Rockwell Automation Allen-Bradley 1606-XLS960E Bedienungsanleitung

Reference Manual

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Catalog Number

1606-XLS960E

Topic Page Topic Page

AC Input 3 Front Side and User Elements 13

Input Inrush Current 4 EMC 14

DC Input 4 Environment 15

Output 5 Protection Features 16

Hold-up Time 7 Safety Features 16

DC-OK Relay Contact 7 Dielectric Strength 17

Shut-down Input 8 Standards and Certifications 17

Remote Control of Output Voltage 9 Approximate Dimensions 18

Internal Data Logging 9 Intended Use 18

Efficiency and Power Losses 10 Installation Requirements 18

Lifetime Expectancy and MTBF 11 Accessories 19

Functional Diagram 11 Application Notes 20

Terminal and Wiring 12

2Rockwell Automation Publication 1606-RM052A-EN-P - August 2018

Power Supply Reference Manual - 24V, 40 A Single-phase Input

1606-XLS960E

24V, 40 A, Single-phase Input Power Supply

The Bulletin 1606-XLS DIN-rail power supplies are efficient and

small. Achieved by a synchronous rectification, a bridge-less PFC

circuit, and some additional unique design details.

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. The use of a unit from a lower wattage class can be used to save

space and cost.

High immunity to transients and power surges and low

electromagnetic emissions makes usage in nearly every environment

possible.

The integrated input fuse and the 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 various applications makes

this unit suitable for nearly every application.

•AC 100-240V Wide-range Input

•Width only 125 mm (4.9 in.), Weight only 1.9 kg (4.2 lb.)

•94.6% Full Load and Excellent Partial Load Efficiencies

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

•110 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 Between -25…+60 °C (-13…140 °F)

•Current Sharing Feature for Parallel Use

•Internal Data Logging for Troubleshooting Included.

•Remote Control of Output Voltage

•DC-OK Relay Contact

•Shut-down Input

•ATEX and IECEx Approved

Attribute Value

Output Voltage nom 24V DC nominal

Adjustment range 24 …28V DC

Output Current Continuous 40…34.3A

Short Term (4 seconds) 60…51.5A

Output Power Continuous 960 W

Short Term (4 seconds) 1440 W

Output Ripple, 20 Hz to 20 MHz < 100mVpp

Input Voltage, -15%/+10% 100…240V AC

Frequency, ± 6% 50…60 Hz

AC Inrush Current, at 120/230V AC 17/ 11 A peak

Efficiency at 120/230V AC 93.6/94.6%

Losses at 120/230V AC 65.6 / 54.8 W

Temperature, operating -25…+70°C

Derating 24 W / °C

+60…70°C

between 85…90V AC

Hold-up Time 27/27 ms

Dimensions W x H x D 125 x 124 x 127 mm

(4.9 x 4.88 x 5 in.)

Weight 1900 g /4.2 lb.

Rockwell Automation Publication 1606-RM052A-EN-P - August 2018 3

Power Supply Reference Manual - 24V, 40 A Single-phase Input

AC Input

Figure 1 - Input Voltage Range

Figure 2 - Turn-on Behavior, Definitions

Figure 3 - Input Current vs. Output Load at 24V

Figure 4 - Power Factor vs. Output Load at 24V

Attribute Value Notes

AC input nom. 100…240V AC suitable for TN, TT, and IT mains networks

AC input range min 90…264V AC continuous operation

min 85…90V AC < 55 °C (131 °F) ambient temperature

continuously allowed

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

term or with output derating according to

Output Current vs. Ambient Temperature on

page 15

min 60…85V AC full power for up to 200 ms

min 0…85V AC no damage to the unit

min 264…300VAC < 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 1

Shut-down

voltage

typ 74V AC

External input

protection

See External Input Protection on page 22.

Attribute 100V

AC 120V

AC 230V

AC Notes

Input current typ 10.5 A 8.6 A 4.5 A at 24V, 40 A, see Figure 3

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 24V, 40 A, see Figure 4

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 24V, 40 A

Start-up delay typ 800 ms 750 ms 700 ms see Figure 2

Rise time typ 15 ms 15 ms 15 ms at 24V, 40 A, resistive

load, 0 mF see Figure 2

typ 18 ms 18 ms 18 ms at 24V, 40 A, resistive

load, 4 0mF see Figure 2

Turn-on

overshoot

max 100 mV 100 mV 100 mV see Figure 2

Turn-on

Rated input range

OUT

74 264V AC

Shut-down

Start-up

delay Rise

Time

Overshoot

- 5%

Output

Voltage

Input

Voltage

40 A

4 8 12 16 20 24 28 32 36

12 A

Output Current

Input Current, typ.

A: 100V AC

B: 120V AC

C: 230V AC

Power Factor, typ.

4 8 12 16 20 24 28 32 36 40A

0.75

0.8

0.85

0.9

0.95

1.0

Output Current

A: 100V AC

B: 120V AC

C: 230V AC

4Rockwell Automation Publication 1606-RM052A-EN-P - August 2018

Power Supply Reference Manual - 24V, 40 A Single-phase Input

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 smaller than the steady state

input current.

Figure 5 - Typical Turn-on Behavior at Nominal Load and 25 °C (77 °F)

Ambient Temperature

DC Input

Do not operate this power supply with DC input voltage.

Attribute Value(2)

100V AC 120V AC 230V AC

Inrush Current(1) Max 25 A 22 A 16 A

Typ 20 A 17 A 11 A

Inrush Energy Max 5 A25 A25 A2

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

(2) Over entire temperature range, mains interruptions >1 second.

Rockwell Automation Publication 1606-RM052A-EN-P - August 2018 5

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Output

Attribute Value

Output nom 24V DC

Adjustment range min 24-28V DC guaranteed

max 29V DC (1)

(1) BonusPower®, short-term power capability (up to typ 4 s) 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 that is

controlled by an output power manager. This BonusPower® is repeatedly available. If the power supply is loaded longer with the BonusPower® than shown in the Bonus-time diagram (See Figure 8 on page 6), the max output

power is automatically reduced to 960 W. If the power requirement is continuously above 960 W and the voltage falls below approx. 20V (due to the current regulating mode at overload), the unit shuts-off and makes periodical

restart attempts. This behavior is called hiccup mode that is described below. If the voltage is above 20V, the unit continuously delivers current.

at clockwise end position of potentiometer

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

typ 24.1V DC ±0.5%, at full load, cold unit, in “parallel use” mode

typ 25.1V 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..40 A, see Figure 6 on page 6

typ 1000 mV in “parallel use” mode: static value, 0 A..40 A, see Figure 10 on page 7

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

Output current nom 40 A continuously available at 24V, see Figure 6 and Figure 10 on page 7

nom 34.3 A continuously available at 28V, see Figure 6 and Figure 10 on page 7

nom 60 A short-term available BonusPower®, at 24V for typical 4 s, see Figure 6 and Figure 10 on

page 7

nom 51.5 A short-term available BonusPower®, at 28V for typical 4 s, see Figure 6 and Figure 10 on

page 7

typ 110 A up to 10 ms, output voltage stays above 20V, see Figure 8 on page 6, This peak current is

available once every second. See Peak Current Capability on page 21 for more peak

current measurements.

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

nom 1440 W(2)

(2) HiccupPLUS Mode Up to 4 s of overloading, the power supply delivers continuous output current. After this, the output power is reduced to nearly zero for approx. 17 s before a new start attempt is automatically performed. If the

overload has been cleared, the device will operate normally. If the overload still exists, the output current will be delivered for 2s to 4s (depending on the overload) again followed by a 17 s rest time. This cycle is repeated as long

as the overload exists. See Figure 7 on page 6. During the off-period, a small rest voltage and rest current is present on the output.

short-term available BonusPower® at 24…28V

BonusPower® time typ 4 s duration until the output voltage dips, see Figure 8 on page 6

BonusPower® recovery time typ 7 s overload free time to reset power manager, see Figure 12 on page 7

Overload behavior cont. current output voltage > 20V DC, see Figure 6 on page 6

HiccupPLUS mode(3)

(3) Discharge current of output capacitors is not included

output voltage < 20V DC, see Figure 6 on page 6

Short-circuit current min 60 A(4)

(4) This is the maximum output voltage that can occur at the clockwise end position of the potentiometer due to tolerances. It is not guaranteed value that can be achieved. The typical value is about 28.5V.

load impedance 25mOhm, see Figure 7 on page 6

max 70 A load impedance 25mOhm, see Figure 7 on page 6

max 23 A average (R.M.S.) current, load impedance 25mOhm, see Figure 7 on page 6

typ 130 A up to 10 ms, load impedance <10mOhm, see Figure 11 on page 7

Output capacitance typ 10 200 μF included in the power supply

6Rockwell Automation Publication 1606-RM052A-EN-P - August 2018

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Figure 6 - Output Voltage vs. Output Current in “Single Use mode” typ

Figure 7 - Short-circuit on output, HiccupPLUS mode, typ

Figure 8 - Bonus time vs. output power

Figure 9 - BonusPower® after input turn-on

Output Voltage

010203040

28V

6050 70A

Output Current

Adjustment Range

Short-term (4s)

then switching

to curve

Continuously

available

Output

Current

65A

17s 17s

17s 2s 2s

Short -circuit Normal

operation

Normal

operation

max.

Bonus Time

100 120 130 140 150 170%

110 160

Output Power

min.

100%

Output

Voltage

Input

Voltage

Bonus

Power

Output

Power

150%

Rockwell Automation Publication 1606-RM052A-EN-P - August 2018 7

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Figure 10 - Output voltage vs. output current in “parallel use” mode,

typ

Figure 11 - Dynamic overcurrent capability, typ

Figure 12 - BonusPower® recovery time(1)

BonusPower® after output short

Hold-up Time

Figure 13 - Hold-up Time vs. Input Voltage

Figure 14 - Shut Down Behavior, Definitions

DC-OK Relay Contact

This feature monitors the output voltage produced by the power

supply. It is independent of a back-fed voltage from a unit that is

connected in parallel to the power supply output.

(1) The BonusPower is available as soon as power comes on and after the end of an output short circuit or

output overload.

Output Voltage

(Parallel Use, typ.)

22V 02040

23V

24V

25V

29V

26V

27V

28V

60A503010

Adjustment

Range

Factory

setting

Output Current

Continuously

allowed Bonus

Power

Output Voltage

(dynamic behavior, < 10ms)

28V

150

6030 90 12015 45 75 105 135

Output Current

Adjustment

Range

Power

Demand

100%

Limitation by

Power Manager

Output

Voltage

Bonus Power disabled

Bonus

Time

Recovery Time

Short of

Output

100%

Output

Voltage

Bonus

Power

Output

Power

150%

100V AC 120V AC 230V AC

typ 54 ms 54 ms 54 ms at 24V, 20 A, see Figure 13

min 45 ms 45 ms 45 ms at 24V, 20 A, see Figure 13

typ 27 ms 27 ms 27 ms at 24V, 40 A, see Figure 13

min 23 ms 23 ms 23 ms at 24V, 40 A, see Figure 13

Attribute Value

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 250 ms. Dips shorter than 1

ms will be ignored.

Contact recloses As soon as the output voltage exceeds 90%

of the adjusted voltage.

10 ms

20 ms

30 ms

40 ms

60 ms

90 120 155 190 230V AC

Input Voltage

50 ms

Hold-up Time

24V, 40 A, typ.

24V, 20 A, min.

24V, 20 A, typ.

24V, 40 A, min.

- 5%

Hold-up Time

Zero Transition

Output

Voltage

Input

Voltage

8Rockwell Automation Publication 1606-RM052A-EN-P - August 2018

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Figure 15 - DC-OK Relay Contact Behavior

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 occurs

immediately while the turn-on is delayed up to 350 ms. In a shut-down

condition, the output voltage is <2V and the output power is <0.5 W.

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.

Figure 16 - Activation of the Shut-down Input

Contact ratings max 60V DC 0.3 A, 30V DC

1 A, 30V AC 0.5 A

resistive load

min 1 mA at 5V DC min permissible

load

Isolation voltage Refer to Dielectric Strength on page 17

IMPORTANT Option C requires a current sink capability of the

voltage source. Do not use a blocking diode. -

The shut-down function has no safety feature

included.

Attribute Value

250ms

0.9* V

ADJ

1ms

10%

open

OUT

= V

ADJ

openclosed closed

1ms

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.

Rockwell Automation Publication 1606-RM052A-EN-P - August 2018 9

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Remote Control of Output Voltage

The shut-down input can also be used to remotely adjust the output voltage between typically 22V DC and 28V DC. All other functions of shut-

down input remain the same.

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

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 the Rockwell Automation service and repair personnel, even when the unit is non-operational. The data allows

for better troubleshooting. Analysis of what happened before a failure can be determined much more accurately.

Acquired Data

•Family name of unit (1606-XLS), revision of firmware

•Operational hours

•Expired portion of lifetime (combination of temperature and time)

•Maximum ambient temperatures with timestamp (max 47 values)

•Maximal input voltages with timestamp (max 47 values) and type of input voltage (AC or DC)

•Failure report (various internal errors)

•Number and timestamp of input overvoltage transients

•Number and timestamp of over-temperature shut-downs

•Number of turn-on sequences

The data will be acquired with a fixed sampling rate unless the peak detectors do trigger due to an abnormal condition. In such cases, the abnormal

condition will be captured. Furthermore, data will be acquired every time shortly before the unit switches off.

Figure 17 - Remote Control of the Output Voltage Figure 18 - Applying the Control Voltage

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

Output Voltage

12V

0V 5V

14V

16V

18V

28V

20V

22V

26V

Control Voltage

24V

10V

Potentiometer:

28V setting

24V setting

Control

Voltage

Shut-

down

Input

n.c.

10 Rockwell Automation Publication 1606-RM052A-EN-P - August 2018

Power Supply Reference Manual - 24V, 40 A Single-phase Input

Efficiency and Power Losses

Attribute 100V AC 120V AC 230V AC Notes

Efficiency, typ 93.2% 93.6% 94.6% at 24V, 40 A

Average efficiency, typ(1)

(1) The average efficiency 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.

92.7% 93.0% 93.9% 25% at 10 A, 25% at 20 A, 25% at 30 A. 25% at 40 A

Power losses, typ 3.6 W 3.5 W 3.3 W with activated shut-down

13.9 W 13.1 W 13.2 W at 24V, 0 A (no load)

36.1 W 34.5 W 30.6 W at 24V, 20 A (half load)

70.0 W 65.6 W 54.8 W at 24V, 40 A (full load)

Figure 19 - Efficiency vs. Output Current at 24V, typ Figure 21 - Power Losses vs. Output Current

Figure 20 - Efficiency vs. Input Voltage at 24V, 40 A, typ Figure 22 - Power Loses vs. Input Voltage at 24V, 40 A. typ

Efciency

8 1216202428323640A

Output Current

96%

120V AC

100V AC

230V AC

Power Losses

0 4 8 1216202428 40A

80 W

120V AV

100V AC

230V AC

32 36

Output Current

Efciency

85 120 155 190 225 260V AC

Input Voltage

95%

Power Losses

80W

85 120 155 190 225 260V AC

Input Voltage

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