Rockwell Automation Allen-Bradley 1606 Series User manual

Reference Manual
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLE960MX-3N
Index
1. Description ............................................................1
2. Specication Quick Reference.........................1
3. Catalog Numbers .................................................1
4. Certication Marks...............................................1
5. AC-Input..................................................................3
6. Input Inrush Current ......................................... 4
7. Output ................................................................... 5
8. Hold-up Time....................................................... 6
9. Eciency and Power Losses .......................... 7
10. Functional Diagram ........................................... 8
11. Front Side and User Elements........................ 8
12. Terminals and Wiring ........................................ 9
13. Reliability............................................................... 9
14. EMC....................................................................... 10
15. Environment ....................................................... 11
16. Protection Features ......................................... 12
17. Safety .................................................................... 12
18. Dielectric Strength ........................................... 12
19. Certications ..................................................... 13
20. Environmental Compliance ................................... 13
21. Physical Dimensions and Weight.......................... 14
22. Installation and Operating Instructions ............. 14
23. Accessories ................................................................... 15
24. Comparison between the 1606-XLE960MX-3N,
a Transformer and a Traditional Switched-mode
Power Supply.................................................................15
25. Application Notes...................................................... 16
25.1. Periodical Peak Power Capability ............ 16
25.2. Charging Batteries ........................................ 16
25.3. Output Circuit Breakers ............................... 17
25.4. External Input Protection............................ 18
25.5. Back-feeding Loads ...................................... 18
25.6. Parallel Use to Increase Output Power . 18
25.7. Parallel Use for Redundancy...................... 18
25.8. Series Operation............................................ 19
25.9. Inductive and Capacitive Loads ............... 19
25.10.Loss of One Input Phase............................. 19
25.11.Use in a Tightly Sealed Enclosure ............ 19
25.12.Mounting Orientations................................ 20
•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.
• 3AC 400V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)
included. 3AC means three phase input. E.g.: DC 12V describes a 12V battery whether it is charged (13.7V) or discharged (10V).
Unless otherwise stated, 3AC 400V parameters are valid at 50Hz and 3AC 480V parameters are valid at 60Hz mains frequency.
• 3x 400Vac—A figure with the unit (Vac) at the end is a value used during testing without any additional tolerance included. 3AC means three
phase input.
Terminology and Abbreviations

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
2Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
Semi-regulated Power Supply
••Alternative or Replacement for AC Transformer
• Three Phase Input – DC Output
• DIN Rail Mountable
• Width only 96mm
• 96% Eciency
• 125% Peak Power Capability
• No Input Inrush Current
• Active Input Transient Blocker
• Full Power Between -25°C and +60°C
• Easy Failure Diagnostics
• No Electrolytic Capacitors on Input Side
• Cost Eective and Robust
• 3 Year Warranty
1. Description 2. Specication Quick Reference
Output voltage DC 48V
Adjustment range none
Output current 20A continuous
25A for typ. 15s
Output power 960W continuous
1200W for typ. 15s
Output ripple < 2500mVpp 20Hz-2kHz
< 300mVpp 2kHz to 20MHz
Input voltage 3AC 480V
Mains frequency 50-60Hz ±6%
AC Input current 1.4A / phase 3x480V
Power factor 0.93 48V, 20A
AC Inrush current typ. 2A peak
Eciency 96.0%
Losses 40.0W
Temperature range -25°C to +70°C operational
Derating 24W/°C +60 to +70°C
The 1606-XLE960MX-3N series implements a new and
innovative concept for generating an isolated DC
voltage from a three-phase mains system.
A semi-regulated resonant converter enables a very
compact design, maximum eciency and extremely
competitive pricing with only a small compromise in
the output voltage regulation, output ripple and
hold-up time.
Weighing just 1.4 kg, the device provides 960 watts
of continuous output power and an additional 25%
power reserve for dynamic loads. The light-weight
design along with compact dimensions facilitate
straightforward installation on a DIN rail.
Primary use are applicatins involving supplies to
motors, valves and other load circuits with a high
power consumption, where an accurate output
voltage regulation which is standard on traditional
switched-mode power supplies is not required.
Furthermore, these switched-mode power supplies
can often replace mains transformers with rectiers.
Dimensions 96x124x159mm WxHxD
3. Catalog Numbers 4. Certication Marks
Power Supply 1606-XLE960MX-3N 480V Input
IND. CONT. EQ.
18WM
LISTED
UL 508
UL 60950-1
EMC, LVD
Accessory 1606-XLSBUFFER48 48V Buer Unit
Marine RINA
GOST R
C-Tick

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 3
Bulletin 1606 Switched Mode Power Supplies
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 aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or
threaten human life.
•This device is designed for use in non-hazardous, ordinary or unclassified locations.
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 section 25.12
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 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
4Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
5. AC-Input
1606-XLE960MX-3N
AC input nom. 3AC 480V
Mains arrangement TN-, TT- or IT-Mains. Consult factory if one phase is grounded.
AC input range min.
3x 432-528Vac
fully regulated output (±2%), Pout > 48W
min. 3x 360-552Vac
*)
permanently allowed,
see Fig. 5-1 for output voltage regulation
max. 3x 565Vac Absolute maximum input voltage with no
damage to the power supply. Output
might be o at this level.
Input frequency nom. 50 – 60Hz ±6%
Turn-on voltage typ. 3x 390Vac see Fig. 5-2
Shut-down voltage typ. 3x 355Vac see Fig. 5-2
Input current nom. 1.4A at 20A, symmetrical input, see Fig. 5-4
Power factor **) typ. 0.93 at 20A, symmetrical input, see Fig. 5-5
Turn-on overshoot typ. 1000mV see Fig. 5-3
Start-up delay ***) typ. 350ms over the entire load range, see Fig. 5-3
Rise time typ. 40ms 0mF, 20A, see Fig. 5-3
typ. 70ms 20mF, 20A, see Fig. 5-3
*) A minimum voltage of 3x408Vac is required to turn the power supply on.
**) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
***) The start-up delay for mains voltage interruptions up to 350ms is close to zero. In such cases, the power supply will
immediately generate the output voltage once the mains voltage interruption is over. Do not use the buer module
1606-XLSBUFFER48 as an accessory when longer mains interruptions need to be bridged (see section 24).
Input Voltage Range Fig. 5-1 Output voltage vs. input voltage and input current
Changes of the input voltage will be fully
regulated within certain limits. The
output voltage will only start to change
proportionally to the input voltage with
extreme under or over-voltages. The
yellow LED reports an input voltage
problem if exceeded by a window of
±15%. The maximum increase of the
output voltage is limited to the 57.2V
OVP level. This level will be kept
regulated for 2s before the power supply
will shut down and re ports “Shut-down”
by the red LED.
48V
40V
52V
44V
504456 576Vac384
V OUT
V IN
480
56V
528 552432408360
P OUT > 48W (>5%)
P OUT = 0W

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 5
Bulletin 1606 Switched Mode Power Supplies
Fig. 5-2 egnaregatlovtupnI Fig. 5-3 Turn-on behavior denitions
Turn-on
fully regulated
range
V
IN
P
OUT
3x 528Vac
Shut-down
3x 432Vac480V Version:
Start-up
delay Rise Time
Overshoot
- 5%
Output
Voltage
Intput
Voltage
Fig. 5-4 Input current vs. output load Fig. 5-5 Power factor vs. output load
25A
2.5 5 15
0
0.3
0.6
0.9
1.2
1.5
1.8A
Input Current per Phase, typ.
Output Current
10 20
25A
2.5 5 15
0.70
0.75
0.8
0.85
0.9
0.95
1.0
Power Factor, typ.
Output Current
10 20
6. Input Inrush Current
There is virtually no input inrush current surge as there are no electrolytic capacitors used on the input side of
the power supply.
The charging current into the EMI suppression capacitors is disregarded for the rst millisecond after switch-on.
1606-XLE960MX-3N
Inrush current max. 4Apeak -25°C to +70°C, see Fig. 6-1
Inrush energy max. 5A2s -25°C to +70°C, see Fig. 6-1
Inrush delay typ. 350ms see Fig. 6-1
Fig. 6-1 Input inrush current, typical behavior
Input Current
Input Voltage
Output Voltage
A
1606-XLE960MX-3N (3x480V)

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
6Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
7. Output
Output voltage nom. 48V
Output voltage adjustment range
none The output voltage is xed. No ajustment possible.
Output current nom. 20A continuous, see Fig. 7-1
25A up to 15s with full output voltage, see Fig. 7-1
Short-circuit current typ. 90A load impedance 50mOhm, see Fig. 7-1
Note: The short-circuit current is available for 0.1s.
Output power nom. 960W continuous
1200W up to 15s
Line regulation max. ±2% see Fig. 5-1
Load regulation max. 1600mV static value, 0A 20A 0A
max. 100mV static value, 2.5A 20A 2.5A
Ripple and noise voltage *) max. 2500mVpp 20Hz-2kHz, 50Ohm
max. 300mVpp 2kHz to 20MHz, 50Ohm
Output capacitance typ. 7 600μF
*) The ripple and noise voltage mostly consist of a mains ripple with 300Hz (50Hz mains) or 360Hz (60Hz mains). The ripple and
noise voltage can be reduced by the utilization of external capacitors.
The power supply is also designed to support loads with a higher short-term current and power requirement. The
short-term duration is rmware controlle d by an output power manager. If the nominal output power is exceeded for
a certain period of time which is dened in zone A, B and C, the power supply responds with an automatic shut-down.
Pressing the reset button or cycling the input power (10s o time is required) initiates a restart attempt. If the fault has
been cleared the device will operate normally.
The short term power can be used periodically . See section 25.1 for further information.
Fig. 7-1 Output voltage vs. output current, typ.
V OUT
20A A07A5240A0
A
15s
48V
100A
30A A09A08A06A05A01
24V
I OUT
B
5s
C
0.1s
3x 408V
3x 480V
3x 552V
1606-XLE960MX-3N
Zone A : 25% extra output power for typ. 15s
Zone B
: 100% higher output current for typ. 5s
Zone C:Quick-acting shut-down after typ. 0.1s

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 7
Bulletin 1606 Switched Mode Power Supplies
8. Hold-up Time
1606-XLE960MX-3N
Hold-up Time typ. 3.1ms 20A, resistive load, see Fig. 8-2
ees,daolrewoptnatsnoc,A02sm7.2.pyt Fig. 8-2
sm2.6.pyt
10A, resistive load
daolrewoptnatsnoc,A01sm4.5.pyt
Hold-up Time min. 2.5ms 20A, resistive load, see Fig. 8-2
ees,daolrewoptnatsnoc,A02sm2.2.nim Fig. 8-2
sm0.5.nim 10A, resistive load
daolrewoptnatsnoc,A01sm4.4.nim
Fig. 8-1 Hold-up time, denitions
The energy is stored in the output capacitor. As
soon as the input is turned o, the output
capacitor will be discharged and the voltage will
dissipate according to the curves in
Fig. 8-2
The lighter the load, the longer the hold-up time.
half the load means twice the hold-up time.
The hold-up time depends on the load
characteristic. The curves below show the hold-up
time for a load with a resistive and a constant
power characteristic.
The hold-up time is dened as the period of time
when the input is turned o and until the output
voltage falls below 48V
–15%
(40.8V). This value is
dened in the IEC61131-2 as the lower limit for the
supplying voltage.
-15%
Hold-
up
Time
Zero Transition
Output
Voltage
Intput
Voltage
Fig. 8-2 Hold-up time vs. input voltage
48V
24V
36V
28V
V OUT
44V
32V
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.5 6.0 6.5 7.0 7.5 8.05.0 8.5 9.0
20A, constant power load, typ.
20A, resistive load, typ.
T
20A, constant power load, min.
20A, resistive load, min.
40.8V
11ms9.5 10 10.5
Note: At no load, the hold-up time can be up to one minute. The green DC-ok LED is on at this time.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
8Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
9. Eciency and Power Losses
1606-XLE960MX-3N
A02%0.69.pytycneiciffE
A02W0.04.pytsessolrewoP
A0W2.81.pyt
Fig. 9-1 Eciency vs. output current Fig. 9-2 Losses vs. output current
Eciency
0255.2
A
88
89
90
91
92
93
94
95
96%
7.5 10 12.5 15 17.5
Output Current
Power Losses
02468101214 20
A
0
10
20
30
40
50W
16 18
Output Current
Fig. 9-3 Eciency vs. input voltage, 48V, 20A Fig. 9-4 Losses vs. input voltage, 48V, 20A
Eciency
350 400 450 500 3x550 Va
c
95.0
95.2
95.4
95.6
Input Voltage
95.8
96.0
96.2% 1606-XLE960MX-3N
Power Losses
350 400 450 500 3x550 Va
c
35
37
39
41
Input Voltage
43
45
47W
1606-XLE960MX-3N

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 9
Bulletin 1606 Switched Mode Power Supplies
10. Functional Diagram
Fig. 10-1 Functional diagram
+
-
Active
Transient
Blocker
Input
Filter
Input
Rectier
Reset
Output
Voltage
Monitor
Over-
Voltage
Protection
Output
Power
Manager
Temp.
Shut-
down
Input
Voltage
Monitor
L3
L2
L1
Semi-
regulated
Power
Converter
Output
Filter
DC-ok
LED
Warning
LED
Shut-down
LED
11. Front Side and User Elements
Fig. 11-1 Front side of 1606-XLE960MX-3N
A. Output Terminals
Large screw terminal
+Positive output
-Negative (return)
output
See section 12
“Terminals and
Wiring” to choose
appropriate wire size.
B. Input Terminals
Screw terminals
L1, L2, L3:
Line inputs
PE (Protective
Earth) input
C. DC-ok LED (green)
Indicates a normal operation. The LED is on
if the output voltage is higher than 43.2V.
D. Warning LED (yellow)
- A steady-state light indicates an output
current higher than the nominal current
and that the internal shutdown timer is
running.
- A double ash indicates a phase-loss or
too low / too high input voltage.
(< 3x400Vac or > 3x560Vac)
- A fast ash warns of an impending
temperature shut-down. A shut-down
can be expected within 10 minutes, if
the ambient temperature or the load
current stays constant.
E. Shut-down LED (red) and reset button F.
The red LED ashes when the device has
shut down. Pressing the reset button or
cycling the input power (10s required)
initiates a restart. When the fault is
cleared, the device will operate normally.
A
B
C
D
E
F

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
10 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
12. Terminals and Wiring
Use appropriate copper cables that are designed for a minimum operating temperatures of 60°C (for ambient up to
45°C) and 75°C (for ambient up to 60°C). Follow national installation codes and regulations! Ensure that all strands of
a stranded wire enter the terminal connection! Do not use the power supply without PE (Ground) connection! Up to
two stranded wires with the same cross section are permitted in one connection point (except PE wire). Ferrules are
allowed, but not required.
tuptuOtupnI
lanimretwercSlanimretwercSepyT
mm6-5.0eriwdiloS 2mm61-5.0 2
mm4-5.0eriwdednartS 2mm01-5.0 2
GWA8-22GWA01-02eguageriwnaciremA
Wire stripping length 7mm / 0.26inch 12mm / 0.5inch
Recommended tightening torque 0.8Nm / 7lb.inch 1.2Nm / 10.6lb.inch
13. Reliability
Lifetime expectancy min. 77 000h 40°C, 20A
A01,C°04sraey51>.nim
A02,C°52sraey51>.nim
A02,C°04h00014590716CEI,00592NSFBTM
A02,C°52h000879
04BGngineBdnuorG,A02,C°04h000991F712KBDHLIMFBTM
267 000h 25°C, 20A, Ground Benign GB25
The Lifetime expectancy shown in the table above indicates the 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 a calc ulation of up to 15 years from date of shipment.
MTBF stands for Mean Time Between Failures, which is calculated according to statistical device failures, and indicates
reliability of a device. It is the statistical representation of the likelihood of failure of a specic unit and does not necessarily
represent the life of a product.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 11
Bulletin 1606 Switched Mode Power Supplies
14. EMC
The power supply is suitable for applications in industrial environments as well as in residential, commercial and light
industry environments without any restrictions. The CE Mark indicates conformance with EMC guideline 89/336/EC,
93/68/EC and the low-voltage directive (LVD) 73/23/EC. A detailed report is available upon request.
EMC Immunity EN 61000-6-1, and EN 61000-6-2 Generic standards
Electrostatic discharge EN 61000-4-2 Contact discharge
Air discharge
8kV
15kV
Criterion A
Criterion A
Electromagnetic RF eld 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 L1
L1 / L2 / L3
+ -
2kV
4kV
500V
Criterion A
Criterion A
Criterion A
-
+
PE
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
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
Class B, output lines
Radiated emission EN 55011, EN 55022 Class B
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
Switching frequency 36kHz Nearly constant
EN 55022
L2, L2 L3, L1 L3
PE
Surge voltage on output EN 61000-4-5 500V Criterion A
Mains voltage dips EN 61000-4-11 0% of 400Vac 20ms Criterion B
40% of 400Vac 200ms Criterion C
70% of 100Vac 500ms Criterion C
0% of 480Vac 20ms Criterion B
40% of 480Vac 200ms Criterion C
70% of 480Vac 500ms Criterion C
Power transients VDE 0160 over entire load range 1300V, 1.3ms Criterion D
Criteria:
A: Power supply shows normal behavior within the dened limits.
B: During the mains voltage dip, the output voltage will decrease according to curves in the Hold-up Time section. The unit works in
normal mode after the voltage dip. If criterion A is required, use 1606-XLSBUFFER48 module in addition to 1606-XLE power supply.
C: Temporary loss of function is possible. Power supply may shutdown and restart by itself. No damage or hazard to the power supply occurs.
D: The input transient blocker opens and the main converter is without input power during such transients. The output voltage decreases as
well, as described in the Hold-up Time section, during such an event.
Harmonic input current EN 61000-3-2 Fullled, active PFC
Voltage uctuations, icker EN 61000-3-3 Fullled

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
12 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
15. Environment
Operational temperature -25°C to +70°C (-13°F to 158°F) reduce output power above +60°C
ees,)F°851otF°041(C°07-0624W/°Cgnitar-edtuptuO Fig. 15-1
Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation
.H.r%59ot5ytidimuH dewollanoitasnednocon
Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis IEC 60068-2-6
Vibration random 0.5m
2
(s
3)
2 hours / axis IEC 60068-2-64
Shock 15g 6ms, 10g 11ms
3 bumps / direction, 18 bumps in total IEC 60068-2-27
tneibmarorewoptuptuoecudeR)tf00002ot0(m0006ot0edutitlA
temperature above 2000m sea level.
Output de-rating (for altitude) 60W/1000m or 5°C/1000m above 2000m, see Fig. 15-2
NEIIIyrogetacegatlov-revO 50178, altitudes up to 2000m
m0006otm0002morfsedutitlAII
evitcudnocnon,87105NE2noitullopfoeergeD
Fig. 15-1 Output current vs. ambient temp., Fig. 15-2 Output current vs. altitude
Allowed
Output Current
0
-25 0 20 40 70°
C
10
20
30
40A
60
Ambient Temperature
Allowed Output
Current
0
0 2000 4000 6000m
10
20
30
40A
Altitude
A...Tamb<60°C
B...Tamb<50°C
C...Tamb<40°C
A
B
C
The ambient temperature is dened 2cm below the unit.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 13
Bulletin 1606 Switched Mode Power Supplies
16. Protection Features
Output protection Electronically protected against overload, no-load and short-circuits *)
Output overvoltage protection max. 57.2Vdc in case of an internal power supply failure, a redundant
circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Input overvoltage shutdown typ. 3x 560Vac 1606-XLE960MX-3N
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm e.g. screws, small parts
Over-temperature protection yes output shut-down, reset required
Input transient protection MOV (Metal Oxyde Varistor) and active transient blocker
Internal input fuse not included see section 26.4
*) An audible noise may be heard during a no-load, overload or short circuit event.
17. Safety
Input/output separation SELV IEC/EN 60950-1
PELV
double or reinforced insulation
EN 60204-1, EN 50178, IEC 60364-4-41
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. 0.40mA 1606-XLE960MX-3N: 3x480V, 60Hz, TN mains
< 0.45mA 1606-XLE960MX-3N: 3x524V, 60 Hz, TN mains
18. Dielectric Strength
Fig. 18-1 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
B
L1
Input
Earth
Output
-
+
L3
L2
Type tests and factory tests:
Conducted by the manufacturer. Do not repeat these tests in
the eld!
Rules for eld test:
Use appropriate test equipment which applies the voltage
with a slow ramp! Connect L1, L2 and L3 together as well as
all output poles.
The output voltage is oating and has no ohmic connection to ground. Grounding of output is allowed.
To fulll the PELV requirements accord ing to EN60204-1 paragraph 6.4.1, RA recommends that either the + pole or
the – pole be connected to the protective earth system. This helps avoiding situations in which a load starts
unexpectedly or cannot be switched o in the occurence of an unnoticed ground fault.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
14 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
\
Product certification information (including Certificates and Declarations of Conformity) can be found at www.ab.com/certifications.
19. Certications
UL 508
IND. CONT. EQ.
18WM
LISTED
LISTED E56639 for use in the U.S.A. (UL 508) and Canada
(C22.2 No. 14-95)
UL 60950 RECOGNIZED E1168663 for use in the U.S.A. (UL 60950-1)
and Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3
EN 60950-1, EN 61204-3 Complies with CE EMC and CE Low Voltage Directives
Marine RINA RINA (Registro Italiano Navale) certied. See below for link
to the Certicate.
GOST R GOST R certication is applicable for products intended for sale and use
within Russia. See below for link to the Certicate.
C-TICK C-Tick compliance is for products intended for sale and use within
the Australian market. See below for link to the C-Tick Declarations
of Conformity.
20. Environmental Compliance
The unit does not release any silicone and is suitable for 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.
The materials used in our production process do not include the following toxic chemicals:
Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated
Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated
Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 15
Bulletin 1606 Switched Mode Power Supplies
21. Physical Dimensions and Weight
Weight 1400g / 3.09lb
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 (157mm) to calculate the total required
installation depth.
Fig. 21-1 Front view Fig. 21-2 Side view
22. Installation and Operating Instructions
Mounting and installation:
Output terminal must be located on top and input terminal on the bottom. For other orientations, see section 25.12.
An appropriate electrical and re end-product enclosure needs to be congured in the end-use application.
Cooling:
Convection cooled, no forced air cooling required. Do not block ventilation grille 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. If the adjacent device is a heat source, 15mm clearance is recommended.
Risk of electrical shock, re, personal injury 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 o 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 object from entering the housing.
Do not use in wet locations or in areas where moisture and/or condensation are likely to occur.
Service parts:
The unit does not contain any eld replaceable part. In case of damage or malfunction, turn power o immediately
and return the unit to the manufacturer for inspection.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
16 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
23. Accessories
Buer Module 1606-XLSBUFFER48
This buer unit is a supplementary device for DC48V power supplies. It delivers power to bridge typical mains failures
or extends the hold-up time after turn-o of the AC power. At times when the power supply provides sucient
voltages, the buer unit stores energy in integrated electrolytic capacitors. In case of mains voltage fault, this energy
is released again in a regulated process.
Fig. 23-1 Buer module 1606-XLSBUFFER48
Fig. 23-2 Wiring diagram: 1606-XLE and
1606-XLSBUFFER24
The buer unit does not require any
control wiring. It can be added in parallel
to the load circuit at any given point.
Buer units can be added in parallel to
increase the output ampacity or the hold-
up time.
Do not use the buer module to bridge mains interruptions which are longer than typ. 350ms. Once the mains is o
for longer than typ. 350ms, the power supply needs an additional 1s to restart.
24. Comparison between the 1606-XLE960MX-3N, a Transformer and
a Traditional Switched-mode Power Supply
1606-XLE960MX-3N
semi-regulated
power supply
Traditional
switched-mode
power supply
Transformer
power supply
Input voltage range + ++ -
Inrush current surge ++ + -
Hold-up time - + -
Phase-loss operation - + -
Eciency +++ ++ -
Output voltage regulation + ++ -
Output adjustment range - ++ -
Ripple & noise voltage - ++ -
Error diagnostics ++ ++ -
Harmonic distortion (PFC) + + -
EMC ++ ++ +
Ease of installation ++ ++ -
Size +++ ++ -
Weight +++ + -
+++ …very, very good ++…very good +…good -…poor
DC
Buer
Unit(s)
Power
Supply Load
AC
+
-

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 17
Bulletin 1606 Switched Mode Power Supplies
25. Application Notes
25.1. Periodical Peak Power Capability
Fig. 25-1 Periodical peak power capability
The short term power can be used
periodically.
The duration of the peak power (TP
)
must be shorter than 15s.
The time between two peak power
pulses must be three times longer than
the duration of the preceding pulse
length.
t
T
100%
125%
P OUT
P NOM
T P > 3x T P
25.2. Charging of Batteries
The power supply shall not be used to charge batteries.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
18 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
25.3. Output Circuit Breakers
Standard miniature circuit breakers (MCBs or UL 1077 supplementary breakers) can be used for branch protection
but make sure that the MCB is rated for DC voltage as well. The following tests show which circuit breakers the power
supply will typically trip.
Circuit breakers have huge tolerances in their tripping behavior. These typical tests can therefore be used only as a
recommendation or for comparing two dierent power supplies. Furthermore, the loop impedance has a major
inuence 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. 25-2 Branch protectors, test circuit 1
Circuit
Breaker
Power
Supply
AC
DC
+
-
I
Load
+
-
S1
Parameters:
Input voltage: 3x400Vac, load current: 0A
The following circuit breaker tripped during the test:
A- or Z- Characteristic: equal or smaller 25A *)
B- Characteristic: equal or smaller 32A *)
C- Characteristic: equal or smaller 20A *)
Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 25-3 Branch protectors, test circuit 2
R
Circuit
Breaker
Power
Supply
AC
DC
+
-
I
S1 Load
+
-
Parameters:
Input voltage: 3x400Vac, load current: 0A
The following circuit breaker tripped during the test:
A- or Z - Characteristic: ≤25A and R= 50mOhm *)
B- Characteristic: ≤32A and R= 29mOhm *)
C- Characteristic: ≤20A and R= 82mOhm *)
What does this resistance mean in wire length?
1.0mm 2
1.5mm2 2.5mm2 4.0mm2 6.0mm2 10mm2
29mOhm 1.6m 2.4m 4.0m 6.5m 9.7m 16.2m
50mOhm 2.8m 4.2m 7.0m 11.1m 16.7m 27.9m
82mOhm 4.6m 6.9m 11.4m 18.3m 27.4m 45.7m
*) A list of the circuit breakers under testing is avaliable upon request.
Example:
Which wire gauge must be used at a length of 8.5m before a B-Characteristic circuit breaker with 32A trips?
Answer: A 32A B-Characteristic circuit breaker requires a loop impedance of less than 29mOhm based on the test
results. The wire length table shows that a length of 9.7m with a cross section of 6.0mm 2has an impedance of
29mOhm. A wire no smaller than 6.0mm2must be used.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 19
Bulletin 1606 Switched Mode Power Supplies
25.4. External Input Protection
The power supply does not include any internal input fuse. The unit is tested and approved for branch circuits up to 16A
(U.S.A 15A). External protection is required only if the supplying branch has an ampacity greater than this. In some
countries local regulations might apply; do check all local codes and requirements. If an external fuse is necessary or
utilized, minimum requirements need to be considered to avoid nuisance tripping of the fuse.
citsiretcarahC-CcitsiretcarahC-B
Ampacity max.
20A 20A
min.
6A 3A
25.5. 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-EMF (Electro Magnetic Force).
This power supply is resistant and does not show adverse eects when a load feeds back voltage to the power supply.
It does not matter whether the power supply is on or o.
If the power supply is fully loaded after a return-feeding event, the output voltage can dip to 21V for approx. 20ms.
The maximum allowed feed back voltage is 55.1Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specied in section 7.
25.6. Parallel Use to Increase Output Power
The power supply shall not be used in parallel to increase output power.
25.7. Parallel Use for Redundancy
Power supplies can be paralleled for a 1+1 redundancy to gain a higher system availability and reliability. 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-XLE power supplies in parallel ( a method called 1+1 redundancy). In case one power supply fails,
the second is automatically able to support the load current without any interruption.
Please note: This simple way to build a redundant system does not cover such failures as an internal short circuit on
the secondary side of the power supply. In such a condition, the shorted unit becomes a load for the other power
supplies and the output voltage can not be maintained. This can be avoided by using decoupling diodes wich are
included in our redundancy modules (references 1606-XLERED and 1606-XLSRED). One redundancy module per XLE
power supply is required.
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 LED and a DC-ok contact are included in some redundancy
modules and are able to report a faulty unit.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
20 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014
Bulletin 1606 Switched Mode Power Supplies
25.8. Series Operation
Power supplies from the 1606-XLE family can be used in series to increase output voltage.
Fig. 25-4 Schematic for series operation
Installation notes for use in series:
Unit B
-
+
Load
+
-
AC
DC
AC
DC
-
+
Unit A
Earth
(see notes)
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) Voltages with a potential above 60Vdc are no longer rated SELV
and can be hazardous in some situations. Such voltages must be
installed with a protection to make the unit touch-safe.
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.
25.9. Inductive and Capacitive Loads
The unit is designed to supply any kind of load, including inductive or capacitive loads with a capacity up to 120mF.
25.10. Loss of One Input Phase
The unit protects itself against a loss of one input phase and does not require an external protection device.
A phase-loss operation is possible for output currents below 4A. Above this level, the yellow LED indicates an
impending shut-down. If the missing phase does not recover, the unit switches o after 3.5s. Pressing the reset
button or cycling the input power (10s required) initiates a restart.
Please note that the input current and the output ripple are higher when one phase is missing.
25.11. 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 denes 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 producing equipment is inside the box.
Enclosure: Rittal Typ IP66 Box PK 9519 100, plastic, 180x180x165mm
Load: 48V, 16A (=80% of the rated current); load is placed outside the box
Input: 3x400Vac
Temperature inside the box: 52.9°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside the box: 25.1°C
Temperature rise: 27.8K