Allen-Bradley Switched Mode Power Supply Reference Manual

Switched Mode Power Supply
Catalog Number 1606-XLS960F
Reference Manual
Original Instructions
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.
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.
These labels may also be on or inside the equipment to provide specific precautions.
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).
The following icon may appear in the text of this document.
Identifies information that is useful and can help to make a process easier to do or easier to understand.
2
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
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
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
1
Table of Contents
Notes:
2
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Terminology and
Abbreviations
Terms
PE
Descriptions
The abbreviation for Protective Earth. PE has the same meaning as the symbol.
The symbol for Protective Earth.
Earth, Ground
AC 230V
230V AC
50 Hz versus 60 Hz
Nom
Typ
—
This document uses the term “earth”, which is the same as the U.S. term “ground”.
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).
A value with the unit (V AC or V DC) at the end is a momentary value without any
additional tolerances included.
Unless otherwise stated, AC 230V parameters are valid at 50 Hz mains frequency.
Indicates a nominal value.
Indicates a typical value.
A dash alone in a table cell indicates that there is no information to be included in that
cell.
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
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 builtin 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.
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
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
3
•
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-OK relay contact
Shut-down input
ATEX and IECEx approved
Specifications
Attributes
Values
Output voltage
DC 48V
Nominal
Adjustment range
48…54V DC
—
Output current
Output power
Notes
20…17.8 A
Continuous
30…26.7 A
Short term (4 s)
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)
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.)
WxHxD
Weight
1900 g (4.2 lb)
—
(1) Between 85…90V AC. See Environment on page 15.
Catalog Numbers
Cat. No.
1606-XLS960F
1606-XLC
1606-XLSBUFFER48
1606-XLSRED40HF
4
Descriptions
Power supply
(48…54V standard unit)
Wall mount bracket
Buffer unit
Redundancy module
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
AC Input
Attributes
Input voltage
Values
Notes
Nom
AC 100…240V
Suitable for TN, TT, and IT mains networks
—
90…264V AC
Continuous operation
—
85…90V AC
<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
Input voltage range
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.
Values
Attributes
AC 100V
AC 120V
Notes
AC 230V
Input current
Typ
10.5 A
8.6 A
4.5 A
At 48V, 20 A, see Figure 4
Power factor (1)
Typ
0.99
0.99
0.99
At 48V, 20 A, see Figure 5
Crest factor (2)
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
Turn-on overshoot
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
Max
100 mV
100 mV
100 mV
See Figure 3
(1) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
(2) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.
Figure 2 - Input Voltage Range
Input
Voltage
Turn-on
Shut-down
Rated Input Range
- 5%
Output
Voltage
V IN
74 80 85
Start-up
Delay
Input Current, Typ
Figure 5 - Power Factor Versus Output Load at 48V
Power Factor, Typ
12 A
1.0
A: 100 V AC
B: 120 V AC
C: 230 V AC
8
Rise
Time
264V AC
Figure 4 - Input Current Versus Output Load at 48V
10
Overshoot
P OUT
Figure 3 - Turn-on Behavior, Definitions
A
A
B
0.95
B
0.9
6
C
4
C
0.8
2
Output Current
0
2
4
6
8
10
12
14
16
A: 100V AC
B: 120V AC
C: 230V AC
0.85
Output Current
0.75
18 20 A
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
2
4
6
8
10
12
14
16
18 20 A
5
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.
Values
Attributes
Inrush current (1)
Inrush energy
AC 100V
AC 120V
AC 230V
Max
25 Apeak
22 Apeak
16 Apeak
Typ
20 Apeak
17 Apeak
11 Apeak
Max
5 A2 s
5 A2 s
5 A2 s
Notes
Over the entire temperature range; mains
interruptions >1 s
(1) 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 - 25 °C (77 °F) Ambient
Temperature
Input Current 5 A/DIV
Input
230V AC
Output
DC Input
48V DC
100 ms/DIV
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
Output voltage
Adjustment range
Factory setting
Line regulation
Values
DC 48V
—
—
48…54V DC
Guaranteed
Max
56V DC (1)
At clockwise end position of potentiometer
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
Max
10 mV
85…300V AC
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
Max
150 mVpp
20 Hz…20 MHz, 50 Ω
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.
Load regulation
Ripple and noise voltage
Output current
6
Notes
Nom
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Attributes
Values
Nom
Output power
Notes
Continuously available at 48…54V
960 W
(2)
Short-term available BonusPower (2) at 48…54V
Nom
1440 W
BonusPower time
Typ
4s
Duration until the output voltage dips, see Figure 11 on page 8
BonusPower recovery time
Typ
7s
Overload free time to reset power manager, see Figure 12 on
page 8
Overload behavior
Short-circuit current
Output capacitance
—
Continuous current Output voltage >40V DC, see Figure 7
—
HiccupPLUS mode (3) Output voltage <40V DC, see Figure 7
Min
30 A (4)
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
Typ
3700 µF
Included in the power supply
Load impedance 50 mΩ, see Figure 9
(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.
Figure 7 - Output Voltage Versus Output Current in
Single Use Mode, Typ
Output Voltage
Figure 8 - Output Voltage Versus Output Current in
Parallel Use Mode, Typ
Output Voltage
Adjustment Range
(Parallel Use, Typ)
56V
56V
A
48
B
A
40
Adjustment Range
54V
B
52V
32
Continuously
allowed
50V
Continuously
available
B Short-term (4 s)
then switching
to curve A
A
24
16
8
0
0
5
10
Hiccup
Mode
Factory
setting
46V
44V
42V
15
20
Bonus
Power
48V
25
0
35 A
30
10
5
15
Output Current
Output
Current
y
g
(dynamic behavior, < 10 ms)
54V
Normal
operation
Short -circuit
30 A
Figure 10 - Dynamic Overcurrent Capability, Typ
Output Voltage
Normal
operation
25
Output Current
Figure 9 - Short-circuit on Output, HiccupPLUS Mode,
Typ
g
20
Adjustment
Range
48
35 A
40
t
0
2s
17 s
2s
17 s
2s
17 s
32
24
16
8
0
Output Current
0
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
10
20
30
40
50
60
70 A
7
Figure 11 - Bonus Time Versus Output Power
Figure 12 - BonusPower Recovery Time
g
Bonus Time
5s
Limitation by
Power Manager
Power
Demand
max
4
100%
min
3
t
2
Output
Voltage
1
Recovery Time
Bonus Power disabled
Bonus
Time
Output Power
0
100
t
110
120
130
140
150
160
170%
The BonusPower is available when power comes on and after the end of an
output short circuit or output overload.
Figure 13 - BonusPower After Input Turn-on
Figure 14 - BonusPower After Output Short
Short of
Output
Input
Voltage
Output
Voltage
Output
Voltage
Bonus
Power
150%
100%
Output
Power
Output
Power
150%
Bonus
Power
100%
Hold-up Time
Values
Attributes
Hold-up Time
AC 100V
AC 120V
AC 230V
Typ
54 ms
54 ms
54 ms
Min
45 ms
45 ms
45 ms
Typ
27 ms
27 ms
27 ms
Min
23 ms
23 ms
23 ms
Figure 15 - Hold-up Time Versus Input Voltage
Notes
At 48V, 10 A, see Figure 15
At 48V, 20 A, see Figure 15
Figure 16 - Shutdown Behavior Definitions
Hold-up Time
Zero Transition
60 ms
48V, 10 A, typ
50
Input
Voltage
48V, 10 A, min
40
30
48V, 20 A, typ
20
48V, 20 A, min
10
90
8
Hold-up Time
Input Voltage
0
120
155
190
- 5%
Output
Voltage
230V AC
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
DC-OK Relay Contact
This feature monitors the output voltage that the power supply unit produces.
It is independent of any back-fed voltage from a unit that is connected in
parallel to the power supply unit output.
Action
Notes
Contact closes
Once the output voltage reaches 90% of the adjusted output voltage
Contact opens
Once the output voltage dips more than 10% below the adjusted output voltage. Short dips are extended
to a signal length of 250 ms. Dips shorter than 1 ms are ignored.
Contact recloses
Once the output voltage exceeds 90% of the adjusted voltage
Contact ratings
Max
60V DC at 0.3 A, 30V DC at 1 A, 30V AC at 0.5 A
Resistive load
Min
1 mA at 5V DC
Min permissible load
See Dielectric Strength on page 16.
Isolation voltage
Figure 17 - DC-OK Relay Contact Behavior
y
g
V OUT = VADJ
10%
>
1 ms
<
1 ms
open
Shutdown Input
closed
0.9* VADJ
250 ms
open
closed
This feature allows a switch-off of the output of the power supply unit with a
signal switch or an external voltage. The shutdown occurs immediately, while
the turn-on is delayed up to 350 ms. In a shut-down condition, the output
voltage is <4V 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
supply units, only wiring option A with individual signal switches is allowed.
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.
Figure 18 - Activation of the Shut-down Input
g
Option A:
Option B:
15 Shutdown
16 Input
OFF: linked
ON : open
(via open
collector)
NC
I
15 Shutdown
16 Input
Option C:
15 Shutdown
16 Input
NC
(via external
voltage
+
OFF: I > 0.3 mA
ON : I < 0.1 mA
-
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
OFF: U < 1V
ON : U = 4…29V
U
-
9
Remote Control of Output
Voltage
You can use the shut-down input to adjust the output voltage remotely,
typically between 44…54V DC. All other functions of the shut-down input
remain the same.
The control voltage is referenced to the main ground (negative output voltage).
.
Figure 19 - Remote Control of the Output Voltage
Figure 20 - Applying the Control Voltage
Output Voltage
Potentiometer:
54V setting
48V setting
56V
52
48
44
40
36
32
28
24
15 Shutdown
16 Input
+
Control
Voltage
NC
-
0
10V
5
Control Voltage
To set the shutdown input to adjust the output voltage remotely:
1. Set the unit into Single Use mode.
2. Set the output voltage adjustment (48…54V) to the maximum desired
voltage.
3. Apply a control voltage to reduce the output voltage.
Efficiency and Power
Losses
Values
Attributes
Efficiency
AC 100V
AC 120V
AC 230V
Notes
Typ
93.5%
93.9%
95.0%
Average efficiency (1) Typ
92.9%
93.3%
93.9%
25% at 5 A, 25% at 10 A, 25% at 15 A, 25% at 20 A
Typ
3.6 W
3.5 W
3.3 W
With activated shut-down
Typ
13.5 W
12.8 W
12.8 W
At 48V, 0 A (no load)
Typ
35.6 W
34.0 W
30.1 W
At 48V, 10 A (half load)
Typ
66.7 W
62.4 W
50.5 W
At 48V, 20 A (full load)
Power losses
At 48V, 20 A
(1) An assumption for a typical application where the power supply unit 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.
Figure 21 - Efficiency Versus Output Current at 48V,
Typ
Figure 22 - Losses Versus Output Current at 48V, Typ
y
Efficiency
Power Losses
96%
95
94
93
92
91
90
89
88
230V AC
120V AC
100V AC
Output Current
4
10
6
8
10
12
14
16
18
80 W
70
60
50
40
30
20
10
0
20 A
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
100V AC
120V AC
230V AC
Output Current
0
2
4
6
8
10
12
14
16
16 20 A
Figure 23 - Efficiency Versus Input Voltage at 48V,
20 A, Typ
Efficiency
Power Losses
95%
80 W
94
70
93
60
92
50
91
40
90
30
Input Voltage
89
85
Functional Diagram
Figure 24 - Losses Versus Input Voltage at 48V, 20 A,
Typ
120
155
Input Voltage
20
190
225
85
260V AC
120
155
190
225
260V AC
Figure 25 - Functional Diagram
Single /
Parallel
Output
Voltage
Regulator
V OUT
L
N
Input Fuse
Input Filter
Inrush Limiter
Temperature
Shutdown
Bridgeless
PFC
Converter
Output
Power
Manager
Output
Overvoltage
Protection
Power
Converter
Overload
LED
DC-ok
LED
Output
Voltage
Monitor
DC-OK
Relay
Event Datalogger
Shutdown
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
+
+
-
Output
Filter
13
14
DC-OK
Contact
15 Shut-down
Input and
Remote
16 Control
11
Front Side and User
Elements
Figure 26 - Front Side
A
B
D
C
4854V
Parallel Use
Single Use
QUALITY
E
DC ok
F
OVL
C
Allen-Bradley
D
1606-XLS
POWER SUPPLY
1606-XLS960F
DC ok
18WM
IND.CONT.EQ.
13
14
Shut- 15
Down
16
Input
AC 200-240V
N L
E
G
H
F
DC 48V / 20A
+
+
A
B
G
H
12
User Elements
Input terminals (screw terminals)
N, L Line input
…PE (protective earth) input
Output terminals (screw terminals, two pins per pole)
+ Positive output
- Negative (return) output
Parallel Use/Single Use selector
Set the jumper to Parallel Use when the power supply units are
connected in parallel to increase the output power. To achieve a
sharing of the load current between the individual units, the Parallel
Use regulates the output voltage in such a manner that the voltage at
no load is approximately 4% higher than at nominal load. See Parallel
Use to Increase Output Power on page 24. A missing jumper is equal to
a Single Use mode.
Output voltage potentiometer
Multi-turn potentiometer; open the flap to set the output voltage.
Factory setting is 48V at full output current, Single Use mode.
DC-OK status indicator (green)
Shows on when the voltage on the output terminals is >90% of the
adjusted output voltage.
Overload status indicator (red)
• Shows on when the voltage on the output terminals is <90% of the
adjusted output voltage, or if there is a short circuit in the output.
• Flashes when the shutdown is activated or the unit is switched off
due to over-temperature.
• Input voltage is required.
DC-OK relay contact
The DC-OK relay contact is synchronized with the DC-OK status
indicator. See DC-OK Relay Contact on page 9.
Shutdown and Remote Control input
Allows the power supply unit to be shut down; can be activated with a
switch contact or an external voltage. The remote control input allows
for adjustment of the output voltage between 44…54V. See Shutdown
Input on page 9 and Remote Control of Output Voltage on page 10.
Indicators (LEDs)
Overload LED
DC-OK LED
DC-OK Contact
Normal mode
OFF
ON
Closed
During BonusPower
OFF
ON
Closed
Overload (Hiccup mode) Flashing
OFF
Open
Output short circuit
Flashing
OFF
Open
Temperature shut-down Flashing
OFF
Open
Active shut-down input
Flashing
OFF
Open
No input power
OFF
OFF
Open
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Terminals and Wiring
The terminals are IP20 fingersafe constructed and suitable for field and
factory wiring.
Attributes
Type
Solid wire
Values
Input
Output
Screw termination
Screw termination
0.5…6 mm
2
0.5…16 mm
DC-OK, Shutdown
2
Spring clamp termination
0.15…1.5 mm2
Stranded wire
0.5…4 mm2
0.5…10 mm2
0.15…1.5 mm2
American Wire Gauge
20…10 AWG
22…8 AWG
26…14 AWG
Max wire diameter
2.8 mm (0.11 in.) (1)
5.2 mm (0.2 in.) (1)
1.5 mm (0.06 in.) (1)
Wire stripping length
7 mm (0.28 in.)
12 mm (0.5 in.)
7 mm (0.28 in.)
Screwdriver
3.5 mm (0.138 in.) or 5 mm
3 mm (0.12 in.), to open
3.5 mm (0.138 in.), slotted (0.2 in.), slotted or
the spring
or cross-head, No 2
cross-head, No 2
Recommended torque
1 N•m (9 lb•in)
2.3 N•m (20.5 lb•in)
—
(1) Includes ferrules.
Wiring instructions:
• Use the appropriate copper cables that are designed for the minimum
operating temperatures:
- 60 °C (140 °F) for an ambient temperature up to 45 °C (113 °F).
- 75 °C (167 °F) for an ambient temperature up to 60 °C (140 °F).
- 90 °C (194 °F) for an ambient temperature up to 70 °C (158 °F).
• Follow national installation codes and installation regulations.
• Confirm that all strands of a stranded wire enter the terminal
connection.
• Do not use the unit without PE connection.
• Unused terminal compartments must be securely tightened.
• Ferrules are allowed.
Lifetime Expectancy
Attribute
Calculated lifetime expectancy
Values
Notes
AC 100V
AC 120V
AC 230V
299,000 hr (1)
305,000 hr (1)
327,000 hr (1)
At 48V, 10 A and 25 °C (77 °F)
106,000 hr
(1)
108,000 hr
116,000 hr
At 48V, 10 A and 40 °C (104 °F)
180,000 hr (1)
193,000 hr (1)
253,000 hr (1)
At 48V, 20 A and 25 °C (77 °F)
64,000 hr
68,000 hr
90,000 hr
At 48V, 20 A and 40 °C (104 °F)
(1) The minimum operating hours (service life). The lifetime expectancy of the built-in electrolytic capacitors determines the
service life. Lifetime expectancy is specified in operational hours and is calculated according to the manufacturer
specification of the capacitor. The manufacturer of the electrolytic capacitors lists a maximum life of up to 15 years (131,400
hr). Any number that exceeds this value is a calculated theoretical lifetime, which can be used to compare devices.
Mean Time Between Failure
(MTBF)
MTBF is calculated according to statistical device failures, and indicates the
reliability of a device. It is the statistical representation of the likelihood of a
unit to fail; it does not necessarily represent the life of a product. An MTBF
value of, for example, 1,000,000 hr means that statistically one unit fails every
100 hours if 10,000 units are installed in the field. However, the running time
of individual failed units cannot be determined.
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
13
Attribute
MTBF SN 29500, IEC 61709
MTBF MIL HDBK 217F
Ground Benign
MTBF MIL HDBK 217F
Ground Fixed
Electromagnetic
Compatibility
Values
AC 230V
Notes
AC 100V
AC 120V
491,000 hr
481,000 hr
537,000 hr
At 48V, 20 A and 25 °C (77 °F)
274,000 hr
269,000 hr
300,000 hr
At 48V, 20 A and 40 °C (104 °F)
170,000 hr
171,000 hr
183,000 hr
At 48V, 20 A and 25 °C (77 °F);
Ground Benign GB25
126,000 hr
127,000 hr
137,000 hr
At 48V, 20 A and 40 °C (104 °F);
Ground Benign GB40
36,000 hr
36,000 hr
39,000 hr
At 48V, 20 A and 25 °C (77 °F);
Ground Fixed GF25
27,000 hr
27,000 hr
30,000 hr
At 48V, 20 A and 40 °C (104 °F);
Ground Fixed GF40
The power supply unit is suitable for applications in an industrial environment
and in a residential, commercial, and light industry environment without any
restrictions.
EMC Immunity According to Generic Standards EN 61000-6-1 and EN 61000-6-2
Attributes
Standards
Electrostatic discharge
EN 61000-4-2
Electromagnetic RF field
EN 61000-4-3
Fast transients (burst)
Surge voltage on input
Surge voltage on output
EN 61000-4-4
EN 61000-4-5
EN 61000-4-5
Surge voltage on signal lines EN 61000-4-5
Conducted disturbance
Mains voltage dips
Voltage interruptions
EN 61000-4-6
EN 61000-4-11
EN 61000-4-11
Criteria (1)
Values
Contact discharge
8 kV
Criterion A
Air discharge
15 kV
Criterion A
80 MHz…2.7 GHz
20V/m
Criterion A
Input lines
4 kV
Criterion A
Output lines
2 kV
Criterion A
Signal lines (coupling clamp) 2 kV
Criterion A
LN
2 kV
Criterion A
L  PE, N  PE
4 kV
Criterion A
+-
1 kV
Criterion A
+ / -  PE
1 kV
Criterion A
DC-OK signal  PE
1 kV
Criterion A
Shut-down input  PE
Not relevant due to wire length (2)
0.15…80 MHz
20V
Criterion A
0% of 100V AC
0V AC, 20 ms
Criterion A
40% of 100V AC
40V AC, 200 ms
Criterion C
70% of 100V AC
70V AC, 500 ms
Criterion A
0% of 200V AC
0V AC, 20 ms
Criterion A
40% of 200V AC
80V AC, 200 ms
Criterion A
70% of 200V AC
140V AC, 500 ms
Criterion A
0% of 200V AC (=0V)
5000 ms
Criterion C
Dips on the input voltage according to SEMI F47 standard
Voltage sags
Powerful transients
SEMI F47
VDE 0160
80% of 120V AC (96V AC)
1000 ms
Criterion A
70% of 120V AC (84V AC)
500 ms
Criterion A
50% of 120V AC (60V AC)
200 ms
Criterion A
Over entire load range
750V, 1.3 ms
Criterion B (3)
(1) Criterion A: Power supply shows normal operation behavior within the defined limits.
Criterion B: Output voltage dips between 48…42V for 5 ms.
Criterion C: Temporary loss of function is possible. The power supply unit can automatically shut down and restart
without damage or hazards to itself.
(2) Do not use longer wires than 30 m (98.42 ft) for the shutdown input or use an additional protection.
(3) Criterion A is fulfilled for output current up to 15 A.
14
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
EMC Emission According to Generic Standards EN 61000-6-3 and EN 61000-6-4
Attributes
Standards
Notes
Conducted emission input lines EN 55011, EN 55032, FCC Part 15,
CISPR 11, CISPR 32
Class B
Conducted emission output lines IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
10 dB higher than average limits for DC power port
according to EN 61000-6-3 (1)
Radiated emission
EN 55011, EN 55032
Class B
Harmonic input current
EN 61000-3-2
Fulfilled for class A equipment
Voltage fluctuations, flicker
EN 61000-3-3
Fulfilled (2)
This device complies with FCC Part 15 rules.
Operation is subjected to following conditions:
• This device must not cause harmful interference.
• This device must accept any interference received, including interference that can cause undesired operation.
(1) Restrictions apply for applications in residential, commercial, and light-industrial environments where local DC power
networks, according to EN 61000-6-3, are involved. No restrictions for all kinds of industrial applications.
(2) Tested with constant current loads, non-pulsing.
The power supply unit has four converters with four different switching
frequencies, which are included. One frequency is nearly constant; others are
input voltage and load dependent.
Switching Frequency
Switching Frequency Values
Notes
1
105 kHz
Resonant converter, nearly constant
2
1...150 kHz
Boost converter, input voltage, and load dependent
3
1...100 kHz
PFC converter, input voltage, and load dependent
4
25...45 kHz
Auxiliary converter, input voltage, and load dependent
Environment
Attributes
Values
Notes
Operational temperature (1) -25…+70 °C (-13…+158 °F)
Reduce output power according to Figure 27 on page 16
Storage temperature
-40…+85 °C (-40…+185 °F)
For storage and transportation
Output derating
24 W/1 °C (24 W/1.8 °F)
Between 60…70 °C (140…158 °F)
5…95% r.H.
IEC 60068-2-30
Humidity
(2)
Vibration sinusoidal
Shock
Altitude
Altitude derating
Overvoltage category
Degree of pollution
2…17.8 Hz: ±1.6 mm (0.063 in.) (3)
17.8…500 Hz: 1 g (0.04 oz)
2 hours/axis
15 g (0.53 oz) 6 ms,
10 g (0.35 oz) 11 ms (3)
3 bumps/direction,
18 bumps in total
IEC 60068-2-6
IEC 60068-2-27
0…2000 m (0…6560 ft)
Without any restrictions
2000…6000 m (6560…20,000 ft)
Reduce output power or ambient temperature, see Figure 28
on page 16
IEC 62103, EN 50178, overvoltage category II
60 W/1000 m (7.5 W/3280 ft), or
5 °C/1000 m (9 °F/3280 ft)
>2000 m (6500 ft), see Figure 28 on page 16
III
IEC 62103, EN 50178, altitudes up to 2000 m (6500 ft)
II
Altitudes from 2000…6000 m (6500…20,000 ft)
2
IEC 62103, EN 50178, not conductive
(1) The same as the ambient temperature and is defined as the air temperature 20 mm (0.79 in.) below the unit.
(2) Do not energize while condensation is present.
(3) Higher levels are allowed when using the 1606-XLC wall mounting bracket.
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
15
Figure 27 - Output Current Versus Ambient
Temperature
Figure 28 - Output Current Versus Altitude
Allowed Output Current at 48V
Allowed Output Current at 48V
30 A
30 A
short-term (4 s)
25
A
20
20
continuous
15
B
10
-25
0
20
A
A: Tamb <60 °C
B: Tamb <50 °C
C: Tamb <40 °C
5
Ambient Temperature
0
continuous
15
A: 90…264V AC
B: 85…90V AC
10
5
short-term (4 s)
25
60 70 °C
0
2000
C
Altitude
0
40
B
4000
6000 m
Protection Features
Attributes
Values
Output protection
Electronically protected against overload, no-load, and short-circuits (1)
Output overvoltage protection
Notes
58.8V DC typ
If there is an internal power supply anomaly, a redundant circuit limits
the maximum output voltage. The output shuts down and automatically
attempts to restart.
60V DC max
Degree of protection
IP 20
EN/IEC 60529 (2)
Penetration protection
>5 mm (0.2 in.)
For example, screws and small parts
Over-temperature protection
Yes
Output shutdown with automatic restart
Input transient protection
MOV
Metal Oxide Varistor
Internal input fuse
Included
Not user-replaceable
(1) An audible noise occurs if there is a protection event.
(2) For use in a controlled environment according to CSA 22.2 No 107.1-01.
Safety Features
Attributes
Input/output separation (1)
Values
Notes
SELV
IEC/EN 60950-1
PELV
IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
Class of protection
I
PE connection not required.
Isolation resistance
>100 MΩ
Input to output, 500V DC
PE resistance
<0.1 Ω
—
Touch current
(leakage current)
Typ
0.39 mA/1.0 mA
Typ
0.56 mA/1.43 mA 120V AC, 60 Hz, TN-, TT-mains/IT-mains
100V AC, 50 Hz, TN-, TT-mains/IT-mains
Typ
0.90 mA/2.25 mA 230V AC, 50 Hz, TN-, TT-mains/IT-mains
Max
0.50 mA/1.21 mA
110V AC, 50 Hz, TN-, TT-mains/IT-mains
Max
0.71 mA/1.73 mA
132V AC, 60 Hz, TN-, TT-mains/IT-mains
Max
1.18 mA/2.28 mA
264V AC, 50 Hz, TN-, TT-mains/IT-mains
(1) Double or reinforced insulation.
Dielectric Strength
16
The output voltage is floating and has no ohmic connection to the ground. The
manufacturer conducts type and factory tests. Field tests can be conducted
with the appropriate test equipment, which applies the voltage with a slow
ramp (2 s up and 2 s down). Connect all input terminals together and connect
all output poles before conducting the test. When testing, set the cutoff
current settings to the values in the following table.
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Figure 29 - Dielectric Strength
Input
DC-OK
B (a)
L
N
13
Test or Setting
Time
A
B
C
D
Type test
60 s
2500V AC
3000V AC
500V AC
500V AC
Factory test
5s
2500V AC
2500V AC
500V AC
500V AC
Field test
5s
2000V AC
2000V AC
500V AC
500V AC
Cutoff current setting —
>20 mA
>20 mA
>40 mA
>1 mA
14
B
A
D
Output
Earth, PE
C
+/-
Shut-down
15/16
(a) When input to DC-OK is tested, confirm that the max voltage between DC-OK
and the output is not exceeded (column D). We recommend connecting DC-OK
pins and the output pins together when performing the test.
To fulfill the PELV requirements according to
EN60204-1 § 6.4.1, we recommend that you connect
the protective earth system to the + pole, the – pole,
or any other part of the output circuit. This
connection helps to avoid situations in which a load
starts unexpectedly or cannot be switched off when
unnoticed earth faults occur.
Certifications and
Standards Compliance
Names
Notes (1)
Symbols
UL 508
IND. CONT. EQ.
UL Certificate
Listed equipment for category NMTR - Industrial Control
Equipment
Applicable for US and Canada
UL 60950-1
UL Certificate
Recognized component for category QQGQ - Information
Technology Equipment
Applicable for US and Canada
ATEX
Agency Certificate (Bureau Veritas) (1)
EN 60079-0 Explosive atmospheres - General requirements
EN 60079-7, EN 60079-15 Equipment protection by type of
protection "e" and "n"
Temperature Code: T3
Type of Protection: nA nC
IECEx
IECEx Certificate (1)
IEC 60079-0 Explosive atmospheres - General requirements
IEC 60079-7, IEC 60079-15 Equipment protection by type of
protection "e" and "n"
Temperature Code: T3
Type of Protection: nA nC
Class I Div 2
CSA Certificate
Power Supplies for Hazardous Location
Applicable for Canada and US
CSA Class: 5318-01 (Canada), 5318-81 (US)
Temperature Code: T3
Groups: A, B, C, and D
Marine (DNV GL)
DNV-GL Certificate
DNV-GL Type approved product
Temperature: Class D
Humidity: Class B
Vibration: Class C
EMC: Class A
Enclosure: Class A
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
17
Names
Symbols
Notes (1)
EC Declaration of Conformity
The CE marking indicates conformance with the following:
– EMC Directive
– Low Voltage Directive (LVD)
– RoHS directive
REACH Directive
Manufacturer's Statement
EU-Directive regarding the Registration, Evaluation,
Authorization, and Restriction of Chemicals
EAC TR Registration
Registration for the Eurasian Customs Union market (Russia,
Kazakhstan, Belarus)
(1) Product certification information (including Certificates and Declarations of Conformity) can be found at rok.auto/certifications.
Approximate Dimensions
and Weight
Attributes
Values and Descriptions
Width
125 mm (4.92 in.)
Height
124 mm (4.88 in.)
Depth
127 mm (0.5 in.) (1)
Weight
1900 g (4.2 lb)
DIN rail
Use 35 mm (1.38 in.) DIN rails according to EN 60715 or EN 50022 with a height of
7.5 mm (0.30 in.) or 15 mm (0.59 in.).
Housing material
Aluminum body, steel cover
Installation clearances
Top: 40 mm (1.57 in.)
Bottom: 20 mm (0.79 in.)
Left/right: 5 mm (0.2 in.) (2)
(1) Add the DIN rail height to the unit depth to calculate the total required installation depth.
(2) Increase the 5 mm (0.2 in.) to 15 mm (0.59 in.) in case the adjacent device is a heat source. When the
device is permanently loaded with less than 50%, the 5 mm (0.2 in.) can be reduced to zero.
Figure 31 - Side View [mm (in.)]
Height 124 (4.88)
Figure 30 - Front View [mm (in.)]
40 (1.57) 19.1 (0.75)
75.4 (2.97)
40.5 (1.54)
Width 125 (4.92)
18
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Width 127 (5.0)
DIN Rail Depth
Accessories
1606-XLC Wall Mounting Bracket
This bracket is used to mount specific units onto a flat surface without using a
DIN rail.
Figure 32 - Wall Mounting Bracket Attached
to Unit
Figure 33 - Wall Mounting Bracket
1606-XLSBUFFER48 Buffer Module
This buffer module is a supplementary device for DC 48V power supply units.
The module delivers power to bridge typical mains failures or extends the holdup time after turn-off of the AC power. In times when the power supply unit
provides sufficient voltages, the buffer module stores energy in integrated
electrolytic capacitors. If there is a mains voltage fault, this energy is released
again in a regulated process.
The buffer module does not require any control wiring. It can be added in
parallel to the load circuit at any given point. Buffer modules can be added in
parallel to increase the output ampacity or the hold-up time.
Figure 34 - Buffer Module
Figure 35 - Buffer Module in Parallel
p
AC
pp
Power
Supply
DC
p
Buffer
Unit(s)
Load
+
-
1606-XLSRED40HF Redundancy Module
The 1606-XLSRED40HF redundancy module is equipped with two input
channels of 20 A each, which are individually decoupled by using mosfet
technology. The output current is up to 40 A.
Mosfets are used instead of diodes to reduce the heat generation and voltage
drop between input and output.
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
19
The 1606-XLSRED40HF redundancy module does not require an additional
auxiliary voltage and is self-powered, even if there is a short circuit across the
output.
Due to the low-power losses, the module is slender and only requires a
46 mm (1.81 in.) wide DIN rail.
Figure 36 - Redundancy Module
Figure 37 - Typical 1+1 Redundant Configuration for 20 A with a Dual
Redundancy Module
48V
20 A
Load
1606-XLS960F
48…54V 960 W
Power Supply
+
DCOK
Single Use
AC Input
N PE
1606-XLS960F
48…54V 960 W
Power Supply
-
Output
Parallel Use
L
Failure
Monitor
48V, 20A
+ +
I
- -
1606-XLSRED40HF
Redundancy
Module
Input
1
Parallel Use
DCOK
Single Use
Input
2
AC Input
+ - + -
L
N PE
48V, 20 A
+ +
- -
I
L
N
PE
Repetitive Pulse Loading
A load current is not typically constant and varies over time. The power supply
unit is designed to support loads with a higher short-term power requirement
without damage or shutdown, or BonusPower. An output power manager
controls the short-term duration. BonusPower is repeatedly available. If the
BonusPower load lasts longer than the hardware controller allows, the output
voltage will dip and the next BonusPower is available after the BonusPower
recovery time has elapsed (see Output on page 6).
To avoid voltage dips, follow the following rules:
• The power demand of the pulse must be below 150% of the nominal
output power.
• The duration of the pulse power must be shorter than the allowed
BonusPower time (see Output on page 6).
• The average (RMS) output current must be below the specified
continuous output current. If the RMS current is higher, the unit
responds with a thermal shutdown after a time. Use the maximum duty
cycle curve in Figure 39 on page 21 to check if the average output current
is below the nominal current.
• The duty cycle must be below 0.75.
20
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Figure 38 - Repetitive Pulse Loads, Definitions
Figure 39 - Maximum Duty Cycle Curve
g
P 0 = 10%
P 0 = 50%
P 0 = 75%
Duty Cycle
PPEAK
TPEAK
0.75
T0
0.6
max
150%
0.4
100%
P 0 = 100%
0.2
P0
P PEAK
0
100
110
DutyCycle
=
1
120
130
140
150%
1
P0
Base load (W)
PPEAK
Pulse load (above 100%)
T0
Duration between pulses (s)
TPEAK
Pulse duration (s)
T0
=
Tpeak
Tpeak + T0
Tpeak - (DutyCycle x Tpeak)
DutyCycle
Example Repetitive Pulse Calculation
A load is powered continuously with 480 W (= 50% of the rated output load).
Occasionally a peak power of 1440 W (= 150% of the rated output load) is
needed for 1 second.
How often can this pulse be supplied without overloading the power supply?
1. Make a vertical line at PPEAK = 150% and a horizontal line where the
vertical line crosses the P0 = 50% curve. Read the maximum duty cycle
from the duty cycle-axis (= 0.37)
2. Calculate the required pause (base load) length T0
3. The result is the required pause length = 1.7 s
4. Max repetition rate = pulse + pause length = 2.7 s
T0
=
Tpeak - (DutyCycle x Tpeak)
DutyCycle
=
1 s - (0.37 x 1 s)
0.37
=
1.7 s
Additional Examples for Pulse Load Compatibility
PPEAK
P0
TPEAK
1440 W
960 W
1s
T0
>25 s
1440 W
0W
1s
>1.3 s
1200 W
480 W
1s
>0.75 s
1440 W
480 W
0.1 s
>0.16 s
1440 W
480 W
1s
>1.6 s
1440 W
480 W
3s
>4.9 s
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
21
Peak Current Capability
The power supply unit can deliver peak currents (up to several milliseconds)
which are higher than the specified short-term currents.
Peak current capability helps to start current-demanding loads. Solenoids,
contactors, and pneumatic modules often have a steady state coil and a
pick-up coil. The inrush current demand of the pick-up coil is several times
higher than the steady-state current and usually exceeds the nominal output
current (including the BonusPower). The same situation applies when starting
a capacitive load.
The peak current capability also achieves the safe operation of subsequent
circuit breakers of load circuits. The load branches are often individually
protected with circuit breakers or fuses. If there is a short or an overload in one
branch circuit, the fuse or circuit breaker needs a certain amount of
overcurrent to open in a timely manner. This safety avoids voltage loss in
adjacent circuits.
The extra current (peak current) is supplied by the power converter and the
built-in large-sized output capacitors of the power supply unit. The capacitors
get discharged during such an event, which causes a voltage dip on the output.
Figure 40 and Figure 41 show typical voltage dips.
Figure 40 - Peak Loading with 2x the Nominal
Current for 50 ms, Typ
Figure 41 - Peak Loading with 5x the Nominal
Current for 5 ms, Typ
48V
48V
37.9V
40 A
28.9V
100 A
0A
0A
10 ms/DIV
Peak load 40 A (resistive load) for 50 ms.
Output voltage: 48V dips to 37.9V
IMPORTANT
1 ms/DIV
Peak load 100 A (resistive load) for 5 ms.
Output voltage: 48V dips to 28.9V
The DC-OK relay triggers when the voltage dips more than 10% for
longer than 1 ms.
Peak Current Voltage Dips
Back-feeding Loads
Attributes
Values
Typ
48…37.9V
Notes
At 40 A for 50 ms, resistive load
Typ
48…34.9V
At 100 A for 2 ms, resistive load
Typ
48…28.9V
At 100 A for 5 ms, resistive load
Loads such as decelerating motors and inductors can feed voltage back to the
power supply unit. This feature is also called return voltage immunity, or
resistance against Back Electromagnetic Force (Back EMF).
This power supply unit is resistant and does not show malfunctions when a
load feeds back voltage to the unit, regardless of whether the unit is on or off.
The maximum allowed feed back voltage is 63V DC. The absorbing energy can
be calculated according to the built-in large-sized output capacitor, which is
specified in Output on page 6.
22
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Inductive and Capacitive
Loads
The unit is designed to supply any kind of loads, including unlimited
capacitive and inductive loads. If extreme large capacitors, such as EDLCs
(electric double layer capacitors or UltraCaps) with a capacitance of >1F are
connected to the output, the unit can charge the capacitor in the HiccupPLUS
mode (see Output on page 6).
Charging of Batteries
This power supply unit is not recommended to charge lead-acid or
maintenance free batteries. The recommended end-of-charge voltage of 55V at
20 °C (68 °F) for four 12V VRLA lead-acid batteries in series cannot be supplied
from the 1606-XLS960F power supply unit.
Output Circuit Breakers
Standard miniature circuit breakers, such as MCB or UL1077, are commonly
used for AC-supply systems and can be used on DC branches.
MCB circuit breakers are designed to protect wires and circuits. If the ampere
value and the characteristics of the MCB circuit breaker are adapted to the wire
size that is used, the wiring is considered thermally safe, regardless of whether
the MCB opens.
To avoid voltage dips and undervoltage situations in adjacent 48V branches
that are supplied by the same source, a fast magnetic tripping of the MCB
circuit breaker is desired. A shutdown within 10 ms is necessary, which
corresponds roughly to the ride-through time of the PLC. A quick shutdown
requires power supply units with high current reserves and large output
capacitors. Furthermore, the impedance of the faulty branch must be
sufficiently small for the current to flow. The following table contains typical
test results that show which B- and C-characteristic MCB circuit breakers
magnetically trip, depending on the wire cross section and wire length.
Figure 42 - Test Circuit
MCB
Power Supply
Load
+
AC
+
Wire length
DC
S1
-
-
S1 Fault simulation switch
Maximal Wire Length for a Fast Magnetic Tripping [m (ft)] (1)
MCB
Wire Length by Gauge
0.75 mm² (18 AWG)
1.0 mm² (17 AWG)
1.5 mm² (16 AWG)
2.5 mm² (14 AWG)
68 (223.1)
89 (292)
>100 (328.1)
>100 (328.1)
C-3A
53 (173.9)
75 (246.1)
>100 (328.1)
>100 (328.1)
C-4A
44 (144.4)
57 (187)
88 (288.7)
>100 (328.1)
C-6A
18 (5901)
25 (82)
38 (124.7)
58 (190.3)
C-8A
9 (29.5)
12 (39.4)
18 (59.1)
24 (78.7)
C-10A
8 (26.2)
11 (36.1)
16 (52.5)
23 (75.5)
C-2A
C-13A
4 (13.1)
5 (16.4)
8 (26.2)
12 (39.4)
B-6A
39 (128)
50 (164.0)
74 (242.8)
>100 (328.1)
B-10A
21 (68.9)
29 (95.1)
44 (144.4)
68 (223.1)
B-13A
13 (42.7)
21 (68.9)
34 (111.5)
52 (170.6)
B-16A
7 (23)
9 (29.5)
13 (42.7)
17 (55.8)
B-20A
2 (6.6)
3 (9.8)
4 (13.1)
5 (16.4)
(1) Consider twice the distance to the load or cable length when calculating the total wire length
(+ and – wire).
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
23
External Input Protection
The unit is tested and approved for branch circuits up to 30 A (US) and 32 A
(IEC). An external protection is required only if the supplying branch has an
ampacity greater than the approved circuit amperage. Check local codes and
local requirements. In some countries, local regulations might apply.
If an external fuse is used, minimum requirements must be considered to
avoid nuisance tripping of the circuit breaker. A minimum value of 16 A B- or
C-characteristic breaker must be used, when the unit is used at AC 100V and
AC 120V mains voltages (including AC 230V). If the unit is used only at AC 230V
mains, a 10 A B- or C-characteristic breaker is sufficient.
Parallel Use to Increase
Output Power
Power supply units from the same series can be paralleled to increase the
output power. The output voltage must be adjusted to the same value
(±100 mV) in Single Use mode with the same load conditions on all units, or
the units can be left with the factory settings. After the adjustments, move the
jumper on the front of the unit from Single Use to Parallel Use to achieve load
sharing. The Parallel Use mode regulates the output voltage so that the voltage
at no load is approximately 4% higher than at nominal load. See Output on
page 6. If no jumper is plugged in, the unit is in Single Use mode. The factory
setting is also Single Use mode.
Figure 43 - Parallel Use to Increase Output Power
Unit A
AC
DC
+
+
Unit B
AC
DC
Load
+
-
-
If more than three units are connected in parallel, a fuse or circuit breaker with
a rating of 30 A or 32 A is required on each output. Alternatively, use a diode or
redundancy module.
Energize all units simultaneously to avoid the overload HiccupPLUS mode. If
the output was in HiccupPLUS mode due to overload or short circuits and the
required output current is higher than the current of one unit, turn off the
power for at least 5 seconds.
Keep a left and right installation clearance of 15 mm (0.59 in.) between the two
power supply units and avoid installing the units on top of each other. Do not
use power supply units in parallel in mounting orientations other than in the
standard mounting orientation (terminals on the bottom of the unit). Do not
use the power supply units in parallel in any other condition where a derating
of the output current is required, such as in altitudes above 60 °C (140 °F).
Understand that leakage current, EMI, inrush current, and harmonics
increase when using multiple power supply units.
24
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Parallel Use for Redundancy Power supplies can be paralleled for redundancy to gain higher system
availability. Redundant systems require a certain amount of extra power to
support the load in case one power supply unit fails. The simplest way is to put
two power supply units in parallel. This type of redundancy is called a 1+1
redundancy. In case one power supply unit fails, the other unit automatically
supports the load current without any interruption. Redundant systems for a
higher power demand are built in an N+1 method. For example, five power
supply units, each rated for 20 A, are paralleled to build an 80 A redundant
system. For N+1 redundancy, the same restrictions apply as for increasing the
output power, see Parallel Use to Increase Output Power on page 24.
IMPORTANT
This redundant system does not cover failures such as an internal short
circuit in the secondary side of the power supply unit. In such a case,
the defective unit becomes a load for the other power supply units and
the output voltage cannot be maintained. This defective unit load can
only be avoided by using redundancy modules that include decoupling
devices, such as diodes or mosfets. See 1606-XLSRED40HF Redundancy
Module on page 19.
Recommendations for building redundant power systems:
• Use separate input fuses for each power supply unit to increase the
reliability of the redundant system.
• Set the unit into Parallel Use mode.
• Monitor the individual units. Use the DC-OK relay contact of the
1606-XLS960F power supply unit.
• Set the output voltages of all units to the same value (±100 mV) or leave
output voltages at the factory setting.
Daisy Chain
A daisy chain (a jump from one power supply unit output to the next) is
allowed as long as the average output current through one terminal pin does
not exceed 54 A. If the current is higher, use a separate distribution terminal
block as shown in Figure 45.
Figure 44 - Daisy Chain of Outputs
Power
Supply
+ +
--
Output
Figure 45 - Using Distribution Terminals
Distribution
Terminals
Power
Supply
+ +
--
Output
Power
Supply
Load
+
-
+ +
--
Output
Power
Supply
+ +
--
Output
Load
+
-
Max 25 A
Continuous
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
25
Series Operation
Figure 46 - Series Operation
Power supplies of the same type can
be connected in series for higher
output voltages. Connect as many
units in series as needed, providing
the sum of the output voltage does
not exceed 150V DC. Voltages with
a potential above 60V DC can be
dangerous and are no longer SELV.
Such voltages must be installed
with a protection against being
touched.
Unit A
AC
+
-
DC
+
Unit B
Load
AC
-
+
-
DC
Earth
Earthing of the output is required when the sum of the output voltage is above
60V DC.
Avoid return voltage (for example, from a decelerating motor or battery) which
is applied to the output terminals.
Keep a left and right installation clearance of 15 mm (0.59 in.) between two
power supply units and avoid installing the units on top of each other. Do not
use power supply units in series in mounting orientations other than the
standard mounting orientation (terminals on the bottom of the unit).
Understand that leakage current, EMI, inrush current, and harmonics
increase when using multiple power supply units.
Operation on Two Phases
Figure 47 - Operation on Two Phases
Power Supply
L1
L2
26
max
L
+10%
N
240V
L3
AC
PE
The power supply unit can be used
on two phases of a three-phase
system, as long as the supplying
voltage is below 240V+10%.
internal
fuse
DC
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
Use in a Tightly Sealed
Enclosure
When the power supply unit is installed in a tightly sealed enclosure, the
temperature inside the enclosure is higher than outside of the enclosure. In
such situations, the inside temperature defines the ambient temperature for
the power supply unit.
The following measurement results can be used as a reference to estimate the
temperature rise inside the enclosure. These measurements are taken with the
power supply unit in the middle of the enclosure, with no other heatproducing items inside the enclosure.
Attributes
Values
Enclosure size
254 x 180 x 165 mm
(4.88 x 7.09 x 6.50 in.)
Rittal Typ IP66 Box
PK 9522 100, plastic
Input voltage
230V AC
Load
48V, 16 A; (=80%) (1)
Temperature inside enclosure
65.6 °C (150.08 °F) (2)
Temperature outside enclosure
24.1 °C (75.38 °F)
Temperature rise
41.5K
(1) The load is placed outside the box.
(2) Temperature in the middle of the right side of the
power supply unit with a distance of 20 mm (0.79 in.).
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
27
Mounting Orientations
Mounting orientations, other than all terminals on the bottom, require a
reduction in continuous output power or a limitation in the maximum allowed
ambient temperature. The amount of reduction influences the lifetime
expectancy of the power supply unit.
Figure 48…Figure 52 on page 28 show two derating curves for continuous
operation.
• Curve A1: Recommended output current.
• Curve A2: Max allowed output current (results in approximately half the
lifetime expectancy of A1).
Output Current
A1
20 A
15
Figure 48 - Mounting Orientation A:
Standard Orientation
Power
Supply
10
5
INPUT
Ambient Temperature
0
OUTPUT
10
20
30
40
50
60 °C
50
60 °C
50
60 °C
Output Current
INPUT
OUTPUT
Figure 49 - Mounting Orientation B:
Upside Down
20 A
15
A2
10
A1
Power
Supply
5
Ambient Temperature
0
10
20
30
40
Output Current
20 A
15
Figure 50 - Mounting Orientation C:
Table-top Mounting
A2
A1
10
5
Ambient Temperature
0
10
20
30
40
Output Current
20 A
15
OUTPUT
Power
Supply
INPUT
Figure 51 - Mounting Orientation D:
Horizontal CW
A2
10
A1
5
Ambient Temperature
0
10
20
30
40
50
60 °C
Output Current
OUTPUT
15
A2
A1
10
INPUT
Figure 52 - Mounting Orientation E:
Horizontal CCW
Power
Supply
20 A
5
Ambient Temperature
0
10
28
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
20
30
40
50
60 °C
Switched Mode Power Supply Reference Manual
Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Resource
Switched Mode Power Supply Specifications Technical Data, publication
1606-TD002
1606-XLS960F Installation Instructions, publication 1606-IN029
System Security Design Guidelines Reference Manual, SECURE-RM001
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-State Control, publication SGI-1.1
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Product Certifications website, rok.auto/certifications
Description
Provides specifications for Bulletin 1606 products and applications.
Provides basic specifications and installation instructions.
Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Provides a quick reference tool for Allen-Bradley® industrial automation controls and
assemblies.
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
You can view or download publications at rok.auto/literature.
Rockwell Automation Publication 1606-RM028A-EN-P - September 2021
29
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Knowledgebase
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(PCDC)
Find help with how-to videos, FAQs, chat, user forums, and product notification updates.
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Download firmware, associated files (such as AOP, EDS, and DTM), and access product
release notes.
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At the end of life, this equipment should be collected separately from any unsorted municipal waste.
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