Allen-Bradley 1606-XLS960E-3 Bedienungsanleitung

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number:

1606-XLS960E-3

Index

•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.

• AC 400V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)

included. E.g.: DC 12V describes a 12V battery whether it is full (13.7V) or flat (10V)

• 400Vac—A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.

• 50Hz vs. 60Hz—As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.

•may—A key word indicating flexibility of choice with no implied preference.

•shall—A key word indicating a mandatory requirement.

•should—A key word indicating flexibility of choice with a strongly preferred implementation.

Terminology and Abbreviations

egaPegaP

1. Intended Use .......................................................3

2. Installation Requirements...................................3

3. AC-Input...............................................................4

4. Input Inrush Current ...........................................5

5. DC-Input...............................................................5

6.Output .................................................................6

7. Hold-up Time.......................................................8

8. DC-OK Relay Contact ..........................................9

9.Shut-down Input .................................................9

10. Remote Control of Output Voltage .................10

11. Internal Data Logging.......................................10

12. Efciency and Power Losses..............................11

13. Reliability...........................................................12

14. Functional Diagram...........................................12

15. Terminals and Wiring........................................13

16.Front Side and User Elements...........................14

17. EMC....................................................................15

18. Environment ......................................................16

19.Protection Features ...........................................17

20. Safety Features..................................................17

21. Dielectric Strength ............................................18

22. Certications .................................................. 18

23. Physical Dimensions and Weight .................... 19

24. Accessories ....................................................... 20

24.1. Wall mountingbracket - 1606-XLC......... 20

24.2. Buffer module - 1606-XLSBUFFER24........20

24.3. 1606-XLSRED80 - Redundancy Modules...20

25. Application Notes.............................................21

25.1. Repetitive Pulse Loading..........................21

25.2. Peak Current Capability ...........................22

25.3. External Input Protection.........................22

25.4. Usingonly 2 Legs of a 3-Phase System ....23

25.5. ChargingBatteries ...............................24

25.6.Output Circuit Breakers............................24

25.7. Parallel Use to Increase Output Power....25

25.8. Parallel Use for Redundancy ....................25

25.9.Series Operation .......................................26

25.10. Inductive and Capacitive Loads................26

25.11. Back-feedingLoads ..................................26

25.12. Use in a Tightly Sealed Enclosure ............26

25.13. MountingOrientations ............................27

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

Bulletin 1606 Switched Mode Power Supplies

Power Supply

3AC 380-480V Wide-range Input

Three Input Fuses Included

Width only 110mm, Weight only 1.5kg

95.3% Full Load and Excellent Partial Load Efciencies

50% BonusPower, 1440W for up to 4s

110A Peak Current for 25ms for Easy Fuse Tripping

Active PFC (Power Factor Correction)

Active Filteringof Input Transients

Negligible Low Input Inrush Current Surge

Full Power Between -25°C and +60°C

Current SharingFeature for Parallel Use

Internal Data Loggingfor TroubleshootingIncluded.

Remote Control of Output Voltage

DC-OK Relay Contact

Shut-down Input

3 Year Warranty

Description

The most outstandingfeatures of the 1606-XLS960E-3

DIN rail power supply are its extremely high

efciencies and its small size, which are achieved by a

synchronous rectication and other technological

breakthroughs.

Large power reserves of 150% support the startingof

heavy loads such as DC motors or capacitive loads. In

many cases this allows the use of a unit from a lower

wattage class which saves space and money.

High immunity to transients and power surges as well as

low electromagnetic emission allow the use of these

power supplies in nearly every environment.

The integrated output power manager, the three input

fuses and near zero input inrush current make

installation and usage simple. Diagnostics are easy due

to the DC-ok relay, a green DC-OK LED and the red

overload LED.

A large international approval package for a variety of

applications makes this unit suitable for nearly every

application.

Specication Quick Reference

Output voltage DC 24V nominal

Adjustment range 24 - 28V

Output current 40 – 34.3A continuous

60 – 51.5A short term (4s)

Output power 960W continuous

1440W short term (4s)

Output ripple < 100mVpp 20Hz to 20MHz

Input voltage 3AC 380-480V -15%/+20%

Mains frequency 50-60Hz ±6%

AC Input current 1.65 / 1.35A at 3x400 / 480Vac

Power factor 0.88 / 0.90 at 3x400 / 480Vac

AC Inrush current typ. 4.5A peak

Efciency 95.3 / 95.2% at 3x400 / 480Vac

Losses 47.3 / 48.4W at 3x400 / 480Vac

Temperature range -25°C to +70°C operational

Derating24W/°C +60 to +70°C

Hold-up time typ. 25 / 25ms at 3x400 / 480Vac

Dimensions 110x124x127mm WxHxD

CatalogNumbers

Power Supply 1606-XLS960E-3 24-28V Standard unit

Accessories 1606-XLC Wall mount bracket

1606-XLSBUFFER24 Buffer unit

1606-XLSRED80 Redundancy module

Certications

IND. CONT. E

UL 508

UL 60950-1

Marine

EMC, LVD, RoHS

Weight 1500g/ 3.3 lb

C-Tick

GOST R

Marine RINA

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 3

Bulletin 1606 Switched Mode Power Supplies

1. 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 equipment where malfunction may cause severe personal injury or threaten human life.

•This device is designed for use in non-hazardous, ordinary or unclassified locations.

2. 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 output and input terminals are located on the bottom of the unit. For other mounting orientations, see

derating requirements in this document. Refer to section 25.13.

•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 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

4Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

Bulletin 1606 Switched Mode Power Supplies

3. AC-Input

AC input nom. 3AC 380-480V suitable for TN, TT and IT mains networks,

grounding of one phase is allowed except in UL 508

applications

AC input range min. 3x 323-576Vac continuous operation

Allowed voltage L to earth max. 576Vac continuous, IEC 60664-1

Input frequency nom. 50–60Hz ±6%

Turn-on voltage typ. 3x 305Vac steady-state value, load independent, see Fig. 3-1

Shut-down voltage typ. 3x 275Vac steady-state value, load independent, see Fig. 3-1

3AC 400V 3AC 480V

Input current typ. 1.65A 1.35A at 24V, 40A, symmetrical phase voltages,

see Fig. 3-3

Power factor*) typ. 0.88 0.90 at 24V, 40A, see Fig. 3-4

Start-up delay typ. 500ms 600ms see Fig. 3-2

Rise time typ. 35ms 35ms at 24V, 40A, resistive load, 0mF see Fig. 3-2

typ. 40ms 40ms at 24V, 40A, resistive load, 40mF see Fig. 3-2

Turn-on overshoot max. 500mV 500mV see Fig. 3-2

*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.

Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, denitions

Turn-on

323V

Rated input range

OUT

275V 576Vac

Shut-down

305V

Start-up

delay Rise

Time

Overshoot

- 5%

Output

Voltage

Input

Voltage

L1 L2 L3

Fig. 3-3 Input current vs. output load at 24V Fig. 3-4 Power factor vs. output load at 24V

40A

4 8 12 16 20 24 28 32 36

0.2

0.4

0.6

0.8

1.0

1.2

1.6A

Input Current, typ.

1.4

Output Current

A: 3x 400Vac

B: 3x 480Vac

Power Factor, typ.

4 8 12 16 20 24 28 32 36 40A

0.70

0.75

0.80

0.85

0.90

0.95

Output Current

A: 3x 400Vac

B: 3x 480Vac

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 5

Bulletin 1606 Switched Mode Power Supplies

4. Input Inrush Current

The power supply is equipped with an active inrush current limitation circuit, which limits the input inrush current

after turn-on to a negligible low value. The input current is usually smaller than the steady state input current.

3AC 400V 3AC 480V

Inrush current*) max. 6Apeak 6Apeak over entire temperature range

typ. 4.5Apeak 4.5Apeak over entire temperature range

Inrush energy max. 1.5A2s 1.5A2s over entire temperature range

Inrush delay typ. 500ms 600ms

*) The charging current into EMI suppression capacitors is disregarded in the rst microseconds after switch-on.

Fig. 4-1 Typical turn-on behaviour at nominal

load and 25°C ambient temperature

Input

Output

Input Current 2A/DIV

3x400Vac

24Vdc

100ms/DIV

5. DC-Input

Do not operate this power supply with DC input voltage.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

6Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

Bulletin 1606 Switched Mode Power Supplies

6. Output

Output voltage nom. 24V

Adjustment range min. 24-28V guaranteed

max. 30V***) at clockwise end position of potentiometer

Factory setting typ. 24.1V ±0.2%, at full load, cold unit, in “single use” mode

typ. 24.1V ±0.2%, at full load, cold unit, in “parallel use” mode

typ. 25.1V at no load, cold unit, in “parallel use” mode

Line regulation max. 10mV 3x323-576Vac

Load regulation max. 50mV in “single use” mode: static value, 0A 40A, see Fig. 6-1

typ. 1000mV in “parallel use” mode: static value, 0A 40A,

see Fig. 6-2

Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm

Output current nom. 40A continuously available at 24V, see Fig. 6-1 and Fig. 6-2

nom. 34.3A continuously available at 28V, see Fig. 6-1 and Fig. 6-2

nom. 60A short term (4s) available BonusPower*) , at 24V,

see Fig. 6-1, Fig. 6-2 and Fig. 6-4

nom. 51.5A short term (4s) available BonusPower*) , at 28V,

see Fig. 6-1, Fig. 6-2 and Fig. 6-4

typ. 110A up to 25ms, output voltage stays above 20V, see Fig.

6-4. This peak current is available once every second.

See section 25.2 for more peak current measurements.

Output power nom. 960W continuously available at 24-28V

nom. 1440W*) short term available BonusPower*) at 24-28V

BonusPower time typ. 4s duration until the output voltage dips, see Fig. 6-3

BonusPower recovery time typ. 7s overload free time to reset power manager, see Fig. 6-5

Overload behavior cont. current see Fig. 6-1

Short-circuit current**) min. 40A continuous, load impedance 25mOhm, see Fig. 6-1

max. 44A continuous, load impedance 25mOhm, see Fig. 6-1

min. 60A short-term (4s), load impedance 25mOhm, see Fig. 6-1

max. 68A short-term (4s), load impedance 25mOhm, see Fig. 6-1

typ. 46A continuous, load impedance <10mOhm

max. 51A continuous, load impedance <10mOhm

Output capacitance typ. 10 200μF included in the power supply

*) BonusPower, short term power capability (up to typ. 4s)

The power supply is designed to support loads with a higher short-term power requirement without damage or shutdown. The short-

term duration is hardware-controlled by an output power manager. BonusPower is repeatedly available. Detailed information

can be found in section 25.1. If the power supply is loaded longer with the BonusPower than shown in the bonus-time diagram (see

Fig. 6-3), the max. output power is automatically reduced to 960W.

**) Discharge current of output capacitors is not included.

***) This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. There is no

guarantee that this value can be achieved. The typical value is about 28.5V.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 7

Bulletin 1606 Switched Mode Power Supplies

Fig. 6-1 Output voltage vs. output current in

“single use” mode, typ.

Fig. 6-2 Output voltage vs. output current in

“parallel use” mode, typ.

Output Voltage

010203040

28V

6050 70A

Output Current

Adjustment Range

A B

Short-term (4s)

BonusPower

Continuously

available

Output Voltage

(Parallel Use, typ.)

22V 02040

23V

24V

25V

29V

26V

27V

28V

60A503010

Adjustment Range

Output Current

Factory

setting

Short-term (4s)

BonusPower

Continuously

available

Fig. 6-3 Bonus time vs. output power Fig. 6-4 Dynamic overcurrent capability, typ.

max.

Bonus Time

100 120 130 140 150 170%

110 160

Output Power

min.

Output Voltage

(dynamic behavior, < 25ms)

28V

150

6030 90 12015 45 75 105 135

Adjustment

Range

Output Current

Fig. 6-5 BonusPower recovery time

Power

Demand

100%

Limitation by

Power Manager

Output

Voltage

Bonus Power disabled

Bonus

Time

Recovery Time

BonusPower is available as soon as power comes on and after the end of an output short circuit or overload.

Fig. 6-6 BonusPower after input turn-on Fig. 6-7 BonusPower after output short

100%

Output

Voltage

Input

Voltage

Bonus

Power

Output

Power

150%

Short of

Output

100%

Output

Voltage

Bonus

Power

Output

Power

150%

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

8Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time

3AC 400V*) 3AC 480V*)

Hold-up Time typ. 50ms 50ms at 24V, 20A, see Fig. 7-1

min. 40ms 40ms at 24V, 20A, see Fig. 7-1

typ. 25ms 25ms at 24V, 40A, see Fig. 7-1

min. 20ms 20ms at 24V, 40A, see Fig. 7-1

*) Curves and gures for operation on only 2 legs of a 3-phase system can be found in section 25-4.

Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, denitions

50ms

320 360 400 440 3x480Vac

Input Voltage

Hold-up Time

24V, 20A, typ.

24V,40A,typ.

24V, 20A, min.

24V,40A,min.

- 5%

Hold-up Time

Output

Voltage

Input

Voltage

L1 L2 L3

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 9

Bulletin 1606 Switched Mode Power Supplies

8. DC OK Relay Contact

This feature monitors the output voltage, which is produced by the power supply itself. It is independent of a back-fed

voltage from a unit connected in parallel to the power supply output.

Contact closes As soon as the output voltage reaches 90% of the adjusted output voltage.

Contact opens As soon as the output voltage dips more than 10% below the adjusted output voltage.

Short dips will be extended to a signal length of 250ms. Dips shorter than 1ms will be ignored.

Contact re-closes As soon as the output voltage exceeds 90% of the adjusted voltage.

Contact ratings max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load

min 1mA at 5Vdc min. permissible load

Isolation voltage See Dielectric Strength table in section 21.

Fig. 8-1 DC-ok relay contact behavior

250ms

0.9* V

ADJ

1ms

10%

open

OUT

= V

ADJ

openclosed closed

1ms

9. Shut-down Input

This feature allows a switch-off of the output of the power supply with a signal switch or an external voltage. The

shut-down function ramps down and has no safety feature included. The shut-down occurs immediately while the

turn-on is delayed up to 350ms. In a shut-down condition, the output voltage is <2V and the output power is <0.5W.

The voltage between different minus pole output terminals must be below 1V when units are connected in parallel. In

a series operation of multiple power supplies only wiring option “A” with individual signal switches is allowed.

Please note that option C requires a current sink capability of the voltage source. Do not use a blocking diode.

Fig. 9-1 Activation of the shut-down input

OFF: linked

ON : open

Shut-

down

Input

Option A:

OFF: I > 0.3mA

ON : I < 0.1mA

Shut-

down

Input

Option B:

(via open

collector) I

n.c.

OFF: U < 1V

ON : U = 4 -29V

Shut-

down

Input

Option C:

(via external

voltage

n.c.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

10 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014

Bulletin 1606 Switched Mode Power Supplies

10. Remote Control of Output Voltage

The shut-down input can also be used to remotely adjust the output voltage between typically 14Vdc and 28Vdc. All

other functions of shut-down input remain the same.

The control voltage is referenced to the main ground (negative output voltage).

Fig. 10-1 Remote control of the output

voltage

Fig. 10-2 Applying the control voltage

Output Voltage

12V

0V 5V 15V

14V

16V

18V

28V

20V

22V

26V

Control Voltage

24V

10V 20V

Potentiometer:

set to 28V

set to 24V

Control

Voltage

Shut-

down

Input

n.c.

Instructions:

1. Set the unit into “Single Use” mode.

2. Set the output voltage adjustment (24-28V) to the maximum desired voltage.

3. Apply a control voltage to reduce the output voltage.

11. Internal Data Logging

A protected microcontroller inside the power supply acquires and stores operating data during the life of the unit. The

data can be downloaded with a small tool and special software by Rockwell Automation service and repair personnel,

even if the unit is faulty. Having the data facilitates troubleshooting. Knowledge of the events occuring just before a

failure allows for a more accurate analysis of the problem.

The data will be acquired with a xed sampling rate unless the peak detectors trigger due to an abnormal condition.

In such cases, the abnormal condition is properly captured.

Acquired data:

- Family name of unit (1606-XLS), revision of rmware

- Operational hours and expired portion of lifetime

- Operational data; latest 60 values with timestamps of the last 158 minutes of:

Number of over-voltage transients,

Average input voltage,

Peak input voltage,

Inside temperature,

Overloads > 2s,

Missing of one input phase (minimum output load required)

- Failure data; various errors such as:

Internal errors,

Over-temperature shut-down,

OVP,

Long-term overloads,

Remarkable temperatures inside the unit,

….

- Number of turn-on sequences and overvoltage transients

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