Rockwell Automation Allen-Bradley 1606 Series Bedienungsanleitung

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLE960MX-3N

Index

1. Description ............................................................1

2. Specication Quick Reference.........................1

3. Catalog Numbers .................................................1

4. Certication Marks...............................................1

5. AC-Input..................................................................3

6. Input Inrush Current ......................................... 4

7. Output ................................................................... 5

8. Hold-up Time....................................................... 6

9. Eciency and Power Losses .......................... 7

10. Functional Diagram ........................................... 8

11. Front Side and User Elements........................ 8

12. Terminals and Wiring ........................................ 9

13. Reliability............................................................... 9

14. EMC....................................................................... 10

15. Environment ....................................................... 11

16. Protection Features ......................................... 12

17. Safety .................................................................... 12

18. Dielectric Strength ........................................... 12

19. Certications ..................................................... 13

20. Environmental Compliance ................................... 13

21. Physical Dimensions and Weight.......................... 14

22. Installation and Operating Instructions ............. 14

23. Accessories ................................................................... 15

24. Comparison between the 1606-XLE960MX-3N,

a Transformer and a Traditional Switched-mode

Power Supply.................................................................15

25. Application Notes...................................................... 16

25.1. Periodical Peak Power Capability ............ 16

25.2. Charging Batteries ........................................ 16

25.3. Output Circuit Breakers ............................... 17

25.4. External Input Protection............................ 18

25.5. Back-feeding Loads ...................................... 18

25.6. Parallel Use to Increase Output Power . 18

25.7. Parallel Use for Redundancy...................... 18

25.8. Series Operation............................................ 19

25.9. Inductive and Capacitive Loads ............... 19

25.10.Loss of One Input Phase............................. 19

25.11.Use in a Tightly Sealed Enclosure ............ 19

25.12.Mounting Orientations................................ 20

•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.

• 3AC 400V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)

included. 3AC means three phase input. E.g.: DC 12V describes a 12V battery whether it is charged (13.7V) or discharged (10V).

Unless otherwise stated, 3AC 400V parameters are valid at 50Hz and 3AC 480V parameters are valid at 60Hz mains frequency.

• 3x 400Vac—A figure with the unit (Vac) at the end is a value used during testing without any additional tolerance included. 3AC means three

phase input.

Terminology and Abbreviations

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2Rockwell Automation Publication 1606-RM025A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

Semi-regulated Power Supply

••Alternative or Replacement for AC Transformer

• Three Phase Input – DC Output

• DIN Rail Mountable

• Width only 96mm

• 96% Eciency

• 125% Peak Power Capability

• No Input Inrush Current

• Active Input Transient Blocker

• Full Power Between -25°C and +60°C

• Easy Failure Diagnostics

• No Electrolytic Capacitors on Input Side

• Cost Eective and Robust

• 3 Year Warranty

1. Description 2. Specication Quick Reference

Output voltage DC 48V

Adjustment range none

Output current 20A continuous

25A for typ. 15s

Output power 960W continuous

1200W for typ. 15s

Output ripple < 2500mVpp 20Hz-2kHz

< 300mVpp 2kHz to 20MHz

Input voltage 3AC 480V

Mains frequency 50-60Hz ±6%

AC Input current 1.4A / phase 3x480V

Power factor 0.93 48V, 20A

AC Inrush current typ. 2A peak

Eciency 96.0%

Losses 40.0W

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

Derating 24W/°C +60 to +70°C

The 1606-XLE960MX-3N series implements a new and

innovative concept for generating an isolated DC

voltage from a three-phase mains system.

A semi-regulated resonant converter enables a very

compact design, maximum eciency and extremely

competitive pricing with only a small compromise in

the output voltage regulation, output ripple and

hold-up time.

Weighing just 1.4 kg, the device provides 960 watts

of continuous output power and an additional 25%

power reserve for dynamic loads. The light-weight

design along with compact dimensions facilitate

straightforward installation on a DIN rail.

Primary use are applicatins involving supplies to

motors, valves and other load circuits with a high

power consumption, where an accurate output

voltage regulation which is standard on traditional

switched-mode power supplies is not required.

Furthermore, these switched-mode power supplies

can often replace mains transformers with rectiers.

Dimensions 96x124x159mm WxHxD

3. Catalog Numbers 4. Certication Marks

Power Supply 1606-XLE960MX-3N

480V Input

IND. CONT. EQ.

18WM

LISTED

UL 508

UL 60950-1

EMC, LVD

Accessory 1606-XLSBUFFER48 48V Buer Unit

Marine RINA

GOST R

C-Tick

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 3

Bulletin 1606 Switched Mode Power Supplies

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 aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or

threaten human life.

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

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 section 25.12

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 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

4Rockwell Automation Publication 1606-RM025A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

5. AC-Input

1606-XLE960MX-3N

AC input nom. 3AC 480V

Mains arrangement

TN-, TT- or IT-Mains. Consult factory if one phase is grounded.

AC input range min.

3x 432-528Vac

fully regulated output (±2%), Pout > 48W

min.

3x 360-552Vac

permanently allowed,

see Fig. 5-1 for output voltage regulation

max. 3x 565Vac Absolute maximum input voltage with no

damage to the power supply. Output

might be o at this level.

Input frequency nom. 50 – 60Hz ±6%

Turn-on voltage typ. 3x 390Vac see Fig. 5-2

Shut-down voltage typ. 3x 355Vac see Fig. 5-2

Input current nom. 1.4A at 20A, symmetrical input, see Fig. 5-4

Power factor **) typ. 0.93 at 20A, symmetrical input, see Fig. 5-5

Turn-on overshoot typ. 1000mV see Fig. 5-3

Start-up delay ***) typ. 350ms over the entire load range, see Fig. 5-3

Rise time typ. 40ms 0mF, 20A, see Fig. 5-3

typ. 70ms 20mF, 20A, see Fig. 5-3

*) A minimum voltage of 3x408Vac is required to turn the power supply on.

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

***) The start-up delay for mains voltage interruptions up to 350ms is close to zero. In such cases, the power supply will

immediately generate the output voltage once the mains voltage interruption is over. Do not use the buer module

1606-XLSBUFFER48 as an accessory when longer mains interruptions need to be bridged (see section 24).

Input Voltage Range

Fig. 5-1 Output voltage vs. input voltage and input current

Changes of the input voltage will be fully

regulated within certain limits. The

output voltage will only start to change

proportionally to the input voltage with

extreme under or over-voltages. The

yellow LED reports an input voltage

problem if exceeded by a window of

±15%. The maximum increase of the

output voltage is limited to the 57.2V

OVP level. This level will be kept

regulated for 2s before the power supply

will shut down and re ports “Shut-down”

by the red LED.

48V

40V

52V

44V

504456 576Vac384

OUT

480

56V

528 552432408360

OUT

> 48W (>5%)

OUT

= 0W

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 5

Bulletin 1606 Switched Mode Power Supplies

Fig. 5-2 egnaregatlovtupnI Fig. 5-3 Turn-on behavior denitions

Turn-on

fully regulated

range

OUT

3x 528Vac

Shut-down

3x 432Vac480V Version:

Start-up

delay Rise

Time

Overshoot

- 5%

Output

Voltage

Intput

Voltage

Fig. 5-4 Input current vs. output load Fig. 5-5 Power factor vs. output load

25A

2.5 5 15

0.3

0.6

0.9

1.2

1.5

1.8A

Input Current per Phase, typ.

Output Current

10 20

25A

2.5 5 15

0.70

0.75

0.8

0.85

0.9

0.95

1.0

Power Factor, typ.

Output Current

10 20

6. Input Inrush Current

There is virtually no input inrush current surge as there are no electrolytic capacitors used on the input side of

the power supply.

The charging current into the EMI suppression capacitors is disregarded for the rst millisecond after switch-on.

1606-XLE960MX-3N

Inrush current max. 4Apeak -25°C to +70°C, see Fig. 6-1

Inrush energy max. 5A2s -25°C to +70°C, see Fig. 6-1

Inrush delay typ. 350ms see Fig. 6-1

Fig. 6-1 Input inrush current, typical behavior

Input Current

Input Voltage

Output Voltage

1606-XLE960MX-3N (3x480V)

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

6Rockwell Automation Publication 1606-RM025A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

7. Output

Output voltage nom. 48V

Output voltage adjustment range

none The output voltage is xed. No ajustment possible.

Output current nom. 20A continuous, see Fig. 7-1

25A up to 15s with full output voltage, see Fig. 7-1

Short-circuit current typ. 90A load impedance 50mOhm, see Fig. 7-1

Note: The short-circuit current is available for 0.1s.

Output power nom. 960W continuous

1200W up to 15s

Line regulation max. ±2% see Fig. 5-1

Load regulation max. 1600mV static value, 0A 20A 0A

max. 100mV static value, 2.5A 20A 2.5A

Ripple and noise voltage *) max. 2500mVpp 20Hz-2kHz, 50Ohm

max. 300mVpp 2kHz to 20MHz, 50Ohm

Output capacitance typ. 7 600μF

*) The ripple and noise voltage mostly consist of a mains ripple with 300Hz (50Hz mains) or 360Hz (60Hz mains). The ripple and

noise voltage can be reduced by the utilization of external capacitors.

The power supply is also designed to support loads with a higher short-term current and power requirement. The

short-term duration is rmware controlle d by an output power manager. If the nominal output power is exceeded for

a certain period of time which is dened in zone A, B and C, the power supply responds with an automatic shut-down.

Pressing the reset button or cycling the input power (10s o time is required) initiates a restart attempt. If the fault has

been cleared the device will operate normally.

The short term power can be used periodically . See section 25.1 for further information.

Fig. 7-1 Output voltage vs. output current, typ.

OUT

20A A07A5240A0

15s

48V

100A

30A A09A08A06A05A01

24V

OUT

0.1s

3x 408V

3x 480V

3x 552V

1606-XLE960MX-3N

Zone A

25% extra output power for typ. 15s

Zone B

100% higher output current for typ. 5s

Zone C:Quick-acting shut-down after typ. 0.1s

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 7

Bulletin 1606 Switched Mode Power Supplies

8. Hold-up Time

1606-XLE960MX-3N

Hold-up Time typ. 3.1ms 20A, resistive load, see Fig. 8-2

ees,daolrewoptnatsnoc,A02sm7.2.pyt

Fig. 8-2

sm2.6.pyt

10A, resistive load

daolrewoptnatsnoc,A01sm4.5.pyt

Hold-up Time min. 2.5ms 20A, resistive load, see Fig. 8-2

ees,daolrewoptnatsnoc,A02sm2.2.nim Fig. 8-2

sm0.5.nim 10A, resistive load

daolrewoptnatsnoc,A01sm4.4.nim

Fig. 8-1

Hold-up time, denitions

The energy is stored in the output capacitor. As

soon as the input is turned o, the output

capacitor will be discharged and the voltage will

dissipate according to the curves in

Fig. 8-2

The lighter the load, the longer the hold-up time.

half the load means twice the hold-up time.

The hold-up time depends on the load

characteristic. The curves below show the hold-up

time for a load with a resistive and a constant

power characteristic.

The hold-up time is dened as the period of time

when the input is turned o and until the output

voltage falls below 48V

–15%

(40.8V). This value is

dened in the IEC61131-2 as the lower limit for the

supplying voltage.

-15%

Hold-

Time

Zero Transition

Output

Voltage

Intput

Voltage

Fig. 8-2

Hold-up time vs. input voltage

48V

24V

36V

28V

OUT

44V

32V

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.5 6.0 6.5 7.0 7.5 8.05.0 8.5 9.0

20A, constant power load, typ.

20A, resistive load, typ.

20A, constant power load, min.

20A, resistive load, min.

40.8V

11ms9.5 10 10.5

Note: At no load, the hold-up time can be up to one minute. The green DC-ok LED is on at this time.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

8Rockwell Automation Publication 1606-RM025A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

9. Eciency and Power Losses

1606-XLE960MX-3N

A02%0.69.pytycneiciffE

A02W0.04.pytsessolrewoP

A0W2.81.pyt

Fig. 9-1 Eciency vs. output current Fig. 9-2 Losses vs. output current

Eciency

0255.2

96%

7.5 10 12.5 15 17.5

Output Current

Power Losses

02468101214 20

50W

16 18

Output Current

Fig. 9-3 Eciency vs. input voltage, 48V, 20A Fig. 9-4 Losses vs. input voltage, 48V, 20A

Eciency

350 400 450 500 3x550

95.0

95.2

95.4

95.6

Input Voltage

95.8

96.0

96.2% 1606-XLE960MX-3N

Power Losses

350 400 450 500 3x550

Input Voltage

47W

1606-XLE960MX-3N

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM025A-EN-P — April 2014 9

Bulletin 1606 Switched Mode Power Supplies

10. Functional Diagram

Fig. 10-1 Functional diagram

Active

Transient

Blocker

Input

Filter

Input

Rectier

Reset

Output

Voltage

Monitor

Over-

Voltage

Protection

Output

Power

Manager

Temp.

Shut-

down

Input

Voltage

Monitor

Semi-

regulated

Power

Converter

Output

Filter

DC-ok

LED

Warning

LED

Shut-down

LED

11. Front Side and User Elements

Fig. 11-1 Front side of 1606-XLE960MX-3N

A. Output Terminals

Large screw terminal

+Positive output

-Negative (return)

output

See section 12

“Terminals and

Wiring” to choose

appropriate wire size.

B. Input Terminals

Screw terminals

L1, L2, L3:

Line inputs

PE (Protective

Earth) input

C. DC-ok LED (green)

Indicates a normal operation. The LED is on

if the output voltage is higher than 43.2V.

D. Warning LED (yellow)

- A steady-state light indicates an output

current higher than the nominal current

and that the internal shutdown timer is

running.

- A double ash indicates a phase-loss or

too low / too high input voltage.

(< 3x400Vac or > 3x560Vac)

- A fast ash warns of an impending

temperature shut-down. A shut-down

can be expected within 10 minutes, if

the ambient temperature or the load

current stays constant.

E. Shut-down LED (red) and reset button F.

The red LED ashes when the device has

shut down. Pressing the reset button or

cycling the input power (10s required)

initiates a restart. When the fault is

cleared, the device will operate normally.

All parameters are specified at 48V, 20A, 3x480Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

10 Rockwell Automation Publication 1606-RM025A-EN-P — April 2014

Bulletin 1606 Switched Mode Power Supplies

12. Terminals and Wiring

Use appropriate copper cables that are designed for a minimum operating temperatures of 60°C (for ambient up to

45°C) and 75°C (for ambient up to 60°C). Follow national installation codes and regulations! Ensure that all strands of

a stranded wire enter the terminal connection! Do not use the power supply without PE (Ground) connection! Up to

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

allowed, but not required.

tuptuOtupnI

lanimretwercSlanimretwercSepyT

mm6-5.0eriwdiloS 2mm61-5.0 2

mm4-5.0eriwdednartS 2mm01-5.0 2

GWA8-22GWA01-02eguageriwnaciremA

Wire stripping length 7mm / 0.26inch 12mm / 0.5inch

Recommended tightening torque 0.8Nm / 7lb.inch 1.2Nm / 10.6lb.inch

13. Reliability

Lifetime expectancy min. 77 000h 40°C, 20A

A01,C°04sraey51>.nim

A02,C°52sraey51>.nim

A02,C°04h00014590716CEI,00592NSFBTM

A02,C°52h000879

04BGngineBdnuorG,A02,C°04h000991F712KBDHLIMFBTM

267 000h 25°C, 20A, Ground Benign GB25

The Lifetime expectancy shown in the table above indicates the 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 a calc ulation of up to 15 years from date of shipment.

MTBF stands for Mean Time Between Failures, which is calculated according to statistical device failures, and indicates

reliability of a device. It is the statistical representation of the likelihood of failure of a specic unit and does not necessarily

represent the life of a product.

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