Rockwell Automation 1606-XLE96B-2 Bedienungsanleitung

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLE96B-2

Index

egaPegaP

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

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

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

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

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

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

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

8. Efciency and Power Losses................................8

9. Functional Diagram.............................................9

10. Front Side and User Elements.............................9

11. Terminals and Wiring........................................10

12. Reliability ...........................................................10

13. EMC ....................................................................11

14. Environment ......................................................12

15. Protection Features ...........................................13

16. Safety Features ..................................................13

17. Dielectric Strength ............................................13

18. Certications .....................................................14

19. Environmental Compliance ............................. 14

20. Physical Dimensions and Weight ..................... 15

21. Accessories ........................................................ 16

22. Application Notes ............................................. 17

22.1. Peak Current Capability ...........................17

22.2. Back-feedingLoads ..................................17

22.3. ChargingBatteries ...............................18

22.4. External Input Protection .........................18

22.5. Inductive and Capacitive Loads ................18

22.6. Parallel Use to Increase Output Power ....19

22.7. Parallel Use for Redundancy ....................19

22.8. Daisy Chainingof Outputs .......................20

22.9. Series Operation .......................................20

22.10. Use in a Tightly Sealed Enclosure ............20

22.11. MountingOrientations ............................21

•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 230V—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).

• 230Vac—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

2Rockwell Automation Publication 1606-RM030A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

Power Supply

AC 380-480V Wide-range Input

Input Fuses Already Included

Requires only Two Legs of a 3-Phase System

Width only 40mm

Efciency up to 85.8%

Input -Transient BlankingCircuit Included

Minimal Inrush Current Surge

Full Power Between -25°C and +60°C

3 Year Warranty

Description

Our power supplies are cost optimized without

compromisingquality, reliability or performance. The

most outstandingfeatures of the 1606-XLE96B-2 are its

high efciency, electronic inrush current limitation, active

input transient lter and wide operational temperature

range. It distinguishes itself by its small size and other

technological design breakthroughs.

The 1606-XLE96B-2 includes all the essential basic functions.

It utilizes only two legs of a three-phase system which saves

on wiringand installation costs. Furthermore, this concept

allows you to use a smaller unit without compromisingthe

size of the terminals. Due to the low power consumption,

an unbalancingof the individual phases is not expected.

Specication Quick Reference

Output voltage DC 12V

Adjustment range 12-15V

Output current 8 – 6.4A

Output power 96W

Output ripple < 100mVpp 20Hz to 20MHz

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

Mains frequency 50-60Hz ±6%

AC Input current 0.64 / 0.56A at 400 / 480Vac

Power factor 0.44 / 0.42 at 400 / 480Vac

AC Inrush current typ. 4A peak

Efciency 85.4 / 85.8% at 400 / 480Vac

Losses 16.4 / 15.9W at 400 / 480Vac

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

Derating2.5W/°C +60 to +70°C

Hold-up time typ. 33 / 58ms at 400 / 480Vac

Dimensions 40x124x117mm WxHxD

CatalogNumbers

Power Supply 1606-XLE96B-2 12-15V Standard unit

Accessories 1606-XLB Wall mount bracket

1606-XLSRED Decouplingmodule

Certication Marks

IND. CONT. EQ.

UL 508

UL 60950-1

Marine

EMC, LVD

Marine RINA

GOST R C-Tick

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM030A-EN-P — April 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 terminals are located on the bottom of the unit. For other mounting orientations, refer to derating

requirements 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 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

4Rockwell Automation Publication 1606-RM030A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

3. AC Input

AC input nom. AC 380-480V TN, TT, IT-mains networks,

grounding of one phase is allowed except for UL508

applications

AC input range 323-576Vac continuous operation,

no damage between 0 and 323Vac

576-700Vac for max. 1 second, occasional (not periodical)

Allowed Voltage Phase to Earth 500Vac IEC 62103

Input frequency nom. 50–60Hz ±6%

Turn-on voltage typ. 270Vac load independent, see Fig. 3-1

Shut-down voltage typ. 185Vac at 12V, 0A, see Fig. 3-1

typ. 215Vac at 12V, 4A

typ. 225Vac at 12V, 8A

AC 400V AC 480V

Input current typ. 0.64A 0.56A at 12V, 8A, see Fig. 3-3

Power factor *) typ. 0.44 0.42 at 12V, 8A, see Fig. 3-4

Start-up delay typ. 75ms 75ms see Fig. 3-2

Rise time typ. 50ms 50ms 0mF, 12V, 8A, see Fig. 3-2

typ. 85ms 85ms 8mF, 12V, 8A, see Fig. 3-2

Turn-on overshoot max. 100mV 100mV 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

185V 576V

Shut-down

260V 700Vac

< 1s

Start-up

delay Rise

Time

Overshoot

- 5%

Output

Voltage

Input

Voltage

Fig. 3-3 Input current vs. output load at 12V Fig. 3-4 Power factor vs. output load

01 34

0.1

0.2

0.4

0.5

0.6

0.8A

Input Current, typ.

Output Current

0.3

0.7

6 7

400Vac

480Vac

01 34

0.30

0.35

0.40

0.45

0.50

Power Factor, typ.

Output Current

480Vac

400Vac

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM030A-EN-P — April 2014 5

Bulletin 1606 Switched Mode Power Supplies

4. DC Input

DC input nom. DC 600V

DC input range 450-780Vdc continuous operation

Allowed Voltage Line to Earth max. 820Vdc IEC 62103

DC input current typ. 0.24A / 0.14A 450Vdc / 780Vdc, 12V, 8A

Turn-on voltage typ. 370Vdc steady state value

Shut-down voltage typ. 260Vdc steady state value

Fig. 4-1 Wiring for DC Input Instructions for DC use:

Load

Power Supply

Battery

FUSE

a) Use a battery or similar DC source.

For other sources, contact Rockwell Automation.

b) Connect +pole to L1 and –pole to L2.

c) Use appropriate external fuses in the + and – lines which

are suitable for the DC-voltage.

d) Connect the PE terminal to a earth wire or to the machine

ground.

e) Operation with DC is not included in the UL approval.

Additional testing might be necessary.

5. Input Inrush Current

An active inrush limitation circuit limits the input inrush current after turn-on of the input voltage and after short

input voltage interruptions.

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

AC 400V AC 480V

Inrush current max. 10Apeak 10Apeak -25°C to +70°C

typ. 4Apeak 4Apeak -25°C to +70°C

Inrush energy max. 0.5A2s 0.5A2s -25°C to +70°C

Fig. 5-1 Input inrush current, typical behavior

1 >

2 >

3 >

Output Voltage

Input Voltage

Input Current

20ms / DIV

Input: 400Vac

Output: 12V, 8A

Ambient: 25°C

Upper curve: Input current 2A / DIV

Middle curve: Input voltage 500V / DIV

Lower curve: Output voltage 5V / DIV

Time basis: 20ms / DIV

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

6Rockwell Automation Publication 1606-RM030A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

6. Output

Output voltage nom. 12V

Adjustment range min. 12-15V guaranteed

max. 16.0V at clockwise end position of potentiometer

Factory setting 12.0V ±0.2%, at full load, cold unit

Line regulation max. 10mV 323-576Vac

Load regulation max. 100mV static value, 0A 8A

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

Output capacitance typ. 5 200μF

Output current nom. 8A at 12V, see Fig. 6-1

nom. 6.4A at 15V, see Fig. 6-1

Output power nom. 96W

Short-circuit current min. 12A continuous current, short circuit impedance 100mOhm

max. 15A continuous current, short circuit impedance 100mOhm

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

typ.

Output Voltage

048

15V

012162 14

Adjustment

Range

Output Current

Peak current capability (up to several milliseconds)

The power supply can deliver a peak current which is higher than the specied short term current. This helps to start

current demanding loads or to safely operate subsequent circuit breakers.

The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be

discharged and causes a voltage dip on the output. Detailed curves can be found in section 23.1.

Peak current voltage dips typ. from 12V to 7V at 16A for 50ms, resistive load

typ. from 12V to 7V at 40A for 2ms, resistive load

typ. from 12V to 3.7V at 40A for 5ms, resistive load

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM030A-EN-P — April 2014 7

Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time

AC 400V AC 480V

Hold-up Time typ. 33ms 58ms at 12V, 8A, see Fig. 7-1

typ. 63ms 110ms at 12V, 4A, see Fig. 7-1

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

100ms

320 360 400 440 480Vac

Input Voltage

Hold-up Time at 12Vdc

4A,typ.

8A,min.

8A,typ.

4A,min.

- 5%

Hold-up Time

Zero Transition

Output

Voltage

Input

Voltage

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

8Rockwell Automation Publication 1606-RM030A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

8. Efciency and Power Losses

AC 400V AC 480V

Efciency typ. 85.4% 85.8% at 12V, 8A

Average efciency *) typ. 84.7% 84.1% 25% at 2A, 25% at 4A, 25% at 6A. 25% at 8A

Power losses typ. 1.5W 1.6W at 0A

8.4W 9.1W at 12V, 4A

typ. 16.4W 15.9W at 12V, 8A

*) The average efciency 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.

Fig. 8-1 Efciency vs. output current at 12V,

typ.

Fig. 8-2 Losses vs. output current at 12V,

typ.

Efciency

87%

245

Output Current

400Vac

480Vac

Power Losses

012 45 8A

18W

Output Current

400Vac

480Vac

Fig. 8-3 Efciency vs. input voltage at 12V,

8A, typ.

Fig. 8-4 Losses vs. input voltage at 12V, 8A,

typ.

Efciency

320 360 400 440 480

87%

84.5

85.5

86.5

86.0

85.0

84.0

520 560

Input Voltage Vac

Power Losses

320 360 400 440 480

18W

520 560

Input Voltage Vac

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM030A-EN-P — April 2014 9

Bulletin 1606 Switched Mode Power Supplies

9. Functional Diagram

Fig. 9-1 Functional diagram

OUT

Output

Over-

Voltage

Protection

PFC

Inductor

Inrush

Limiter

Transient

Filter

Input Fuses

Input Filter

Input

Rectier

Output

Voltage

Regulator

Power

Converter Output

Filter

Output

Power

Manager

Temper-

ature

Shut-

down DC-ok

LED

10. Front Side and User Elements

Fig. 10-1 Front side

AOutput Terminals

Screw terminals, dual terminals per pole

+ Positive output

-Negative (return) output

BInput Terminals

Screw terminals

L1, L2 Phase input

PE (Protective Earth) input

COutput voltage potentiometer

Open the ap to set the output voltage. Factory set: 12.0V

DDC-OK LED (green)

On when the voltage on the output terminals is > 10.5V

All parameters are specified at 12V, 2.5A,230Vac input, 25ªC ambient and after a 5 minutes run-in time, unless noted otherwise.

10 Rockwell Automation Publication 1606-RM030A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

11. Terminals and Wiring

Input Output

Type screw terminals screw terminals

Solid wire 0.5-6mm20.5-6mm2

Stranded wire 0.5-4mm20.5-4mm2

American Wire Gauge 20-10 AWG 20-10 AWG

Wire stripping length 7mm / 0.275inch 7mm / 0.275inch

Screwdriver 3.5mm slotted or

Pozidrive No 2

3.5mm slotted or

Pozidrive No 2

Recommended tightening torque 0.8Nm, 7lb.in 0.8Nm, 7lb.in

Instructions:

a) Use appropriate copper cables that are designed for an operating temperature of:

60°C for ambient up to 45°C and 75°C for ambient up to 60°C minimum.

b) Follow national installation codes and regulations!

c) Ensure that all strands of a stranded wire enter the terminal connection!

d) Up to two stranded wires with the same cross section are permitted in one connection point (except PE wire).

e) Do not use the unit without grounding it to the earth (PE).

f) Screws of unused terminal compartments should be securely tightened.

g) Ferrules are allowed, but not required.

12. Reliability

AC 400V AC 480V

Lifetime expectancy *) 51 000h 55 000h at 12V, 8A and 40°C

152 000h 147 000h at 12V, 4A and 40°C

144 000h 156 000h at 12V, 8A and 25°C

MTBF **) SN 29500, IEC 61709 983 000h 967 000h at 12V, 8A and 40°C

1 799 000h 1 769 000h at 12V, 8A and 25°C

MTBF **) MIL HDBK 217F 484 000h 455 000h at 12V, 8A and 40°C; Ground Benign GB40

636 000h 600 000h at 12V, 8A and 25°C; Ground Benign GB25

*) The Lifetime expectancy 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 specied in operational hours and is calculated according to the

capacitor’s manufacturer specication. The prediction model allows only a calculation of up to 15 years from date of shipment.

**) MTBF stands for Mean Time Between Failure, which 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.

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