Rockwell Automation Allen-Bradley 1606-XLE480ERL User manual

Redundancy Power Supply -
24V, 20 A, 480 W, Single-phase
Catalog Numbers 1606-XLE480ERL, -XLE480ERZ, -XLE480CRZ,
-XLE480EDRZ
Reference Manual Original Instructions

2Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply - 24V, 20 A, 480 W, Single-phase 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.
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).

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 3
Table of Contents
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input Inrush Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hold-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DC OK Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifetime Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mean Time Between Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Instructions for Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing Units While the System is Running . . . . . . . . . . . . . . . . . . . . . 17
Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electromagnetic Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety and Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Certifications and Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . 23
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Applications Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Peak Current Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Adjusting the Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Charging of Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Output Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Series Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Parallel Use to Increase Output Power . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parallel Use For Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation on Two Phases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Use in a Tightly Sealed Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Notes

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 5
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Product Overview
The Bulletin 1606-XLE line features cost optimized power supplies without
compromising quality, reliability, and performance. The 1606-XLE480ERL and
1606-XLE480ERZ power supplies offer high efficiency, electronic inrush
current limitation, active PFC, wide operational temperature range, and
compact size. The units include a decoupling MOSFET for building 1+1 or n+1
redundant power supply systems.
These redundancy power supplies come with three connection terminal
options; screw terminals, spring-clamp terminals or, plug connector terminals
that allow replacement on an active application.
Catalog number 1606-XLE480EDRZ features an enhanced DC input voltage
range and catalog number 1606-XLE480ECRZ is additionally equipped with
conformal coated printed circuit boards.
These power supplies are suitable for a wide range of applications due to high
immunity to transients and power surges, low electromagnetic emission, a DC
OK signal contact for remote monitoring, and extensive international
approvals.
• AC 100…240V Wide-range Input
• Width only 48 mm (1.89 in)
• Built-in Decoupling Mosfet for 1+1 and n+1 Redundancy
• Efficiency up to 95.2%
• 20% Output Power Reserves
• Safe HiccupPLUS Overload Mode
• Easy Fuse Breaking – 3 times nominal current for 12 ms
• Active Power Factor Correction (PFC)
• Minimal Inrush Current Surge
• Full Power Between -40…+60 °C (-40… +140 °F)
• DC OK Relay Contact
• Current Sharing Feature Included

6Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Specifications
Catalog Numbers
Attribute Value Notes
Output current 24V DC Nominal
Adjustment range — —
Output current
24 A Below +45 °C (+113° F) ambient
20 A At +60 °C (+140 °F) ambient
15 A At +70 °C (+158 °F) ambient
Derate linearly between +45…70 °C (113…158 °F)
AC Input voltage 100…240V AC -15%/+10%
Mains frequency 50…60, 50 Hz ±6%
AC Input current 4.28/2.25 A At 120/230V AC
Power factor 0.99/0.98 At 120/230V AC
Input voltage DC DC 110…150V±20% For 1606-XLE480ERxx
DC 110…300V±20% For 1606-XLE480EDxx
Input current DC 4.64 A/1.66 A At 110/300V DC
AC Inrush current 10/4.5 Apk At 120/230V AC
Efficiency 93.8/95.2% At 120/230V AC
Losses 31.7/24.2 W At 120/230V AC
Hold-up time 32/32 ms At 120/230V AC
Temperature range -40…+70 °C
(-40…+158 °F) —
Size (w x h x d) 48 x 124 x 127 mm
(1.89 x 4.88 x 5 in.) Without DIN rail and plug connectors
Weight 830 g (1.83 lb) 1606-XLE480ERL
850 g (1.87 lb) 1606-XLE480ERZ
Catalog Number Description
1606-XLE480ERL 24V, 20 A 480 W Single-phase power supply with quick connect, spring-clamp terminals
1606-XLE480ERZ 24V, 20 A 480 W Single-phase power supply with hot swappable plug connectors
1606-XLE480ECRZ 24V, 20 A 480 W Single-phase power supply with conformal coated printed circuit boards
1606-XLE480EDRZ 24V, 20 A 480 W Single-phase power supply with enhanced DC input
1606-XLA-W50 Wall Mount Bracket

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 7
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
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 8.
Attribute Value Notes
AC input Nom AC 100…240V —
AC input range Min 85…264V AC Continuous operation
Min 264…300V AC For maximal 500 ms (occasional)
Allowed voltage L or N to earth Max 300V AC Continuous, according to IEC 62477-1
Input frequency Nom 50…60Hz ±6%
Turn-on voltage Typ 82V AC Steady-state value, see Figure 1.
Shut-down voltage Typ 72V AC Steady-state value, see Figure 1.
External input protection
AC 100V AC 120V AC 230V Notes
Input current Typ 5.17 A 4.28 A 2.25 A At 20 A, see Figure 3.
Power factor Typ 0.996 0.996 0.980 At 20 A, see Figure 4.
Crest factor Typ 1.65 1.63 1.63 At 20 A, The crest factor is the mathematical ratio of the peak value to
RMS value of the input current waveform.
Startup delay Typ 450 ms 450 ms 450 ms See Figure 2.
Rise time
Typ 145 ms 145 ms 145 ms At 20 A const. current load, 0mF load
capacitance, see Figure 2.
Typ 160 ms 160 ms 160 ms At 20 A const. current load, 20mF load
capacitance, see Figure 2.
Turn-on
overshoot Max 1000 mV 1000 mV 1000 mV See Figure 2.
Figure 1 - Input Voltage Range Figure 2 - Turn-on Behavior, Definitions
Figure 3 - Input Current Versus Output Current Figure 4 - Power Factor Versus Output Current
Turn-on
85V
Rated
input range
max.
500 ms
V
IN
P
OUT
300V AC264V
Shut-down
24 A
2 4 6 8 10 12 14 16 18
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 24 A
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

8Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
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 5 - Wiring for DC Input
Attribute Value Notes
DC input Nom DC 110…150V ±20% for 1606-XLE480ER_
Nom DC 110…300V ±20% for 1606-XLE480EC_
DC input range Min 88…180V DC Continuous operation for 1606-XLE480ER_
88…360V DC Continuous operation for 1606-XLE480EC_
DC input current Typ 4.64 A At 110V DC and 20 A load current
Typ 1.66 A At 300V DC and 20 A load current
Allowed Voltage (+) or (-)
input to Earth Max 375V DC Continuousaccording to IEC62477-1
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

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 9
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
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 6 - Typical Turn-on Behavior at Nominal Load and 25 °C (77 °F) Ambient
Attribute AC 100V AC 120V AC 230V Notes
Inrush current Max 15 Apeak 12 Apeak 5.5 Apeak Temperature independent
Typ 12 Apeak 10 Apeak 4.5 Apeak Temperature independent
Inrush energy Max 1 A2s1A
2s1A 2s Temperature independent

10 Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Output The output provides a SELV/PELV/ES1 rated voltage, which is galvanically
isolated from the input voltage. The output of the devices includes a
decoupling MOSFET for building 1+1 or n+1 redundant power supply systems.
The device is designed to supply any kind of loads, including capacitive and
inductive loads. If large capacitors, such as electric double layer capacitors
(EDLCs or “UltraCaps”) with a capacitance > 1 F are connected to the output,
the unit might charge the capacitor in the HiccupPLUS mode.
The device is featured with a “soft output regulation characteristic” to achieve
current share between multiple devices when they are connected in parallel.
The “soft output regulation characteristic” regulates the output voltage in such
a manner that the voltage at no load is approximately 4% higher than at
nominal load.
Attribute Value Notes
Output voltage Nom DC 24V 23.8…25.2V
Adjustment range See Adjusting the Output Voltage on page 26
Factory settings 24.1V ±0.2%, at 20 A, cold unit (results to Typ 23.9V±0.2% at
24 A and Typ 25.1V±0.2% at no load)
Line regulation Max 10 mV 85…300V AC
Load regulation Typ 1000 mV Static value, 0 A --> 20 A; see Figure 7.
Ripple and noise Max 100 mVpp 20 Hz…20 MHz, 50 Ω
Output current
Nom 24A(1)
(1) This current is also available for temperatures up to +70°C (158 °F) with a duty cycle of 10% and/ or not longer than 1 minute
every 10 minutes.
Below 45 °C (113 °F) ambient temperature, see Figure 22.
Nom 20 A At 60 °C (140 °F) ambient temperature, see Figure 22.
Nom 15 A At 70 °C (158 °F) ambient temperature, see Figure 22.
Fuse breaking(2)
(2) The fuse braking current is an enhanced transient current which helps to start heavy loads or to trip fuses on faulty output
branches. The output voltage stays above 20V. See Peak Current Capability on page 25 for additional measurements.
Typ 60 A Up to 12 ms once every 5 seconds, see Figure 9.
Overload protection Included Electronically protected against overload, no-load, and short-circuits. In a protection event, audible noise may
occur.
Overload behavior Continuous current Output voltage >13V DC, see Figure 7.
Intermittentcurrent(3)
(3) At heavy overloads (when output voltage falls below 13V), the power supply delivers continuous output current for 2s. After
this, the output is switched off for approx. 18 s before a new start attempt is automatically performed. This cycle is
repeated as long as the overload exists. If the overload has been cleared, the device will operate normally. See Figure 8.
Output voltage <13V DC, see Figure 7.
Overload/ short-
circuit current
Max 29.8 A Continuous current, see Figure 7.
Typ 29 A Intermittent current peak value for Typ 2 s Load impedance 10 mΩ, see Figure 8.
Discharge current of output capacitors is not included
Max 9.8 A Intermittent current average value (R.M.S.) Load
impedance 10 mΩ, see Figure 8.
Output capacitance Typ 8 000 µF Included inside the power supply
Back-feeding loads Max 35V
The unit is resistant and does not show malfunctioning
when a load feeds back voltage to the power supply. It
does not matter whether the power supply is on or off.
The absorbing energy can be calculated according to the
built-in large sized output capacitor.

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 11
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Hold-up Time
Figure 7 - Output Voltage Versus Output Current, Typical Figure 8 - Short-Circuit on Output, Hiccup PLUS Mode, Typical
Output Voltage
0
025
4
8
12
28V
16
20
24
40 A
155 10 20 30 35
Output Current
A: continuous current
B: intermitted current
A
B
Output
Current
0
29A
18s 18s
18s 2s 2s
2s
t
Short -circuit Normal
operation
Normal
operation
Figure 9 - Dynamic Overcurrent, Capability, Typical
Output Voltage (dynamic behavior, < 12ms)
0
0
4
8
12
28V
16
20
24
70A30
10 40 50
20 60
Output Current
Attribute AC 100V AC 120V AC 230V Notes
Hold-up Time
Typ 65 ms 65 ms 65 ms At 10 A, see Figure 10
Min 54 ms 54 ms 54 ms At 10 A, see Figure 10
Typ 32 ms 32 ms 32 ms At 20 A, see Figure 10
Min 24 ms 24 ms 24 ms At 20 A, see Figure 10
Figure 10 - Hold-up Time Versus Input Voltage Figure 11 - Shut-down Behavior, Definitions
0
10
20
30
40
80 ms
85 120 155 190 230V AC
Input Voltage
50
60
Hold-up Time
20 A, typ.
10 A, min.
10 A, typ.
70
20 A, min.
- 5%
Hold-up Time
Zero Transition
Output
Voltage
Input
Voltage

12 Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
DC OK R elay C ontact This feature monitors the output voltage of the power supply in front of the
decoupling device.
Figure 12 - DC OK Relay Contact Behavior
Attribute Value
Contact closes As soon as the output voltage reaches Typ 22V DC.
Contact opens As soon as the output voltage dips below 22V DC.
Short dips will be extended to a signal length of 100 ms. Dips shorter than 1 ms will be ignored.
Switching 1V
Contact ratings Maximal 60V DC: 0.3 A,30V DC: 1A, 30V AC: 0.5A, resistive load
Minimal permissible load: 1 mA at 5V DC
Isolation voltage See Dielectric Strength on page 22
100 ms
22V DC
<
1 ms
open openclosed closed
>
1...4 ms

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 13
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Efficiency and Power
Losses Attribute AC 100V AC 120V AC 230V Notes
Efficiency Typ 93.2% 93.8% 95.2% At20 A
Typ 93.1% 93.7% 95.1% At 24 A (Power Boost)
Average
efficiency(1)
(1) The average efficiency is an assumption for a typical application where the power supply is loaded with 25% of the nominal
load for 25% of the time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of
the time and with 100% of the nominal load for the rest of the time.
Typ 92.8% 93.4% 94.6% 25% at 0.5 A, 25% at 10 A,
25% at 15 A. 25% at 20 A
Power losses
Typ 3.9 W 3.5 W 3.3 W At 0 A
Typ 17.4 W 16.4 W 13.8 W At 10 A
Typ 35.0 W 31.7 W 24.2 W At20 A
Typ 42.7 W 38.7 W 29.7 W At 24 A (Power Boost)
Figure 13 - Efficiency Versus Output Current, Typical Figure 14 - Losses Versus Output Current, Typical
Figure 15 - Efficiency Versus Input Voltage at 20 A, Typical Figure 16 - Losses Versus Input Voltage at 20 A, Typical
EŨciency
4 6 8 10 12 14 18 20 24 A
87
88
90
91
92
93
94
95
96%
Output Current
16 22
(a)
(b)
(c)
(a) 100V AC
(b) 120V AC
(c) 230V AC
Power Losses
0 2 6 8 12 14 24 A
5
0
10
20
30
40 W
18 20
4 10 16
Output Current
22
(a)
(b)
(c)
(a) 100V AC
(b) 120V AC
(c) 230V AC
35
25
15
EŨciency
120 180 230 264 V AC
90
91
92
93
Input Voltage
94
95
96%
100
Power Losses
120 180 230 264 V AC
10
15
20
25
Input Voltage
30
35
40 W
100

14 Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Lifetime Expectancy The Lifetime expectancy that is shown in the table indicates the minimum
operating hours (service life) and is determined by the lifetime expectancy of
the built-in electrolytic capacitors. Lifetime expectancy is specified in
operational hours and is calculated according to the capacitor’s manufacturer
specification. The manufacturer of the electrolytic capacitors only guarantees
a maximum life of up to 15 years (131,400 hr). Any number exceeding this value
is a calculated theoretical lifetime that can be used to compare devices.
Mean Time Between Failure Mean Time Between Failure (MTBF) is calculated according to statistical
device failures, and indicates reliability of a device. It is the statistical
representation of the likelihood of a unit to fail and does not necessarily
represent the life of a product.
The MTBF figure is a statistical representation of the likelihood of a device to
fail. An MTBF figure of, for example, 1,000,000 hr means that statistically one
unit will fail every 100 hours if 10,000 units are installed in the field. However,
it cannot be determined if the failed unit has been running for 50,000 hr or
only for 100 hr.
For these types of units the MTTF (mean time to failure) value is the same value
as the MTBF value.
Attribute AC 100V AC 120V AC 230V Notes
Lifetimeexpectancy
117,000 hr 136,000 hr 164,000 hr At 10 A and 40 °C (140 °F)
331,000 hr 386,000 hr 465,000 hr At 10 A and 25 °C (77 °F)
40,000 hr 53,000 hr 90,000 hr At 20 A and 40 °C (140 °F)
114,000 hr 150,000 hr 253,000 hr At 20 A and 25 °C (77 °F)
16,000 hr 25,000 hr 47,000 hr At 24 A and 40 °C (140 °F)
44,000 hr 69,000 hr 134,000 hr At 24 A and 25 °C (77 °F)
Attribute AC 100V AC 120V AC 230V Notes
MTBF SN 29500, IEC
61709
387,000 hr 412,000 hr 543,000 hr At 20 A and 40 °C (140 °F)
723,000 hr 768,000 hr 976,000 hr At 20 A and 25 °C (77 °F)
MTBF MIL HDBK 217F
164,000 hr 169,000 hr 199,000 hr At 20 A and 40 °C (140 °F); Ground Benign GB40
224,000 hr 231,000 hr 272,000 hr At 20 A and 25 °C (77 °F); Ground Benign GB25
34,000 hr 36,000 hr 42,000 hr At 20 A and 40 °C (140 °F); Ground Fixed GF40
45,000 hr 47,000 hr 56,000 hr At20 A and 25 °C (77 °F);Ground Fixed GF25

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 15
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Functional Diagram Figure 17 - Functional Diagram 1606-XLE480ERL
Figure 18 - Functional Diagram 1606-XLE480ERZ, -XLE480CRZ, -XLE480EDRZ
Output
Over-
Voltage
Protection
PFC
Converter
Power
Converter
Output
Filter
Output
Power
Manager
Temper-
ature
Shut-
down
Input Fuse
Input Filter
Input Rectiťer
Active Inrush Limiter
L
N
Decoupling
+
+
-
-
-
Output
Voltage
Regulator
Output
Voltage
Monitor
V
OUT
DC OK
Contact
DC OK
LED
DC OK
Relay
+
-
Output
Over-
Voltage
Protection
PFC
Converter
Power
Converter
Output
Filter
Output
Power
Manager
Temper-
ature
Shut-
down
Input Fuse
Input Filter
Input Rectiťer
Active Inrush Limiter
L
N
Decoupling
Output
Voltage
Regulator
Output
Voltage
Monitor
V
OUT
DC OK
Contact
DC OK
LED
DC OK
Relay

16 Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field- and factory
wiring.
Instructions for Wiring
• Use appropriate copper cables that are designed for minimum operating
temperatures of: 60 °C (140 °F) for ambient up to 45 °C (113 °F),
75 °C (167 °F) for ambient up to 60 °C (140 °F)
and 90°C (194 °F) for ambient up to 70 °C (158 °F) minimum.
• Follow national installation codes and installation regulations.
• Confirm that all strands of a wire enter the terminal connection.
• Unused terminal compartments should be securely tightened.
• Ferrules are allowed and recommended.
1606-XLE480ERL Input Output DC OK-Signal
Type Quick-connect spring-clamp termination Push-in termination
Max Solid wire 6 mm21.5 mm2
Max Stranded wire 4 mm21.5 mm2
American Wire Gauge AWG 20…10 AWG 24…6
Max wire diameter
(including ferrules) 2.8 mm 1.6 mm
Wire stripping length 10 mm (0.4 in.) 7 mm (0.28 in.)
Screwdriver — 3 mm slotted to open the
spring
1606-XLE480ERZ, -XLE480EDRZ,
-XLE480ECRZ Input Output DC OK-Signal
Type Plug connector with screw termination(1)
(1) Do not unplug the connectors more than 20 times in total.
Max Solid wire 4 mm26 mm21.5 mm2
Max Stranded wire 2.5 mm24 mm21.5 mm2
American Wire Gauge AWG 20…12 AWG 24…10 AWG 24…16
Max wire diameter (including
ferrules) 2.4 mm 3.2 mm 1.8 mm
Wire stripping length 7 mm (0.28 in.) 12 mm (0.47 in.) 6 mm (0.24 in.)
Screwdriver 3 mm (0.11 in.) slotted or cross-head No 2 3 mm (0.11 in.) slotted

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 17
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Replacing Units While the
System is Running
This feature is available only for the 1606-XLE480ERZ, -XLE480CRZ, and
-XLE480EDRZ units, which are equipped with hot-swappable plug connectors
.
Figure 19 - Replacing the Power Supply or Redundancy Module while the System is Running
Replacement Instructions
Example for left power supply:
1. Switch-off circuit breaker (1a).
2. Remove plug (2a).
3. Remove plug (3a). The plug prevents the cables from shorting.
4. Change power supply.
5. Put the plug (3a) back in.
6. Put the plug (2a) back in.
7. Turn-on the circuit breaker (1a).
8. The circuit is redundant again.
To replace the right power supply, repeat the process above using (1 b), (2 b), and
(3 b).
Load
I I
L
N
PE
1a
L N PE
+
-
1606-XLE480ERZ
Power Supply
DC-OK
DC-
OK
Output 24V 20A
Input
L N PE
+
-
1606-XLE480ERZ
Power Supply
DC-OK
DC-
OK
Output 24V 20A
Input
1b
2a
3a 3b
2b

18 Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Front Side and User
Elements
Figure 20 - 1606-XLE480ERL Figure 21 - 1606-XLE480ERZ,
-XLE480CRZ, -XLE480EDRZ User Elements
1
Input Terminals
N, L N, L Line Input
PE (Protective Earth) Input
2
Output Terminals
Two identical + poles and two identical - poles
+Positive Output
-Negative (return) Output
3 Output Voltage Potentiometer
4DC OK light-emitting diode (LED) (green)
On when the output voltage is above 22V.
5
DC OK Relay Contact
The DC OK relay contact is synchronized with the DC OK light-
emitting diode (LED). See DC OK Relay Contact on page 12.
1
2
3
4
5
1
2
3
4
5

Rockwell Automation Publication 1606-RM108A-EN-P - August 2020 19
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Electromagnetic
Capability
The electromagnetic capability (EMC) behavior of the device is designed for
applications in industrial environment as well as in residential, commercial,
and light industry environments.
EMC Immunity (1) According to the generic standards EN 61000-6-1 and EN 61000-6-2.
Electrostatic discharge EN 61000-4-2 Contact discharge
Air discharge 8 kV 15 kV Criterion A Criterion A
Electromagnetic RF field EN 61000-4-3 80 MHz…2.7 GHz 20V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines Output lines
DC OK signal (coupling clamp)
4 kV
2 kV
2 kV
Criterion A
Criterion A
Criterion A
Surge voltage on input EN 61000-4-5 L N
L PE, N PE 2 kV 4kV Criterion A Criterion A
Surge voltage on output EN 61000-4-5 + -
+/- PE 1kV 2 kV Criterion A Criterion A
Surge voltage on Signals EN 61000-4-5 DC OK signal PE 1kV Criterion A
Conducted disturbance EN 61000-4-6 0.15…80 MHz 20V Criterion A
Mains voltage dips EN 61000-4-11
0% of 100V AC
40% of 100V AC
70% of 100V AC
0% of 200V AC
40% of 200V AC
70% of 200V AC
0V AC, 20 ms
40V AC, 200 ms
70V AC, 500 ms
0V AC, 20 ms
80V AC, 200 ms
140V AC, 500 ms
Criterion A
Criterion C
Criterion C
Criterion A
Criterion A
Criterion A
Voltage interruptions EN 61000-4-11 0% of 200V AC (=0V) 5000 ms Criterion C
Voltage sags SEMI F47 0706 80% of 120V AC (96V AC) 70% of 120V AC (84V AC)
50% of 120V AC (60V AC)
1000 ms
500 ms
200 ms
Criterion A
Criterion A
Criterion A
Powerful transients VDE 0160 Over entire load range 750V, 0.3 ms Criterion A
(1) Criteria:
A: Power supply shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible.Device may shut down and restarts by itself. No damage or hazards for the power supply will occur.
EMC Emission According to the generic standards EN 61000-6-3 and EN 61000-6-4.
Conducted emission input lines EN 55011, EN 55015, EN 55022, FCC Part
15, CISPR 11, CISPR 22 Class B
Conducted emission output lines IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 5dB higher than average limits for DC power port according to
EN 61000-6-3(1)
Radiatedemission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 Class A equipment: fulfilled
Class C equipment: fulfilled in the load range from 8 to 24 A
Voltage fluctuations, flicker EN 61000-3-3 Fulfilled, tested with constant current loads, non-pulsing
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.
(1) Restrictions apply for applications in residential, commercial and light-industrial environments, where local DC power networks according to EN 61000-6-3 are involved. No restrictions for
all kinds of industrial applications.
Switching Frequencies
PFC converter 100 kHz Fixed frequency
Mainconverter 80…140 kHz Output load dependent
Auxiliary converter 60 kHz Fixed frequency

20 Rockwell Automation Publication 1606-RM108A-EN-P - August 2020
Redundancy Power Supply —24V, 20 A, 480 W, Single Phase
Environment
Attribute Value Notes
Operational temperature -40…+70 °C (-40…158°F) Operational temperature is the same as the ambient or surrounding temperature and is defined as the air
temperature 2 cm below the unit.
Storage temperature -40…+85°C (-40…185°F) For storage and transportation
Output de-rating
0.27 A/°C
0.5 A/°C
1.25 A/1000 m or 5°C/1000 m
0.75 A/-5 kPa or 3°C/-5 kPa
+45…60 °C (+113…140 °F)
+60…70 °C (140…158 °F) For altitudes >2000 m (6560ft)
See Figure 23. For atmospheric pressures <80 kPa,
See Figure 23
The de-rating is not hardware controlled. The customer has to take this into consideration to stay below the de-rated current limits in order not to overload the unit.
Humidity 5 to 95% r.hr. According to IEC 60068-2-30 Do not energize while
condensation is present.
Atmospheric pressure 110…47 kPa See Figure 23
Altitude Up to 6000 m (20,000 ft)
Over-voltage category
III According to IEC 60664-1 for altitudes up to 2000m
II According to IEC 60664-1, for altitudes between 2000 and 6000 m and atmospheric pressures from 80…47
kPa.
Degree of pollution 2 According to IEC 62477-1, not conductive
Vibration sinusoidal 2…17.8 Hz: ±1.6mm; 17.8…500 Hz: 2g 2 hours/axis According to IEC 60068-2-6
Shock
30g 6ms, 20g 11ms 3 bumps per direction, 18 bumps in
total According to IEC 60068-2-27
Shock and vibration are tested in combination with DIN-Rails according to EN 60715 with a height of 15mm and a
thickness of 1.3mm and standard orientation.
LABS compatibility As a rule, only non-silicon precipitating materials are used. The unit conforms to the LABS criteria and is suitable
for use in paint shops.
Corrosive gases Tested according to ISA-71.04-1985, Severity Level G3 and IEC 60068-2-60 Test Ke Method 4 for a service life of
minimum 10 years in these environments.
Audible noise Some audible noise may be emitted from the power supply during no load, overload or short circuit.
Figure 22 - Output Current Versus Ambient Temperature Figure 23 - Output Current Versus Altitude
Allowed Output Current
0
-40 020 40 70°C
4A
8A
12A
16A
20A
24A
60
B
A
Ambient Temperature
A... continuous
B... short term (max. 5s)
2000m 4000m 6000m
4 A
8 A
12 A
16 A
20 A
24 A
Altitude
Allowed Output Current
B
C
A... Tamb < 60°C
B... Tamb < 50°C
C... Tamb < 45°C
D... Shortterm
A
D
AP
*)
80kPa 62kPa 47kPa110kPa
0m
*) Atmospheric pressure