection yes output shut-down with automatic restart
Input transient protection MOV (Metal Oxide Varistor) and active transient filter
Internal input fuse T6.3A H.B.C. not user replaceable
Note: In case of a protection event, audible noise may occur.
18. SAFETY
Input / output separation SELV IEC/EN 60950-1
PELV EN 60204-1, EN 50178, 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 between housing and PE terminal
Touch current (leakage current) typ. 0.19mA 100Vac, 50Hz, TN mains
typ. 0.29mA 120Vac, 60Hz, TN mains
typ. 0.53mA 230Vac, 50Hz, TN mains
< 0.25mA 110Vac, 50Hz, TN mains
< 0.38mA 132Vac, 60Hz, TN mains
< 0.74mA 264Vac, 50Hz, TN mains
19. DIELECTRIC STRENGTH
To fulfill the PELV requirements according to EN60204-1 § 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 any more when unnoticed earth faults occur.
Fig. 19-1 Dielectric strength
A B C
Type test 60s 2500Vac 3000Vac 500Vac
Factory test 5s 2500Vac 2500Vac 500Vac
Field test 5s 2000Vac 2000Vac 500Vac
A
C
N
L
Input
Earth, PE
Output
-
+
B
Type tests and factory tests:
Conducted by the manufacturer. Do not repeat test in field!
Rules for field test:
Use appropriate test equipment which applies the voltage with
a slow ramp! Connect L and N together as well as all output
poles.
The output voltage is floating and has no ohmic connection to ground.
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
20. APPROVALS
IEC 60950-1 IECEE
CB SCHEME
CB Scheme,
Information Technology Equipment
UL 508
IND. CONT. E
Q
.
LISTED E198865 listed for use in U.S.A. (UL 508) and Canada (C22.2
No. 14-95)
Industrial Control Equipment
UL 60950-1
RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-
1) and Canada (C22.2 No. 60950)
Information Technology Equipment, Level 5
UL 1604
RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and
Canada (C22.2 No. 213-M1987)
Hazardous Location Class I Div 2 T4 Groups A,B,C,D and
Class I Zone 2 Groups IIA, IIB and IIC
The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations as well as for Class I
Zone 2 Groups IIA, IIB and IIC locations. Substitution of components may impair suitability for
Class I Division 2 environment. Do not disconnect equipment unless power has been switched off.
Wiring must be in accordance with Class I, Division 2 wiring methods of the National Electrical
Code, NFPA 70, and in accordance with other local or national codes.
SEMI F47
SEMI F47-0200 Power Quality Star
Ride-through compliance for semiconductor industry.
Full SEMI range compliance (Input: 120Vac or 208Vac, output: 240W)
21. FULFILLED STANDARDS
EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN/IEC 61131-2 Programmable Controllers
EN 50178 Electronic Equipment in Power Installations
22. USED SUBSTANCES
The unit does not release any silicone and is suitable for the use in paint shops.
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The production material within our production does not include following toxic chemicals:
Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCT), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN),
Polybrom Biphenyll (PBB), Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated
Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO), Cadmium, Asbest, Mercury, Silicia
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
23. PHYSICAL DIMENSIONS AND WEIGHT
Weight 440g / 0.97lb
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 depth (102mm) to calculate the total required installation
depth.
Fig. 23-1 Front view Fig. 23-2 Side view
24. INSTALLATION AND OPERATION INSTRUCTIONS
Hazardous voltage inside device. Risk of electric shock, severe burns, or death.
•Do not use the unit without proper earth connection (Protective Earth). Use the pin on the terminal block for earth
connection and not one of the screws on the housing.
•Turn power off before working on the power supply. Protect against inadvertent re-powering.
•Make sure the wiring is correct by following all local and national codes.
•Do not open, modify or repair the unit.
•Use caution to prevent any foreign objects from entering into the housing.
•Do not use in wet locations or in areas where moisture or condensation can be expected.
Mounting Orientation:
Output terminal must be located on top and input terminal on the bottom. For other orientations see section 26.14.
Cooling:
Convection cooled, no forced cooling required. Do not cover ventilation grid (e.g. cable conduits) by more than 30%!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently with full
power. In case the adjacent device is a heat source, 15mm clearance is recommended.
Service parts:
The unit does not contain any serviceable parts. The tripping of an internal fuse is caused by an internal defect.
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
25. ACCESSORIES
1606-XLB Wall mounting bracket
This bracket is used to mount 1606 units onto a flat surface without utilizing a DIN-Rail. The two aluminum brackets and the
black plastic slider of the unit have to be detached, so that the two steel brackets can be mounted.
Fig. 25-1 1606-XLB Wall Mounting Bracket Fig. 25-2 Assembled Wall Mounting Bracket
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
26. APPLICATION NOTES
26.1. REPETITIVE PULSE LOADING
Typically, a load current is not constant. It varies over time. For pulse load compatibility, following rules must be met:
a) The pulse power demand must be below 150% of the nominal power.
b) The duration of the pulse power must be shorter than the allowed Power-Boost. (see output section)
c) The average (R.M.S.) output current must be below the specified continuous output current.
If the R.M.S. current is higher, the unit might respond with a thermal shut-down after a while. Use the max. duty cycle
curve (Fig. 26-2) to check if the average output current is below the nominal current.
d) For altitudes higher than 2000m reduce the pulse loading (15W/1000m) or the ambient temperature (5°C/1000m)
Fig. 26-1 Repetitive pulse loads, definitions Fig. 26-2 Max. Duty Cycle Curve
100%
P
PEA K
T
PEA K
P
0
T
0
max.
150%
150%100
0
0.2
0.4
0.6
0.8
1.0
DutyCycle
110 120 130 140
P
PEAK
P
0
=10%
P
0
=50%
P
0
=75%
P
0
=100%
P0Base load (W)
PPEAK Pulse load (above 100%)
T0Duration between pulses (s)
TPEAK Pulse duration (s)
D uty C ycle
T
0
=
T peak - (D uty C ycle x T peak )
T
peak + T 0
T peak
D uty C ycle =
Utilizing the Max. Duty Cycle Curve:
Example to determine the repetition rate of pulses without dipping of the output voltage:
Parameters of application:
Pulse length is TPEAK = 1s
Steady state load P0=120W
(= 50% of IRATED)
Peak load PPEAK = 360W
(= 150% of IRATED)
Determining the repetition rate:
1) make a vertical line at PPEAK = 150%
2) make a horizontal line where the vertical line crosses the P0= 50% curve
3) Read the Max. Duty Cycle from the Duty Cycle-axis (= 0.37)
4) Calculate the min. pause (base load) length T0:
D uty C ycle
T
0
=
T peak - (D uty C ycle x T peak )
=
0.37
1s - (0.37 x 1s)
=1.7s
5) Pulse length = 1s, min. pause length = 1.7s
6) Max. repetition rate = pulse length +pause length = 2.7s
More examples for pulse load compatibility:
PPEAK P
0T PEA
KT0PPEAK P
0T PEA
KT0
120W 80W 1s >25s 120W 40W 0.1s >0.16s
120W 0W 1s >1.3s 120W 40W 1s >1.6s
100W 40W 1s > 0,75s 120W 40W 3s >4.9s
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
26.2. PEAK CURRENT CAPABILITY
Solenoids, contactors and pneumatic modules often have a steady state coil and a pick-up coil. The inrush current demand
of the pick-up coil is several times higher than the steady state current and usually exceeds the nominal output current
(including the Power-Boost) The same situation applies, when starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit, the
fuse needs a certain amount of over-current to trip or to blow. The peak current capability ensures the safe operation of
subsequent circuit breakers.
Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the power
supply can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The following two examples
show typical voltage dips:
Fig. 26-3 Peak load 6.8A for 50ms, typ. Fig. 26-4 Peak load 13.5A for 5ms, typ.
Output
Volt age
Output
Cu r r e n t
10ms/DIV
24V
0A
6.8A
18.5V
Output
Volt age
Output
Cu r r e n t
1ms/DIV
24V
0A
13.5A 7.5V
Peak load 6.8A (resistive) for 50ms
Output voltage dips from 24V to 18.5V.
Peak load 13.5A (resistive) for 5ms
Output voltage dips from 24V to 7.5V.
26.3. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called
return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force).
This power supply is resistant and does not show malfunctioning when a load feeds back voltage to the power supply. It
does not matter, whether the power supply is on or off.
The maximum allowed feed back voltage is 35Vdc. The absorbing energy can be calculated according to the built-in large
sized output capacitor which is specified in chapter 8.
26.4. CHARGING OF BATTERIES
The power supply can be used for float-charging of lead-acid or maintenance free 24V VRLA batteries.
Instructions for charging batteries:
a) Set the output voltage, at disconnected load, very precisely to the end-of-charge voltage according to the expected
battery temperature.
End-of-charge voltage 27.8V 27.5V 27.15V 26.8V
Battery temperature 10°C 20°C 30°C 40°C
b) Use a 15A or16A circuit breaker (or blocking diode ) between the power supply and the battery.
c) Ensure that the output current of the power supply is below the allowed charging current of the battery.
d) Use only matched batteries when putting 12V types in series.
e) The return current to the power supply is typ. 6.3mA at 25Vdc when the power supply is switched off (except in case a
blocking diode is utilized).
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
26.5. OUTPUT CIRCUIT BREAKERS
Standard miniature circuit breakers (MCBs) can be used for branch protection. Ensure that the MCB is rated for DC voltage,
too. The following tests show which circuit breakers the power supply typically trips.
Circuit breakers have huge tolerances in their tripping behavior. Therefore, these typical tests can only be used as a
recommendation or for comparing two different power supplies. Furthermore, the loop impedance has a major influence on
whether a breaker trips or not. Two tests were performed, representing typical situations:
Test 1: Short circuit with S1 on the power supply end of the cable (loop impedance approx. 20mOhm)
Fig. 26-5 Branch protectors, test circuit 1
Ci r cu i t
Breaker
Po w er
Supply
AC
DC
+
-
I
Load
+
-
S1
Parameters:
Input voltage: 230Vac, load current: 0A
Tripping time shorter than 5s.
The following circuit breaker tripped during the test:
A- or Z- Characteristic:: equal or smaller 6A
C- Characteristic: equal or smaller 1A
Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 26-6 Branch protectors, test circuit 2
R
Ci r cu i t
Breaker
Po w er
Supply
AC
DC
+
-
I
S1 Load
+
-
Parameters:
Input voltage: 230Vac, load current: 0A
Tripping time shorter than 5s.
The following circuit breaker tripped during the test:
A- or Z- Characteristic:: ≤6A and R< 180mOhm
C- Characteristic: ≤1A and R< 390mOhm
What does this resistance mean in wire length?
0.5mm20.7mm21.0mm21.5mm22.5mm24.0mm2
180mOhm 10.9m 15.2m 21.7m 32.6m 54.3m 86.9m
220mOhm 6.1m 8.6m 12.3m 18.4m 30.6m 49.0m
Example:
Which wire gauge must be used to trip a Z-Characteristic circuit breaker with a rating of 6A? The load wire length is 21m.
Answer: A 6A Z-Characteristic circuit breaker requires a loop impedance of less than 180mOhm (test results). The wire
length table shows that up to 25.1m wire with a cross section of 2.5mm2are below 180mOhm. A wire not smaller than
2.5mm2shall be used.
26.6. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 20A. External protection is only required, if the supplying branch has
an ampacity greater than this. In some countries local regulations might apply. Check also local codes and local
requirements.
If an external fuse is necessary or utilized, a minimum value is required to avoid undesired tripping of the fuse.
B-Characteristic C-Characteristic
Ampacity max. 20A 20A
min. 6A 6A
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
26.7. PARALLEL USE TO INCREASE OUTPUT POWER
Power supplies can be paralleled to increase the output power.
Uni t A
AC
DC
Uni t B
AC
DC
-
+
-
+
Load
+
-
a) Use only power supplies from the same series.
b) A fuse (or diode) on the output is only required if more than
three units are connected in parallel.
c) Do not load terminals with more than 25A. Follow wiring
instructions according to chapter 0
d) Keep an installation clearance of 15mm (left/right) between two
power supplies and avoid installing the power supplies on top of
each other.
26.8. PARALLEL USE FOR REDUNDANCY
Power supplies can be paralleled for 1+1 redundancy to gain a higher system availability. Redundant systems require a
certain amount of extra power to support the load in case one power supply unit fails. The simplest way is to put two 1606-
XLS80E power supplies in parallel. In case one power supply unit fails, the other one is automatically able to support the
load current without any interruption. This simple way to build a redundant system has two major disadvantages:
a. The faulty power supply can not be recognized. The green LED will still be on since it is reverse-powered from the other
power supply.
b. It does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a (nearly
impossible) case, the defective unit becomes a load for the other power supplies and the output voltage can not be
maintained any more.
This can only be avoided by utilizing decoupling diodes which are included in the decoupling module 1606-XLSRED or
redundancy module 1606-XLERED with alarm contacts.
Recommendations for building redundant power systems:
a) Use separate input fuses for each power supply.
b) Monitor the individual power supply units. A DC-ok lamp and a DC-ok contact is included in the redundancy module
1606-XLERED. This feature reports a faulty unit.
c) When possible, connect each power supply to different phases or circuits.
26.9. DAISY CHAINING OF OUTPUTS
Daisy chaining (jumping from one power supply output to the next) is allowed as long as the maximum current through one
terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.
Fig. 26-7 Daisy chaining of outputs Fig. 26-8 Using distribution terminals
Po w er
Supply
+ + - -
Input
Po w er
Supply
+ + - -
Input
Load
+ -
max 25A!
L N PE
Po w er
Supply
+ +
- -
L N PE
Po w er
Supply
+ +
- -
Load
+ -
Distribution
Ter m i nal s
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Rockwell Automation
1606-XLS80E 24V, 3.4A; Single Phase Input
26.10.SERIES OPERATION
The power supply can be put in series to increase the output voltage.
Fig. 26-9 Schematic for series operation Instructions for use in series:
Ear t h
Uni t A
AC
DC
Uni t B
AC
DC
-
+
-
+
Load
+
-
a) It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed
150Vdc.
b) Warning ! Voltages with a potential above 60Vdc are not SELV
any more and can be dangerous. Such voltages must be
installed with a protection against touching.
c) For serial operation use power supplies of the same type.
d) Earthing of the output is required when the sum of the output
voltage is above 60Vdc.
e) Keep an installation clearance of 15mm (left/right) between two
power supplies and avoid installing the power supplies on top of
each other.
Note: Avoid return voltage (e.g. from a decelerating motor or battery)
which is applied to the output terminals.
26.11.INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of load, including unlimited capacitive and inductive loads.
26.12.OPERATION ON TWO PHASES
Fig. 26-10 Schematic for two phase operation
240V +15% max.
Fuse
L2
L1
L3
L
N
PE
Power Suppl
y
AC
DC
internal
fused
Instructions for two phase operation:
a) A phase to phase connection is allowed as long as the
supplying voltage is below 240V(+15%).
b) Use a fuse or a circuit breaker to protect the N input. The N
input is internally not protected and is in this case connected
to a hot wire.
Appropriate fuses or circuit breakers are specified in section 0
“External Input Protection”.
26.13.USE IN A TIGHTLY SEALED ENCLOSURE
When the power supply is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than
outside. The inside temperature defines the ambient temperature for the power supply.
Results from such an installation:
Power supply is placed in the middle of the box, no other heat producer inside the box
Enclosure: Type IP66 Box PK 9516 100, plastic, 110x180x165mm
Load: 24V, 3.4A; (=100%) load is placed outside the box
Input: 230Vac
Temperature inside enclosure: 41.3°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 25.1°C
Temperature rise: 16.2°C
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