Rockwell Automation 1606-XLS960F Bedienungsanleitung

Reference Manual Original Instructions

Switched Mode Power Supply

Catalog Number 1606-XLS960F

2Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Switched Mode Power Supply 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.

These labels may also be on or inside the equipment to provide specific precautions.

The following icon may appear in the text of this document.

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).

Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 1

Table of Contents

Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Input Inrush Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

Shutdown Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

Lifetime Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Mean Time Between Failure (MTBF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Certifications and Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . 17

Approximate Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Repetitive Pulse Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

Back-feeding Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Charging of Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Output Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

External Input Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Parallel Use to Increase Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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

Daisy Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

Operation on Two Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Use in a Tightly Sealed Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Table of Contents

Notes:

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 3

Terminology and

Abbreviations

All values in this document are specified under the following conditions unless

otherwise noted:

• 48V, 20 A, 230V AC input voltage

• 25 °C (77 °F) ambient temperature

• After a 5 minutes run-in time

Product Overview

Product features include:

• AC 100…240V wide-range input

• Width 125 mm (4.9 in.)

• 95.0% full load and excellent partial load efficiencies

• 50% BonusPower, 1440 W for up to 4 s

Terms Descriptions

PE The abbreviation for Protective Earth. PE has the same meaning as the symbol.

The symbol for Protective Earth.

Earth, Ground This document uses the term “earth”, which is the same as the U.S. term “ground”.

AC 230V A value that is displayed with the AC or DC before the value represents a nominal

voltage with standard tolerances included. For example, DC 12V describes a 12V

battery, no matter if it is full (13.7V) or flat (10V).

230V AC A value with the unit (V AC or V DC) at the end is a momentary value without any

additional tolerances included.

50 Hz versus 60 Hz Unless otherwise stated, AC 230V parameters are valid at 50 Hz mains frequency.

Nom Indicates a nominal value.

Typ Indicates a typical value.

—A dash alone in a table cell indicates that there is no information to be included in that

cell.

Figure 1 - 1606-XLS960F

The 1606-XLS960F is a high-efficiency

DIN rail power supply unit, which uses

a synchronous rectification, a

bridgeless PFC circuit, and additional

design details to achieve a compact

size.

Large power reserves of 150% and built-

in large sized output capacitors

support the starting of heavy loads,

such as DC motors or capacitive loads.

Therefore, a unit from a lower wattage

class can be used.

The 1606-XLS960F power supply unit

has a high immunity to transients and

power surges, and has low

electromagnetic emissions.

The integrated input fuse, near-zero

input inrush current, and diagnostic

indicators simplify installation and

usage.

The 1606-XLS960F power supply unit

features a large international approval

package for various applications.

4Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

• 55 A high peak current for 10 ms, for easy fuse tripping

• Safe HiccupPLUS overload mode

• Active PFC (Power Factor Correction)

• Negligible low-input inrush current surge

• Full power -25…+60 °C (-13…+140 °F)

• Current sharing feature for parallel use

• Remote control of output voltage

•DC-OKrelaycontact

•Shut-downinput

• ATEX and IECEx approved

Specifications

Catalog Numbers

Attributes Values Notes

Output voltage DC 48V Nominal

Adjustment range 48…54V DC —

Output current 20…17.8 A Continuous

30…26.7 A Short term (4 s)

Output power 960 W Continuous

1440 W Short term (4 s)

Output ripple <150 mVpp 20 Hz…20 MHz

Input voltage AC 100…240V -15/+10%

Mains frequency 50…60 Hz ±6%

AC input current 8.6/4.5 A At 120/230V AC

Power factor 0.99/0.99 At 120/230V AC

AC inrush current 17/11 A peak At 120/230V AC

Efficiency 93.9/95.0% At 120/230V AC

Losses 62.4/50.5 W At 120/230V AC

Temperature range -25…+70 °C

(-13…+158 °F) Operational

Derating 24 W/1 °C

(24 W/1.8 °F) (1)

(1) Between 85…90V AC. See Environment on page 15.

60…70 °C (140…158 °F)

Hold-up time 27/27 ms At 120/230V AC

Dimensions 125 x 124 x 127 mm

(4.92 x 4.88 x 5 in.) W x H x D

Weight 1900 g (4.2 lb) —

Cat. No. Descriptions

1606-XLS960F Power supply

(48…54V standard unit)

1606-XLC Wall mount bracket

1606-XLSBUFFER48 Buffer unit

1606-XLSRED40HF Redundancy module

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 5

AC Input

Attributes Values Notes

Input voltage Nom AC 100…240V Suitable for TN, TT, and IT mains networks

Input voltage range

— 90…264V AC Continuous operation

—85…90VAC

<55 °C (131 °F) ambient temperature

continuously allowed

>55 °C (131 °F) ambient temperature short term

or with output derating, see Figure 27 on page 16

— 60…85V AC Full power for up to 200 ms

— 0…85V AC No damage to the unit

— 264…300V AC <500 ms

Allowed voltage L or N to earth Max 300V AC Continuous, IEC 62103

Input frequency Nom 50…60Hz ±6%

Turn-on voltage Typ 80V AC Steady-state value, load independent, see

Figure 2

Shut-down voltage Typ 74V AC Steady-state value, load independent, see

Figure 2

External input protection — See External Input Protection on page 24.

Attributes Values Notes

AC 100V AC 120V AC 230V

Input current Typ 10.5 A 8.6 A 4.5 A At 48V, 20 A, see Figure 4

Power factor (1)

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

Typ 0.99 0.99 0.99 At 48V, 20 A, see Figure 5

Crest factor (2)

(2) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.

Typ 1.47 1.53 1.56 At 48V, 20 A

Startup delay Typ 800 ms 750 ms 700 ms See Figure 3

Rise time Typ 16 ms 16 ms 16 ms At 48V, 20 A, resistive load, 0 mF, see Figure 3

Typ 55 ms 55 ms 55 ms At 48V, 20 A, resistive load, 20 mF, see Figure 3

Turn-on overshoot Max 100 mV 100 mV 100 mV See Figure 3

Figure 2 - Input Voltage Range Figure 3 - Turn-on Behavior, Definitions

Figure 4 - Input Current Versus Output Load at 48V Figure 5 - Power Factor Versus Output Load at 48V

Turn-on

Rated Input Range

VIN

POUT

74 264V AC

Shut-down

Start-up

Delay Rise

Time

Overshoot

-5%

Output

Voltage

Input

Voltage

20 A

2 4 6 8 10 12 14 16 18

12 A

Input Current, Typ

A: 100 V AC

B: 120 V AC

C: 230 V AC

Output Current

Power Factor, Typ

2 4 6 8 10 12 14 16 18 20 A

0.75

0.8

0.85

0.9

0.95

1.0

Output Current

A: 100V AC

B: 120V AC

C: 230V AC

6Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Input Inrush Current The power supply unit 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 smaller than the steady state input current.

DC Input Do not operate this power supply unit with DC-input voltage. Use the

1606-XLE480FP-D unit instead. It can be necessary to run two

1606-XLE480EP-D units in parallel.

Output

Attributes Values Notes

AC 100V AC 120V AC 230V

Inrush current (1)

(1) The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.

Max 25 Apeak 22 Apeak 16 Apeak

Over the entire temperature range; mains

interruptions >1 s

Typ 20 Apeak 17 Apeak 11 Apeak

Inrush energy Max 5 A2s5A

2s5A

Figure 6 - Typical Turn-on Behavior at Nominal

Load - 25 °C (77 °F) Ambient

Temperature

Input Current 5 A/DIV

Input

Output 48V DC

230V AC

100 ms/DIV

Attributes Values Notes

Output voltage Nom DC 48V —

Adjustment range — 48…54V DC Guaranteed

Max 56V DC (1) At clockwise end position of potentiometer

Factory setting

Typ 48.0V DC ±0.2%, at full load, cold unit, in Single Use mode

Typ 46.0V DC ±0.5%, at full load, cold unit, in Parallel Use mode

Typ 48.0V DC At no load, cold unit, in Parallel Use mode

Line regulation Max 10 mV 85…300V AC

Load regulation

Max 50 mV In Single Use mode: static value, 0 A 20 A, see Figure 7 on

page 7

Typ 2000 mV In Parallel Use mode: static value, 0 A 20 A, see Figure 8 on

page 7

Ripple and noise voltage Max 150 mVpp 20 Hz…20 MHz, 50 Ω

Output current

Nom 20 A Continuously available at 48V, see Figure 7 on page 7 and Figure 8

on page 7

Nom 17.8 A Continuously available at 54V, see Figure 7 on page 7 and Figure 8

on page 7

Nom 30 A Short-term available BonusPower (2), at 48V for typical 4 s, see

Figure 7 on page 7 and Figure 8 on page 7

Nom 26.7 A Short-term available BonusPower (2), at 54V for typical 4 s, see

Figure 7 on page 7 and Figure 8 on page 7

Typ 55 A

Up to 10 ms, output voltage stays above 40V, see Figure 10 on

page 7. This peak current is available once every second. See Peak

Current Capability on page 22.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 7

Output power Nom 960 W Continuously available at 48…54V

Nom 1440 W (2) Short-term available BonusPower (2) at 48…54V

BonusPower time Typ 4 s Duration until the output voltage dips, see Figure 11 on page 8

BonusPower recovery time Typ 7 s Overload free time to reset power manager, see Figure 12 on

page 8

Overload behavior —Continuous current Output voltage >40V DC, see Figure 7

—HiccupPLUS mode (3) Output voltage <40V DC, see Figure 7

Short-circuit current

Min 30 A (4) Load impedance 50 mΩ, see Figure 9

Max 35 A (4) Load impedance 50 mΩ, see Figure 9

Max 11.5 A Average (RMS) current, load impedance 50 mΩ, see Figure 9

Typ 62 A Up to 10 ms, load impedance <10 mΩ, see Figure 10

Output capacitance Typ 3700 µF Included in the power supply

(1) Max output voltage that can occur at the clockwise end position of the potentiometer, due to tolerances. It is not a

guaranteed value that can be achieved. The typical value is about 55V.

(2) BonusPower, short-term power capability (up to typ 4 s): The power supply unit 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. This BonusPower is repeatedly available. See Repetitive Pulse Loading on page 20. If the power supply unit is

loaded longer with the BonusPower than shown in Figure 11 on page 8, the maximum output power is automatically reduced

to 960 W. If the power requirement is continuously above 960 W and the voltage falls below approximately 40V (due to the

current regulating mode at overload), the unit shuts off and makes periodical restart attempts. This behavior is called

HiccupPLUS mode, see Figure 9. If the voltage is above 40V, the unit continuously delivers current.

(3) For up to 4 s of overloading, the power supply unit delivers continuous output current. After overloading, the output power

reduces to nearly zero for approximately 17 s before a new start attempt is automatically performed. If the overload is

cleared, the device operates normally. If the overload still exists, the output current is delivered for 2…4 s (depending on the

overload) again followed by a 17 s rest time. This cycle repeats as long as the overload exists. During the off-period, a small

rest voltage and a rest current are present on the output.

(4) Discharge current of output capacitors is not included.

Attributes Values Notes

Figure 7 - Output Voltage Versus Output Current in

Single Use Mode, Typ Figure 8 - Output Voltage Versus Output Current in

Parallel Use Mode, Typ

Figure 9 - Short-circuit on Output, HiccupPLUS Mode,

Typ Figure 10 - Dynamic Overcurrent Capability, Typ

Output Voltage

0 5 10 15 20

56V

25 35 A

Output Current

Adjustment Range

Hiccup

Mode

Short-term (4 s)

then switching

to curve

Continuously

available

A B

Output Voltage (Parallel Use, Typ)

42V 01020

44V

46V

48V

56V

50V

52V

54V

30 A

25155

Adjustment Range

Factory

setting

Continuously

allowed Bonus

Power

Output Current

Output

Current

35 A

17 s 17 s

17 s 2 s 2 s

2 s

Short -circuit Normal

operation

Normal

operation

Output Voltage

(dynamic behavior, < 10 ms)

54V

70 A30 6010 20 40 50

Adjustment

Range

Output Current

8Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

The BonusPower is available when power comes on and after the end of an

output short circuit or output overload.

Hold-up Time

Figure 11 - Bonus Time Versus Output Power Figure 12 - BonusPower Recovery Time

max

Bonus Time

100 120 130 140 150 170%

5 s

110 160

Output Power

min

Power

Demand

100%

Limitation by

Power Manager

Output

Voltage

Bonus Power disabled

Bonus

Time

Recovery Time

Figure 13 - BonusPower After Input Turn-on Figure 14 - 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%

Attributes Values Notes

AC 100V AC 120V AC 230V

Hold-up Time

Typ 54 ms 54 ms 54 ms At 48V, 10 A, see Figure 15

Min 45 ms 45 ms 45 ms

Typ 27 ms 27 ms 27 ms At 48V, 20 A, see Figure 15

Min 23 ms 23 ms 23 ms

Figure 15 - Hold-up Time Versus Input Voltage Figure 16 - Shutdown Behavior Definitions

60 ms

90 120 155 190 230V AC

Input Voltage

Hold-up Time

48V, 20 A, typ

48V, 10 A, min

48V, 10 A, typ

48V, 20 A, min

-5%

Hold-up Time

Zero Transition

Output

Voltage

Input

Voltage

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