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.