Rockwell Automation 1606-XLS960F User manual

Reference Manual Original Instructions
Switched Mode Power Supply
Catalog Number 1606-XLS960F

2Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Switched Mode Power Supply Reference Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 1
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Input Inrush Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hold-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DC-OK Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control of Output Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifetime Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mean Time Between Failure (MTBF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Certifications and Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . 17
Approximate Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Repetitive Pulse Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Peak Current Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Back-feeding Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Charging of Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Output Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
External Input Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parallel Use to Increase Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parallel Use for Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Daisy Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Series Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operation on Two Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Use in a Tightly Sealed Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Table of Contents
Notes:

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 3
Terminology and
Abbreviations
All values in this document are specified under the following conditions unless
otherwise noted:
• 48V, 20 A, 230V AC input voltage
• 25 °C (77 °F) ambient temperature
• After a 5 minutes run-in time
Product Overview
Product features include:
• AC 100…240V wide-range input
• Width 125 mm (4.9 in.)
• 95.0% full load and excellent partial load efficiencies
• 50% BonusPower, 1440 W for up to 4 s
Terms Descriptions
PE The abbreviation for Protective Earth. PE has the same meaning as the symbol.
The symbol for Protective Earth.
Earth, Ground This document uses the term “earth”, which is the same as the U.S. term “ground”.
AC 230V A value that is displayed with the AC or DC before the value represents a nominal voltage with standard tolerances included. For example, DC 12V describes a 12V
battery, no matter if it is full (13.7V) or flat (10V).
230V AC A value with the unit (V AC or V DC) at the end is a momentary value without any
additional tolerances included.
50 Hz versus 60 Hz Unless otherwise stated, AC 230V parameters are valid at 50 Hz mains frequency.
Nom Indicates a nominal value.
Typ Indicates a typical value.
—A dash alone in a table cell indicates that there is no information to be included in that
cell.
Figure 1 - 1606-XLS960F
The 1606-XLS960F is a high-efficiency
DIN rail power supply unit, which uses
a synchronous rectification, a
bridgeless PFC circuit, and additional
design details to achieve a compact
size.
Large power reserves of 150% and built-
in large sized output capacitors
support the starting of heavy loads,
such as DC motors or capacitive loads.
Therefore, a unit from a lower wattage
class can be used.
The 1606-XLS960F power supply unit
has a high immunity to transients and
power surges, and has low
electromagnetic emissions.
The integrated input fuse, near-zero
input inrush current, and diagnostic
indicators simplify installation and
usage.
The 1606-XLS960F power supply unit
features a large international approval
package for various applications.

4Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
• 55 A high peak current for 10 ms, for easy fuse tripping
• Safe HiccupPLUS overload mode
• Active PFC (Power Factor Correction)
• Negligible low-input inrush current surge
• Full power -25…+60 °C (-13…+140 °F)
• Current sharing feature for parallel use
• Remote control of output voltage
•DC-OKrelaycontact
•Shut-downinput
• ATEX and IECEx approved
Specifications
Catalog Numbers
Attributes Values Notes
Output voltage DC 48V Nominal
Adjustment range 48…54V DC —
Output current 20…17.8 A Continuous
30…26.7 A Short term (4 s)
Output power 960 W Continuous
1440 W Short term (4 s)
Output ripple <150 mVpp 20 Hz…20 MHz
Input voltage AC 100…240V -15/+10%
Mains frequency 50…60 Hz ±6%
AC input current 8.6/4.5 A At 120/230V AC
Power factor 0.99/0.99 At 120/230V AC
AC inrush current 17/11 A peak At 120/230V AC
Efficiency 93.9/95.0% At 120/230V AC
Losses 62.4/50.5 W At 120/230V AC
Temperature range -25…+70 °C
(-13…+158 °F) Operational
Derating 24 W/1 °C
(24 W/1.8 °F) (1)
(1) Between 85…90V AC. See Environment on page 15.
60…70 °C (140…158 °F)
Hold-up time 27/27 ms At 120/230V AC
Dimensions 125 x 124 x 127 mm
(4.92 x 4.88 x 5 in.) W x H x D
Weight 1900 g (4.2 lb) —
Cat. No. Descriptions
1606-XLS960F Power supply
(48…54V standard unit)
1606-XLC Wall mount bracket
1606-XLSBUFFER48 Buffer unit
1606-XLSRED40HF Redundancy module

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 5
AC Input
Attributes Values Notes
Input voltage Nom AC 100…240V Suitable for TN, TT, and IT mains networks
Input voltage range
— 90…264V AC Continuous operation
—85…90VAC
<55 °C (131 °F) ambient temperature
continuously allowed
>55 °C (131 °F) ambient temperature short term
or with output derating, see Figure 27 on page 16
— 60…85V AC Full power for up to 200 ms
— 0…85V AC No damage to the unit
— 264…300V AC <500 ms
Allowed voltage L or N to earth Max 300V AC Continuous, IEC 62103
Input frequency Nom 50…60Hz ±6%
Turn-on voltage Typ 80V AC Steady-state value, load independent, see
Figure 2
Shut-down voltage Typ 74V AC Steady-state value, load independent, see
Figure 2
External input protection — See External Input Protection on page 24.
Attributes Values Notes
AC 100V AC 120V AC 230V
Input current Typ 10.5 A 8.6 A 4.5 A At 48V, 20 A, see Figure 4
Power factor (1)
(1) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
Typ 0.99 0.99 0.99 At 48V, 20 A, see Figure 5
Crest factor (2)
(2) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.
Typ 1.47 1.53 1.56 At 48V, 20 A
Startup delay Typ 800 ms 750 ms 700 ms See Figure 3
Rise time Typ 16 ms 16 ms 16 ms At 48V, 20 A, resistive load, 0 mF, see Figure 3
Typ 55 ms 55 ms 55 ms At 48V, 20 A, resistive load, 20 mF, see Figure 3
Turn-on overshoot Max 100 mV 100 mV 100 mV See Figure 3
Figure 2 - Input Voltage Range Figure 3 - Turn-on Behavior, Definitions
Figure 4 - Input Current Versus Output Load at 48V Figure 5 - Power Factor Versus Output Load at 48V
Turn-on
85
Rated Input Range
VIN
POUT
74 264V AC
Shut-down
80
Start-up
Delay Rise Time
Overshoot
-5%
Output
Voltage
Input
Voltage
20 A
2 4 6 8 10 12 14 16 18
0
2
4
6
8
10
12 A
Input Current, Typ
A: 100 V AC
B: 120 V AC
C: 230 V AC
A
B
C
Output Current
Power Factor, Typ
2 4 6 8 10 12 14 16 18 20 A
0.75
0.8
0.85
0.9
0.95
1.0
Output Current
A: 100V AC
B: 120V AC
C: 230V AC
A
B
C

6Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Input Inrush Current The power supply unit 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 smaller than the steady state input current.
DC Input Do not operate this power supply unit with DC-input voltage. Use the
1606-XLE480FP-D unit instead. It can be necessary to run two
1606-XLE480EP-D units in parallel.
Output
Attributes Values Notes
AC 100V AC 120V AC 230V
Inrush current (1)
(1) The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
Max 25 Apeak 22 Apeak 16 Apeak
Over the entire temperature range; mains
interruptions >1 s
Typ 20 Apeak 17 Apeak 11 Apeak
Inrush energy Max 5 A2s5A
2s5A 2s
Figure 6 - Typical Turn-on Behavior at Nominal
Load - 25 °C (77 °F) Ambient
Temperature
Input Current 5 A/DIV
Input
Output 48V DC
230V AC
100 ms/DIV
Attributes Values Notes
Output voltage Nom DC 48V —
Adjustment range — 48…54V DC Guaranteed
Max 56V DC (1) At clockwise end position of potentiometer
Factory setting
Typ 48.0V DC ±0.2%, at full load, cold unit, in Single Use mode
Typ 46.0V DC ±0.5%, at full load, cold unit, in Parallel Use mode
Typ 48.0V DC At no load, cold unit, in Parallel Use mode
Line regulation Max 10 mV 85…300V AC
Load regulation
Max 50 mV In Single Use mode: static value, 0 A 20 A, see Figure 7 on
page 7
Typ 2000 mV In Parallel Use mode: static value, 0 A 20 A, see Figure 8 on
page 7
Ripple and noise voltage Max 150 mVpp 20 Hz…20 MHz, 50 Ω
Output current
Nom 20 A Continuously available at 48V, see Figure 7 on page 7 and Figure 8
on page 7
Nom 17.8 A Continuously available at 54V, see Figure 7 on page 7 and Figure 8
on page 7
Nom 30 A Short-term available BonusPower (2), at 48V for typical 4 s, see
Figure 7 on page 7 and Figure 8 on page 7
Nom 26.7 A Short-term available BonusPower (2), at 54V for typical 4 s, see
Figure 7 on page 7 and Figure 8 on page 7
Typ 55 A
Up to 10 ms, output voltage stays above 40V, see Figure 10 on
page 7. This peak current is available once every second. See Peak
Current Capability on page 22.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 7
Output power Nom 960 W Continuously available at 48…54V
Nom 1440 W (2) Short-term available BonusPower (2) at 48…54V
BonusPower time Typ 4 s Duration until the output voltage dips, see Figure 11 on page 8
BonusPower recovery time Typ 7 s Overload free time to reset power manager, see Figure 12 on
page 8
Overload behavior —Continuous current Output voltage >40V DC, see Figure 7
—HiccupPLUS mode (3) Output voltage <40V DC, see Figure 7
Short-circuit current
Min 30 A (4) Load impedance 50 mΩ, see Figure 9
Max 35 A (4) Load impedance 50 mΩ, see Figure 9
Max 11.5 A Average (RMS) current, load impedance 50 mΩ, see Figure 9
Typ 62 A Up to 10 ms, load impedance <10 mΩ, see Figure 10
Output capacitance Typ 3700 µF Included in the power supply
(1) Max output voltage that can occur at the clockwise end position of the potentiometer, due to tolerances. It is not a
guaranteed value that can be achieved. The typical value is about 55V.
(2) BonusPower, short-term power capability (up to typ 4 s): The power supply unit 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. This BonusPower is repeatedly available. See Repetitive Pulse Loading on page 20. If the power supply unit is
loaded longer with the BonusPower than shown in Figure 11 on page 8, the maximum output power is automatically reduced
to 960 W. If the power requirement is continuously above 960 W and the voltage falls below approximately 40V (due to the
current regulating mode at overload), the unit shuts off and makes periodical restart attempts. This behavior is called
HiccupPLUS mode, see Figure 9. If the voltage is above 40V, the unit continuously delivers current.
(3) For up to 4 s of overloading, the power supply unit delivers continuous output current. After overloading, the output power
reduces to nearly zero for approximately 17 s before a new start attempt is automatically performed. If the overload is
cleared, the device operates normally. If the overload still exists, the output current is delivered for 2…4 s (depending on the
overload) again followed by a 17 s rest time. This cycle repeats as long as the overload exists. During the off-period, a small
rest voltage and a rest current are present on the output.
(4) Discharge current of output capacitors is not included.
Attributes Values Notes
Figure 7 - Output Voltage Versus Output Current in
Single Use Mode, Typ Figure 8 - Output Voltage Versus Output Current in Parallel Use Mode, Typ
Figure 9 - Short-circuit on Output, HiccupPLUS Mode,
Typ Figure 10 - Dynamic Overcurrent Capability, Typ
Output Voltage
0
0 5 10 15 20
8
16
24
56V
32
40
48
30
25 35 A
Output Current
Adjustment Range
Hiccup
Mode
AB
A
B
Short-term (4 s)
then switching
to curve
Continuously
available
A
A B
Output Voltage (Parallel Use, Typ)
42V 01020
44V
46V
48V
56V
50V
52V
54V
30 A
25155
Adjustment Range
Factory
setting
Continuously
allowed Bonus
Power
Output Current
gy
Output
Current
0
35 A
17 s 17 s
17 s 2 s 2 s
2 s
t
Short -circuit Normal
operation
Normal
operation
g
Output Voltage (dynamic behavior, < 10 ms)
0
0
8
16
24
54V
32
40
48
70 A30 6010 20 40 50
Adjustment
Range
Output Current

8Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
The BonusPower is available when power comes on and after the end of an
output short circuit or output overload.
Hold-up Time
Figure 11 - Bonus Time Versus Output Power Figure 12 - BonusPower Recovery Time
g
max
Bonus Time
0
100 120 130 140 150 170%
1
2
3
4
5 s
110 160
Output Power
min
Power
Demand
100%
t
t
Limitation by
Power Manager
Output
Voltage
Bonus Power disabled
Bonus
Time
Recovery Time
Figure 13 - BonusPower After Input Turn-on Figure 14 - 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%
Attributes Values Notes
AC 100V AC 120V AC 230V
Hold-up Time
Typ 54 ms 54 ms 54 ms At 48V, 10 A, see Figure 15
Min 45 ms 45 ms 45 ms
Typ 27 ms 27 ms 27 ms At 48V, 20 A, see Figure 15
Min 23 ms 23 ms 23 ms
Figure 15 - Hold-up Time Versus Input Voltage Figure 16 - Shutdown Behavior Definitions
0
10
20
30
40
60 ms
90 120 155 190 230V AC
Input Voltage
50
Hold-up Time
48V, 20 A, typ
48V, 10 A, min
48V, 10 A, typ
48V, 20 A, min
-5%
Hold-up Time
Zero Transition
Output
Voltage
Input
Voltage