Rockwell Automation Allen-Bradley 1606-XLE480ERL Bedienungsanleitung

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

OUT

300V AC264V

Shut-down

24 A

2 4 6 8 10 12 14 16 18

Input Current, typ.

20 22

a) 100V AC

b) 120V AC

c) 230V AC

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

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

Power Supply

Battery

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.

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