Allen-Bradley Power Supply Reference Manual
Allen-Bradley Power Supply is a DIN rail mounted device designed for industrial, office, communication, and instrumentation equipment. It features high efficiency, small footprint, and large power reserves for starting heavy loads. The unit is easy to install and operate with features like a DC-OK relay, green DC-OK LED, red overload LED, and a large international approval package.
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Reference Manual
egaPegaP
1. Intended Use .......................................................3
2. Installation Requirements...................................3
3. AC-Input...............................................................4
4. Input Inrush Current ...........................................5
5. DC-Input...............................................................5
6. Output .................................................................6
7. Hold-up Time.......................................................8
8. DC-OK Relay Contact ..........................................9
9. Shut-down Input .................................................9
10. Remote Control of Output Voltage .................10
11. Internal Data Logging.......................................10
12. Efficiency and Power Losses..............................11
13. Lifetime Expectancy and MTBF.........................12
14. Functional Diagram...........................................12
15. Terminals and Wiring........................................13
16. Front Side and User Elements...........................14
17. EMC....................................................................15
18. Environment ......................................................16
19. Protection Features ...........................................17
20. Safety Features ..................................................17
21. Dielectric Strength ............................................18
22. Certifications ................................................... 18
23. Physical Dimensions and Weight ..................... 19
24. Accessories ........................................................ 20
24.1. 1606-XLC Wall Mounting Bracket ............ 20
24.2. 1606-XLSBUFFER48 Module ..................... 20
25. Application Notes ............................................. 22
25.1. Repetitive Pulse Loading ..........................22
25.2. Peak Current Capability ...........................23
25.3. External Input Protection .........................23
25.4. Charging of Batteries ...............................24
25.5. Output Circuit Breakers ............................24
25.6. Parallel Use to Increase Output Power ....25
25.7. Parallel Use for Redundancy ....................25
25.8. Series Operation .......................................26
25.9. Inductive and Capacitive Loads ................26
25.10. Back-feeding Loads ..................................26
25.11. Operation on Two Phases ........................27
25.12. Use in a Tightly Sealed Enclosure ............27
25.13. Mounting Orientations ............................28
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLS960FE
Index
• PE and symbol—PE is the abbreviation for Protective Earth and has the same meaning as the symbol .
• Earth, Ground—This document uses the term “earth” which is the same as the U.S. term “ground”.
• T.b.d.—To be defined, value or description will follow later.
• AC 230V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)
included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
• 230Vac—A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.
• 50Hz vs. 60Hz—As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.
• may—A key word indicating flexibility of choice with no implied preference.
• shall—A key word indicating a mandatory requirement.
• should—A key word indicating flexibility of choice
Terminology and Abbreviations
egaPegaP
1. Intended Use .......................................................3
2. Installation Requirements...................................3
3. AC-Input...............................................................4
4. Input Inrush Current ...........................................5
5. DC-Input...............................................................5
6. Output .................................................................6
7. Hold-up Time.......................................................8
8. DC-OK Relay Contact ..........................................9
9. Shut-down Input .................................................9
10. Remote Control of Output Voltage .................10
11. Internal Data Logging.......................................10
12. Efficiency and Power Losses..............................11
13. Lifetime Expectancy and MTBF.........................12
14. Functional Diagram...........................................12
15. Terminals and Wiring........................................13
16. Front Side and User Elements...........................14
17. EMC....................................................................15
18. Environment ......................................................16
19. Protection Features ...........................................17
20. Safety Features ..................................................17
21. Dielectric Strength ............................................18
22. Certifications ................................................... 18
23. Physical Dimensions and Weight ..................... 19
24. Accessories ........................................................ 20
24.1. 1606-XLC Wall Mounting Bracket ............ 20
24.2. 1606-XLSBUFFER48 Module ..................... 20
25. Application Notes ............................................. 22
25.1. Repetitive Pulse Loading ..........................22
25.2. Peak Current Capability ...........................23
25.3. External Input Protection .........................23
25.4. Charging of Batteries ...............................24
25.5. Output Circuit Breakers ............................24
25.6. Parallel Use to Increase Output Power ....25
25.7. Parallel Use for Redundancy ....................25
25.8. Series Operation .......................................26
25.9. Inductive and Capacitive Loads ................26
25.10. Back-feeding Loads ..................................26
25.11. Operation on Two Phases ........................27
25.12. Use in a Tightly Sealed Enclosure ............27
25.13. Mounting Orientations ............................28
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLS960FE
Index
• PE and symbol—PE is the abbreviation for Protective Earth and has the same meaning as the symbol .
• Earth, Ground—This document uses the term “earth” which is the same as the U.S. term “ground”.
• T.b.d.—To be defined, value or description will follow later.
• AC 230V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)
included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
• 230Vac—A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.
• 50Hz vs. 60Hz—As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.
• may—A key word indicating flexibility of choice with no implied preference.
• shall—A key word indicating a mandatory requirement.
• should—A key word indicating flexibility of choice
Terminology and Abbreviations
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
2 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
Bulletin 1606 Switched Mode Power Supplies
Power Supply
AC 200-240V Input
Width only 125mm, Weight only 1.8kg
95.0% Full Load and Excellent Partial Load Efficiencies
50% BonusPower, 1440W for up to 4s
55A High Peak Current for 25ms for Easy Fuse Tripping
Safe HiccupPLUS Overload Mode
Active PFC (Power Factor Correction)
Negligible Low Input Inrush Current Surge
Full Power Between -25°C and +60°C
Current Sharing Feature for Parallel Use
Internal Data Logging for Troubleshooting Included.
DC-OK Relay Contact
Shut-down Input
3 Year Warranty
Description
The most outstanding features of our family of DIN rail
power supplies are their extremely high efficiency and
their small footprint, which are achieved by a
synchronous rectification and other technological
innovations.
The 1606-XLS960FE is a device for 200-240V mains
voltages. Large power reserves of 150% support the
starting of heavy loads such as DC motors or capacitive
loads. In many cases, this allows the use of a unit from a
lower wattage class which saves space and money.
High immunity to transients and power surges as well as
low electromagnetic emission make usage in nearly
every environment possible.
The integrated output power manager and input fuses
as well as 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 a variety of
applications makes this unit suitable for nearly every
application.
Specification Quick Reference
Output voltage DC 48V nominal
Adjustment range 48 - 54V
Output current 20 – 17.8A continuous
30 – 26.7A short term (4s)
Output power 960W continuous
1440W short term (4s)
Output ripple < 150mVpp 20Hz to 20MHz
Input voltage AC 200-240V -15%/+10%
Mains frequency 50-60Hz ±6%
AC Input current 4.6A at 230Vac
Power factor 0.96 at 230Vac
AC Inrush current typ. 14A peak at 230Vac
Efficiency 95.0% at 230Vac
Losses 50.5W at 230Vac
Temperature range -25°C to +70°C operational
Derating 24W/°C +60 to +70°C
Hold-up time typ. 30ms at 230Vac
Dimensions 125x124x127mm WxHxD
Weight 1800g / 3.97lb
Catalog Numbers
Power Supply 1606-XLS960FE 48-54V Standard unit
Accessories 16060-XLC Wall mount bracket
1606-XLSBUFFER48 Buffer unit
Certifications
IND. CONT. EQ.
UL 508 UL 60950-1 EMC, LVD, RoHS
Marine Marine RINA GOST R C-TICK
2 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
Bulletin 1606 Switched Mode Power Supplies
Power Supply
AC 200-240V Input
Width only 125mm, Weight only 1.8kg
95.0% Full Load and Excellent Partial Load Efficiencies
50% BonusPower, 1440W for up to 4s
55A High Peak Current for 25ms for Easy Fuse Tripping
Safe HiccupPLUS Overload Mode
Active PFC (Power Factor Correction)
Negligible Low Input Inrush Current Surge
Full Power Between -25°C and +60°C
Current Sharing Feature for Parallel Use
Internal Data Logging for Troubleshooting Included.
DC-OK Relay Contact
Shut-down Input
3 Year Warranty
Description
The most outstanding features of our family of DIN rail
power supplies are their extremely high efficiency and
their small footprint, which are achieved by a
synchronous rectification and other technological
innovations.
The 1606-XLS960FE is a device for 200-240V mains
voltages. Large power reserves of 150% support the
starting of heavy loads such as DC motors or capacitive
loads. In many cases, this allows the use of a unit from a
lower wattage class which saves space and money.
High immunity to transients and power surges as well as
low electromagnetic emission make usage in nearly
every environment possible.
The integrated output power manager and input fuses
as well as 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 a variety of
applications makes this unit suitable for nearly every
application.
Specification Quick Reference
Output voltage DC 48V nominal
Adjustment range 48 - 54V
Output current 20 – 17.8A continuous
30 – 26.7A short term (4s)
Output power 960W continuous
1440W short term (4s)
Output ripple < 150mVpp 20Hz to 20MHz
Input voltage AC 200-240V -15%/+10%
Mains frequency 50-60Hz ±6%
AC Input current 4.6A at 230Vac
Power factor 0.96 at 230Vac
AC Inrush current typ. 14A peak at 230Vac
Efficiency 95.0% at 230Vac
Losses 50.5W at 230Vac
Temperature range -25°C to +70°C operational
Derating 24W/°C +60 to +70°C
Hold-up time typ. 30ms at 230Vac
Dimensions 125x124x127mm WxHxD
Weight 1800g / 3.97lb
Catalog Numbers
Power Supply 1606-XLS960FE 48-54V Standard unit
Accessories 16060-XLC Wall mount bracket
1606-XLSBUFFER48 Buffer unit
Certifications
IND. CONT. EQ.
UL 508 UL 60950-1 EMC, LVD, RoHS
Marine Marine RINA GOST R C-TICK
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM018A-EN-P — February 2014 3
Bulletin 1606 Switched Mode Power Supplies
1. Intended Use
• This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office,
communication, and instrumentation equipment.
• Do not use this power supply in aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or
threaten human life.
• This device is designed for use in non-hazardous, ordinary or unclassified locations.
2. Installation Requirements
• This device may only be installed and put into operation by qualified personnel.
• This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
• If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.
• Mount the unit on a DIN rail so that the terminals are located on the bottom of the unit. For other mounting orientations, refer to Mounting.
• This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid
(e.g. cable conduits) by more than 15%!
• Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the
device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat
source (e.g. another power supply).
SHOCK HAZARD: Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input
block for earth connection and not one of the screws on the housing.
- Turn power off before working on the device. Protect against inadvertent re-powering
- Make sure that the wiring is correct by following all local and national codes
- Do not modify or repair the unit
- Do not open the unit as high voltages are present inside
- Use caution to prevent any foreign objects from entering the housing
- Do not use in wet locations or in areas where moisture or condensation can be expected
- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.
WARNING: EXPLOSION HAZARDS!
Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment or S/P jumper unless
power has been switched off or the area is known to be non-hazardous.
Rockwell Automation Publication 1606-RM018A-EN-P — February 2014 3
Bulletin 1606 Switched Mode Power Supplies
1. Intended Use
• This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office,
communication, and instrumentation equipment.
• Do not use this power supply in aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or
threaten human life.
• This device is designed for use in non-hazardous, ordinary or unclassified locations.
2. Installation Requirements
• This device may only be installed and put into operation by qualified personnel.
• This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
• If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.
• Mount the unit on a DIN rail so that the terminals are located on the bottom of the unit. For other mounting orientations, refer to Mounting.
• This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid
(e.g. cable conduits) by more than 15%!
• Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the
device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat
source (e.g. another power supply).
SHOCK HAZARD: Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input
block for earth connection and not one of the screws on the housing.
- Turn power off before working on the device. Protect against inadvertent re-powering
- Make sure that the wiring is correct by following all local and national codes
- Do not modify or repair the unit
- Do not open the unit as high voltages are present inside
- Use caution to prevent any foreign objects from entering the housing
- Do not use in wet locations or in areas where moisture or condensation can be expected
- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.
WARNING: EXPLOSION HAZARDS!
Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment or S/P jumper unless
power has been switched off or the area is known to be non-hazardous.
All parameters are specified at 48V, 20A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
4 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
Bulletin 1606 Switched Mode Power Supplies
3. AC Input
AC input nom. AC 200-240V suitable for TN, TT and IT mains networks
AC input range min. 170-264Vac continuous operation
min. 110-170Vac full power for up to 200ms
min. 0-170Vac no damage to the unit
264-300Vac < 500ms
Allowed voltage L or N to earth max. 300Vac continuous, IEC 62103
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 164Vac steady-state value, load independent, see Fig. 3-1
Shut-down voltage typ. 151Vac steady-state value, load independent, see Fig. 3-1
Input current typ. 4.6A at 48V, 20A, see Fig. 3-3
Power factor*) typ. 0.96 at 48V, 20A, see Fig. 3-4
Crest factor**) typ. 1.65 at 48V, 20A
Start-up delay typ. 750ms see Fig. 3-2
Rise time typ. 18ms at 48V, 20A, resistive load, 0mF see Fig. 3-2
typ. 35ms at 48V, 20A, resistive load, 20mF see Fig. 3-2
Turn-on overshoot max. 200mV see Fig. 3-2
*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
**) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.
Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, definitions
Turn-on
170V
Rated input range
V IN
POUT
151V 264Vac
Shut-down
164V
Start-up
delay Rise
Time
Overshoot- 5%Output
Voltage
Input
Voltage
Fig. 3-3 Input current vs. output load at 48V Fig. 3-4 Power factor vs. output load at 48V
20A2 4 6 8 10 12 14 16 18
0
1
2
3
4
5
6A
Input Current, typ.
Output Current
Power Factor, typ.
2 4 6 8 10 12 14 16 18 20A
0.75
0.80
0.85
0.90
0.95
1.00
Output Current
4 Rockwell Automation Publication 1606-RM018A-EN-P — February 2014
Bulletin 1606 Switched Mode Power Supplies
3. AC Input
AC input nom. AC 200-240V suitable for TN, TT and IT mains networks
AC input range min. 170-264Vac continuous operation
min. 110-170Vac full power for up to 200ms
min. 0-170Vac no damage to the unit
264-300Vac < 500ms
Allowed voltage L or N to earth max. 300Vac continuous, IEC 62103
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 164Vac steady-state value, load independent, see Fig. 3-1
Shut-down voltage typ. 151Vac steady-state value, load independent, see Fig. 3-1
Input current typ. 4.6A at 48V, 20A, see Fig. 3-3
Power factor*) typ. 0.96 at 48V, 20A, see Fig. 3-4
Crest factor**) typ. 1.65 at 48V, 20A
Start-up delay typ. 750ms see Fig. 3-2
Rise time typ. 18ms at 48V, 20A, resistive load, 0mF see Fig. 3-2
typ. 35ms at 48V, 20A, resistive load, 20mF see Fig. 3-2
Turn-on overshoot max. 200mV see Fig. 3-2
*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
**) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.
Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, definitions
Turn-on
170V
Rated input range
V IN
POUT
151V 264Vac
Shut-down
164V
Start-up
delay Rise
Time
Overshoot- 5%Output
Voltage
Input
Voltage
Fig. 3-3 Input current vs. output load at 48V Fig. 3-4 Power factor vs. output load at 48V
20A2 4 6 8 10 12 14 16 18
0
1
2
3
4
5
6A
Input Current, typ.
Output Current
Power Factor, typ.
2 4 6 8 10 12 14 16 18 20A
0.75
0.80
0.85
0.90
0.95
1.00
Output Current
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
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Key Features
- High Efficiency
- Compact Size
- BonusPower
- Active PFC (Power Factor Correction)
- Low Inrush Current
- Wide Operating Temperature Range
- Current Sharing for Parallel Use
- Internal Data Logging
- DC-OK Relay Contact
- Shut-down Input
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Frequently Answers and Questions
How does the power supply handle overload conditions?
The power supply utilizes a HiccupPLUS overload mode. Up to 4 seconds of overloading, it delivers continuous output current. After that, it reduces the output power to nearly zero for 17 seconds before attempting to restart. This cycle repeats as long as the overload persists. During the off-period, a small rest voltage and current are present on the output.
What is BonusPower, and how does it work?
BonusPower is a feature that allows the power supply to deliver a short-term power increase (up to 4 seconds) with a higher output current than the continuous rating. This provides added power reserve for applications requiring occasional high loads.
What are the mounting requirements for this power supply?
The unit is meant to be mounted on a DIN rail with the terminals on the bottom. Ensure sufficient air flow around the device, and maintain recommended clearances for proper cooling.
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