Rockwell Automation Allen-Bradley 1606-XLE480EP User manual

Power Supply - 24V, 20 A,
480 W, Single-phase Input
Catalog Numbers 1606-XLE480EP, 1606-XLE480EPC,
1606-XLE480EL, 1606-XLE480EH, 1606-XLE480EM,
1606-XLE480EP-D
Reference Manual Original Instructions

2Rockwell Automation Publication 1606-RM102A-EN-P - July 2020
Power Supply - 24V, 20 A, 480 W, Single-phase Input Reference Manual Original Instructions
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.
Labels may also be on or inside the equipment to provide specific precautions.
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).
July

Rockwell Automation Publication 1606-RM102A-EN-P - July 2020 3
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Input Inrush Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hold-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DC OK Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remote ON/OFF Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connection Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Daisy chaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lifetime Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mean Time Between Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety and Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fulfilled Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wall/Panel Mount Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1606-XLSBUFFER24 Buffer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1606-XLSRED40 Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . . . 26
1606-XLSRED4HE Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . 27
1606-XLSREDS40HE Redundancy Module . . . . . . . . . . . . . . . . . . . . . 27
Peak Current Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Output Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Use the Power Supply to Charge Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 30
Series Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Parallel Use to Increase Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parallel Use for Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1+1 Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
N+1 Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation on Two Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Use in a Tightly Sealed Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4Rockwell Automation Publication 1606-RM102A-EN-P - July 2020
Notes:

Rockwell Automation Publication 1606-RM102A-EN-P - July 2020 5
Terminology and
Abbreviations
All parameters that are listed in this document are typical values that are
specified under the following conditions unless otherwise noted: 230V AC,
50 Hz input voltage, 24V, 20 A output load, 25 °C (77 °F) ambient temperature,
after a 5 minutes run-in time.
Product Overview Bulletin 1606-XLE power supplies are cost optimized without compromising
quality, reliability, and performance. Bulletin XLE power supplies offer high
efficiency, electronic inrush current limitation, active power factor correction
(PFC), wide operational temperature range, and compact size.
The 1606-XLE480EPC is equipped with conformal coated printed circuit
boards that are preferred for applications in harsh areas.
The 1606-XLE480EP-D is equipped with quick-connect spring-clamp terminals
that are preferred for applications that are exposed to mechanical vibration.
The 1606-XLE480EH has push-in terminals that are optimized for easy cabinet
wiring.
The 1606-XLE480EM is equipped with a remote ON/OFF feature and the 1606-
XLE480EP-D features an enhanced DC input voltage range.
The devices have a power reserve of 20% included, which may even be used
continuously up to +45 °C (113 °F).
Bulletin 1606-XLE480 power supplies have the features and approval ratings to
meet the needs of a wide range of applications. Features include a high
resistance to transients and power surges, low electromagnetic emission, and
DC OK relay contact.
Term, Abbreviation,
or Symbol Definition
PE PE is the abbreviation for Protective Earth and has the same meaning as the symbol in the
following row.
The symbol for Protective Earth. This symbol has the same meaning as PE.
Earth, Ground This document uses the term ‘earth’ which is the same as the U.S. term ‘ground.’
PELV Protection by extra-low voltage.
SELV Safety by extra-low voltage.
AC 230V A value that is displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%) included. For example: DC 12V describes a 12V
battery disregarding whether it is full (13.7V) or flat (10V)
230V AC A figure with the unit (V AC) at the end is a momentary figure without any additional
tolerances included.
50 Hz versus 60 Hz As long as not otherwise stated, AC 230V parameters are valid at 50 Hz mains frequency.
typ A typical value.
nom A nominal value.
— (alone in a table
cell) A single dash alone in a table cell indicates that there is no information to be included in that cell.

6Rockwell Automation Publication 1606-RM102A-EN-P - July 2020
Power supply features:
• AC 100…240V wide-range input
• Width only 48 mm (1.89 in.)
• Efficiency up to 95.6%
• Excellent partial load efficiency
• 20% output power reserves
• Easy fuse breaking – 3 times nominal current for 12 ms
• Safe HiccupPLUS overload mode
• Active power factor correction (PFC)
• Minimal inrush current surge
• Full power between -25…+60 °C (-13…140 °F)
•DCOKrelaycontact
• Current-sharing feature for parallel use
Figure 1 - 1606-XLE480EP Figure 2 - 1606-XLE480EPC Figure 3 - 1606-XLE480EL
Figure 4 - 1606-XLE480EH Figure 5 - 1606-XLE480EM Figure 6 - 1606-XLE480EP-D

Rockwell Automation Publication 1606-RM102A-EN-P - July 2020 7
Specifications
Catalog Numbers
Attributes Values Notes
Output voltage DC 24V Nominal
Adjustment range 24…28V Factory setting 24.1V
Output current
24.0…20.6 A Below +45 °C (113 °F) ambient
20.0…17.1 A At +60 °C (140 °F) ambient
15.0…13.0 A At +70 °C (158 °F) ambient
Derate linearly between 45…70 °C (113…158 °F)
Input voltage AC AC 100…240V -15%/+10%
Mains frequency 50…60 Hz ±6%
Input current AC 4.26 / 2.23 A At 120 / 230V AC
Power factor 0.99 / 0.98 At 120 / 230V AC
Input voltage DC DC 110…150V±20% For 1606-XLE480EP (-xx)
DC 110…300V±20% For 1606-XLE480EP-D
Input current DC 4.64 A / 1.66 A At 110 / 300V DC
AC Inrush current 10.0 / 4.5 A pk At 120 / 230V AC
Efficiency 94.2 / 95.6% At 120 / 230V AC
Losses 29.6 / 22.1 W At 120 / 230V AC
Hold-up time 32 / 32 ms At 120 / 230V AC
Temperature range -25…+70 °C (-13…158 °F) —
Size (W x H x D) 48 x 124 x 127 mm
(1.89 x 4.88 x 5.00 in.) Without DIN rail
Weight 830 g (1.83 lb) —
Component Types Catalog Numbers Descriptions
Power supplies
1606-XLE480EP Standard version of power supply
1606-XLE480EPC With conformal coated PC-boards
1606-XLE480EP-D With quick-connect spring-clamp terminals
1606-XLE480EH With push-in terminals
1606-XLE480EM With remote ON/OFF feature
1606-XLE480EP-D Enhanced DC input
1606-XLE480ERL With built-in redundancy
1606-XLE480ERZ With built-in redundancy
Mount bracket 1606-XLA-XLE Wall/Panel mount bracket
Buffer module 1606-XLSBUFFER24 Buffer module
Redundancy modules
1606-XLSRED40 Dual redundancy module
1606-XLSRED4HE Dual redundancy module
1606-XLSREDS40HE Single channel redundancy module

8Rockwell Automation Publication 1606-RM102A-EN-P - July 2020
AC Input The device is suitable to be supplied from TN-, TT-, and IT mains networks
with AC voltage. For suitable DC supply voltages, see DC Input on page 9.
Attribute Value Notes
AC input Nom AC 100…240V —
AC input range Min 85…264V AC Continuous operation
Min 264…300V AC Occasionally for maximal 500 ms
Allowed voltage L or N to earth Max 300V AC Continuous, according to IEC 60664-1
Input frequency Nom 50…60 Hz ±6%
Turn-on voltage Typ 82V AC Steady-state value, see Figure 7 on page 8
Shut-down voltage Typ 72V AC Steady-state value, see Figure 7 on page 8
Attribute Values Notes
AC 100V AC 120V AC 230V
Input current Typ 5.15 A 4.26 A 2.23 A At 24V, 20 A, see Figure 9 on page 8
Power factor Typ 0.996 0.996 0.980 At 24V, 20 A, see Figure 10 on page 8
Crest factor Typ 1.65 1.63 1.63 At 24V, 20 A, The crest factor is the mathematical ratio of the peak
value to RMS value of the input current waveform.
Start-up delay Typ 450 ms 450 ms 450 ms See Figure 8 on page 8
Rise time
Typ 145 ms 145 ms 145 ms At 24V, 20 A constant current load, 0 mF load capacitance, see
Figure 8 on page 8
Typ 160 ms 160 ms 160 ms At 24V, 20 A constant current load, 20 mF load capacitance, see
Figure 8 on page 8
Turn-on overshoot Max 200 mV 200 mV 200 mV In single use mode, see Figure 8 on page 8
Figure 7 - Input voltage range Figure 8 - Turn-on behavior, definitions
Figure 9 - Input current versus output current at 24V
output voltage Figure 10 - Power factor versus output current at 24V output voltage
Turn-on
85V
Rated
input range
max.
500ms
V
IN
P
OUT
300V AC264V
Shut-down
Start-up
delay Rise Time
Overshoot
- 5%
Output
Voltage
Input
Voltage
24A
24681012141618
0
1
2
3
4
5
6A
Input Current, typ.
20 22
a) 100V AC
b) 120V Ac
c) 230V Ac
b
a
c
Output Current
Power Factor, typ.
2 4 6 8 10 12 14 16 18 24A
0.75
0.8
0.85
0.9
0.95
1.0
20 22
a) 100V AC
b) 120V AC
c) 230V AC
a, b
c
Output Current

Rockwell Automation Publication 1606-RM102A-EN-P - July 2020 9
DC Input The device is suitable to be supplied from a DC input voltage. Use a battery or a
similar DC source. A supply from the intermediate DC bus of a frequency
converter is not recommended and can cause a malfunction or damage the
unit.
Connect +pole to L, –pole to N and the PE terminal to an earth wire or to the
machine ground.
Figure 11 - Wiring for DC Input
Attribute Value Notes
DC input Nom DC 110…150V ±20% For 1606-XLE480EP, 1606-XLE480EPC, 1606-
XLE480EP-D, 1606-XLE480EH, 1606-XLE480EM
DC 110…300V ±20% For 1606-XLE480EP-D
DC input range Min 88…180V DC Continuous operation for 1606-XLE480EP, 1606-XLE480EPC,
1606-XLE480EP-D, 1606-XLE480EH, 1606-XLE480EM
88…360V DC Continuous operation for 1606-XLE480EP-D
DC input current Typ 4.64 A At 110V DC, at 24V, 20 A
1.66 A At 300V DC, at 24V, 20 A
Allowed Voltage (+)
or (-) input to Earth Max 375V DC Continuous according to IEC 60664-1
Turn-on voltage Typ 80V DC Steady state value
Shut-down voltage Typ 70V DC Steady state value
+
-
Load
L
PE
+
-
Power Supply
AC
DC
Battery
N

10 Rockwell Automation Publication 1606-RM102A-EN-P - July 2020
Input Inrush Current An active inrush limitation circuit limits the input inrush current after turn-on
of the input voltage.
The charging current into EMI suppression capacitors is disregarded in the
first microseconds after switch-on.
Figure 12 - Typical turn-on behavior at nominal load and 25 °C (77 °F) ambient
Attributes Values Notes
AC 100V AC 120V AC 230V
Inrush current Max 15 A pk 12 A pk 5.5 A pk Temperature independent
Typ 12 A pk 10 A pk 4.5 A pk Temperature independent
Inrush energy Max 1 A2s 1 A2s 1 A2s Temperature independent