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.