Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLS960E-3

Index
Page Page
1. Intended Use .......................................................3 22. Certifications .................................................. 18
2. Installation Requirements...................................3 23. Physical Dimensions and Weight .................... 19
3. AC-Input...............................................................4 24. Accessories ....................................................... 20
4. Input Inrush Current ...........................................5 24.1. Wall mounting bracket - 1606-XLC......... 20
5. DC-Input...............................................................5 24.2. Buffer module - 1606-XLSBUFFER24........ 20
6. Output .................................................................6 24.3. 1606-XLSRED80 - Redundancy Modules... 20
7. Hold-up Time.......................................................8 25. Application Notes .............................................21
8. DC-OK Relay Contact ..........................................9 25.1. Repetitive Pulse Loading..........................21
9. Shut-down Input .................................................9 25.2. Peak Current Capability ...........................22
10. Remote Control of Output Voltage .................10 25.3. External Input Protection.........................22
11. Internal Data Logging.......................................10 25.4. Using only 2 Legs of a 3-Phase System ....23
12. Efficiency and Power Losses..............................11 25.5. Charging Batteries ...............................24
13. Reliability ...........................................................12 25.6. Output Circuit Breakers............................24
14. Functional Diagram...........................................12 25.7. Parallel Use to Increase Output Power....25
15. Terminals and Wiring........................................13 25.8. Parallel Use for Redundancy ....................25
16. Front Side and User Elements...........................14 25.9. Series Operation .......................................26
17. EMC....................................................................15 25.10. Inductive and Capacitive Loads................26
18. Environment ......................................................16 25.11. Back-feeding Loads ..................................26
19. Protection Features ...........................................17 25.12. Use in a Tightly Sealed Enclosure ............26
20. Safety Features ..................................................17 25.13. Mounting Orientations ............................27
21. Dielectric Strength ............................................18

Terminology and Abbreviations

• 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 400V—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 whether it is full (13.7V) or flat (10V)
• 400Vac—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 with a strongly preferred implementation.
Bulletin 1606 Switched Mode Power Supplies

Power Supply
3AC 380-480V Wide-range Input
Three Input Fuses Included
Width only 110mm, Weight only 1.5kg
95.3% Full Load and Excellent Partial Load Efficiencies
50% BonusPower, 1440W for up to 4s
110A Peak Current for 25ms for Easy Fuse Tripping
Active PFC (Power Factor Correction)
Active Filtering of Input Transients
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.
Remote Control of Output Voltage
DC-OK Relay Contact
Shut-down Input
3 Year Warranty

Description Specification Quick Reference

The most outstanding features of the 1606-XLS960E-3 Output voltage DC 24V nominal
DIN rail power supply are its extremely high Adjustment range 24 - 28V
efficiencies and its small size, which are achieved by a Output current 40 – 34.3A continuous
synchronous rectification and other technological
60 – 51.5A short term (4s)
breakthroughs.
Output power 960W continuous
Large power reserves of 150% support the starting of
1440W short term (4s)
heavy loads such as DC motors or capacitive loads. In
Output ripple < 100mVpp 20Hz to 20MHz
many cases this allows the use of a unit from a lower
wattage class which saves space and money. Input voltage 3AC 380-480V -15%/+20%
Mains frequency 50-60Hz ±6%
High immunity to transients and power surges as well as
low electromagnetic emission allow the use of these AC Input current 1.65 / 1.35A at 3x400 / 480Vac
power supplies in nearly every environment. Power factor 0.88 / 0.90 at 3x400 / 480Vac
AC Inrush current typ. 4.5A peak
The integrated output power manager, the three input
fuses and near zero input inrush current make Efficiency 95.3 / 95.2% at 3x400 / 480Vac
installation and usage simple. Diagnostics are easy due Losses 47.3 / 48.4W at 3x400 / 480Vac
to the DC-ok relay, a green DC-OK LED and the red Temperature range -25°C to +70°C operational
overload LED. Derating 24W/°C +60 to +70°C
A large international approval package for a variety of Hold-up time typ. 25 / 25ms at 3x400 / 480Vac
applications makes this unit suitable for nearly every Dimensions 110x124x127mm WxHxD
application. Weight 1500g / 3.3 lb

Catalog Numbers Certifications

Power Supply 1606-XLS960E-3 24-28V Standard unit

Accessories 1606-XLC Wall mount bracket IND. CONT. EQ.

UL 60950-1 GOST R
1606-XLSBUFFER24 Buffer unit UL 508 Marine RINA
1606-XLSRED80 Redundancy module

Marine EMC, LVD, RoHS C-Tick

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
2 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 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 equipment 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 output and input terminals are located on the bottom of the unit. For other mounting orientations, see
derating requirements in this document. Refer to section 25.13.
• This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid
(e.g. cable conduits) by more than 30%!
• Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the
device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat
source (e.g. another power supply).

SHOCK HAZARD: Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input
block for earth connection and not one of the screws on the housing.
- Turn power off before working on the device. Protect against inadvertent re-powering
- Make sure that the wiring is correct by following all local and national codes
- Do not modify or repair the unit
- Do not open the unit as high voltages are present inside
- Use caution to prevent any foreign objects from entering the housing
- Do not use in wet locations or in areas where moisture or condensation can be expected
- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.

WARNING: EXPLOSION HAZARDS!

Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment or S/P jumper unless
power has been switched off or the area is known to be non-hazardous.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 3
Bulletin 1606 Switched Mode Power Supplies

3. AC-Input
AC input nom. 3AC 380-480V suitable for TN, TT and IT mains networks,
grounding of one phase is allowed except in UL 508
applications
AC input range min. 3x 323-576Vac continuous operation
Allowed voltage L to earth max. 576Vac continuous, IEC 60664-1
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 3x 305Vac steady-state value, load independent, see Fig. 3-1
Shut-down voltage typ. 3x 275Vac steady-state value, load independent, see Fig. 3-1

3AC 400V 3AC 480V

Input current typ. 1.65A 1.35A at 24V, 40A, symmetrical phase voltages,
see Fig. 3-3
Power factor*) typ. 0.88 0.90 at 24V, 40A, see Fig. 3-4
Start-up delay typ. 500ms 600ms see Fig. 3-2
Rise time typ. 35ms 35ms at 24V, 40A, resistive load, 0mF see Fig. 3-2
typ. 40ms 40ms at 24V, 40A, resistive load, 40mF see Fig. 3-2
Turn-on overshoot max. 500mV 500mV see Fig. 3-2
*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.

Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, definitions

POUT Rated input range Input

Voltage

L1 L2 L3
Shut-down

Turn-on

Output - 5%

Overshoot
Voltage
VIN
Start-up Rise
delay Time
275V 305V 323V 576Vac

Fig. 3-3 Input current vs. output load at 24V Fig. 3-4 Power factor vs. output load at 24V
Input Current, typ. Power Factor, typ.
1.6A 0.95
A: 3x 400Vac
1.4 A: 3x 400Vac B: 3x 480Vac
0.90 B
1.2 B: 3x 480Vac A A

1.0 B 0.85
0.8
0.6 0.80
0.4
0.75
0.2
Output Current Output Current
0 0.70
4 8 12 16 20 24 28 32 36 40A 4 8 12 16 20 24 28 32 36 40A

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
4 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

4. 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 usually smaller than the steady state input current.

3AC 400V 3AC 480V

*)
Inrush current max. 6Apeak 6Apeak over entire temperature range
typ. 4.5Apeak 4.5Apeak over entire temperature range
Inrush energy max. 1.5A2s 1.5A2s over entire temperature range
Inrush delay typ. 500ms 600ms
*) The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.

Fig. 4-1 Typical turn-on behaviour at nominal

load and 25°C ambient temperature

Input Current 2A/DIV

Input

3x400Vac

24Vdc
Output 100ms/DIV

5. DC-Input
Do not operate this power supply with DC input voltage.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 5
Bulletin 1606 Switched Mode Power Supplies

6. Output
Output voltage nom. 24V
Adjustment range min. 24-28V guaranteed
max. 30V***) at clockwise end position of potentiometer
Factory setting typ. 24.1V ±0.2%, at full load, cold unit, in “single use” mode
typ. 24.1V ±0.2%, at full load, cold unit, in “parallel use” mode
typ. 25.1V at no load, cold unit, in “parallel use” mode
Line regulation max. 10mV 3x323-576Vac
Load regulation max. 50mV in “single use” mode: static value, 0A 40A, see Fig. 6-1
typ. 1000mV in “parallel use” mode: static value, 0A 40A,
see Fig. 6-2
Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm
Output current nom. 40A continuously available at 24V, see Fig. 6-1 and Fig. 6-2
nom. 34.3A continuously available at 28V, see Fig. 6-1 and Fig. 6-2
nom. 60A short term (4s) available BonusPower*) , at 24V,
see Fig. 6-1, Fig. 6-2 and Fig. 6-4
nom. 51.5A short term (4s) available BonusPower*) , at 28V,
see Fig. 6-1, Fig. 6-2 and Fig. 6-4
typ. 110A up to 25ms, output voltage stays above 20V, see Fig.
6-4. This peak current is available once every second.
See section 25.2 for more peak current measurements.
Output power nom. 960W continuously available at 24-28V
nom. 1440W*) short term available BonusPower*) at 24-28V
BonusPower time typ. 4s duration until the output voltage dips, see Fig. 6-3
BonusPower recovery time typ. 7s overload free time to reset power manager, see Fig. 6-5
Overload behavior cont. current see Fig. 6-1
Short-circuit current**) min. 40A continuous, load impedance 25mOhm, see Fig. 6-1
max. 44A continuous, load impedance 25mOhm, see Fig. 6-1
min. 60A short-term (4s), load impedance 25mOhm, see Fig. 6-1
max. 68A short-term (4s), load impedance 25mOhm, see Fig. 6-1
typ. 46A continuous, load impedance <10mOhm
max. 51A continuous, load impedance <10mOhm
Output capacitance typ. 10 200μF included in the power supply
*) BonusPower, short term power capability (up to typ. 4s)
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-controlled by an output power manager. BonusPower is repeatedly available. Detailed information
can be found in section 25.1. If the power supply is loaded longer with the BonusPower than shown in the bonus-time diagram (see
Fig. 6-3), the max. output power is automatically reduced to 960W.
**) Discharge current of output capacitors is not included.
***) This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. There is no
guarantee that this value can be achieved. The typical value is about 28.5V.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
6 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

Fig. 6-1 Output voltage vs. output current in Fig. 6-2 Output voltage vs. output current in
“single use” mode, typ. “parallel use” mode, typ.

Output Voltage Adjustment Range Output Voltage (Parallel Use, typ.)

28V 29V Adjustment Range
A B
24 28V
20 27V A B

16 26V Factory
A B setting
Continuously
12 A
available 25V
Short-term (4s)
8 B
BonusPower 24V A Continuously
available
4 23V B
Short-term (4s) A B
BonusPower
0 22V
0 10 20 30 40 50 60 70A 0 10 20 30 40 50 60A
Output Current Output Current

Fig. 6-3 Bonus time vs. output power Fig. 6-4 Dynamic overcurrent capability, typ.

Bonus Time Output Voltage (dynamic behavior, < 25ms)

5s max. 28V
24
4
20 Adjustment
min. Range
3 16
2 12
8
1
4
Output Power Output Current
0 0
100 110 120 130 140 150 160 170% 0 15 30 45 60 75 90 105 120 135 150A

Fig. 6-5 BonusPower recovery time

Limitation by
Power Power Manager
Demand

100%

Bonus Recovery Time

Time Bonus Power disabled
Output
Voltage

BonusPower is available as soon as power comes on and after the end of an output short circuit or overload.

Fig. 6-6 BonusPower after input turn-on Fig. 6-7 BonusPower after output short

Input Short of
Output
Voltage
Output
Voltage
Output
Voltage
Bonus 150% Bonus
150% Power
Power Output
100% Power 100%
Output
Power

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 7
Bulletin 1606 Switched Mode Power Supplies

7. Hold-up Time
3AC 400V*) 3AC 480V*)
Hold-up Time typ. 50ms 50ms at 24V, 20A, see Fig. 7-1
min. 40ms 40ms at 24V, 20A, see Fig. 7-1
typ. 25ms 25ms at 24V, 40A, see Fig. 7-1
min. 20ms 20ms at 24V, 40A, see Fig. 7-1
*) Curves and figures for operation on only 2 legs of a 3-phase system can be found in section 25-4.

Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, definitions

Hold-up Time 24V, 20A, typ.

L1 L2 L3
50ms
24V, 20A, min. Input
40 Voltage
30 24V, 40A, typ.
20 24V, 40A, min. - 5%
Output
10 Voltage
Input Voltage Hold-up Time
0
320 360 400 440 3x480Vac

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
8 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

8. DC OK Relay Contact
This feature monitors the output voltage, which is produced by the power supply itself. It is independent of a back-fed
voltage from a unit connected in parallel to the power supply output.

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 250ms. Dips shorter than 1ms will be ignored.
Contact re-closes As soon as the output voltage exceeds 90% of the adjusted voltage.
Contact ratings max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
min 1mA at 5Vdc min. permissible load
Isolation voltage See Dielectric Strength table in section 21.

Fig. 8-1 DC-ok relay contact behavior

VOUT = VADJ

10% 0.9* VADJ

< >
1ms 1ms 250ms

open closed open closed

9. 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 function ramps down and has no safety feature included. The shut-down occurs immediately while the
turn-on is delayed up to 350ms. In a shut-down condition, the output voltage is <2V and the output power is <0.5W.
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.
Please note that option C requires a current sink capability of the voltage source. Do not use a blocking diode.
Fig. 9-1 Activation of the shut-down input

Option A: Option B: Option C:

(via open n.c. 15 Shut- n.c. 15 Shut-
15 Shut- down (via external down
down collector) 16 Input
I voltage 16 Input
16 Input +

OFF: linked OFF: U < 1V U

OFF: I > 0.3mA -
ON : open ON : U = 4 -29V -
ON : I < 0.1mA

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 9
Bulletin 1606 Switched Mode Power Supplies

10. Remote Control of Output Voltage

The shut-down input can also be used to remotely adjust the output voltage between typically 14Vdc and 28Vdc. All
other functions of shut-down input remain the same.
The control voltage is referenced to the main ground (negative output voltage).

Fig. 10-1 Remote control of the output Fig. 10-2 Applying the control voltage
voltage
Output Voltage
28V Potentiometer:
set to 28V
26V set to 24V
24V 15 Shut-
22V down
+ 16 Input
20V Control n.c.
18V Voltage
16V -
14V
12V
0V 5V 10V 15V 20V
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.

11. 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 Rockwell Automation service and repair personnel,
even if the unit is faulty. Having the data facilitates troubleshooting. Knowledge of the events occuring just before a
failure allows for a more accurate analysis of the problem.
The data will be acquired with a fixed sampling rate unless the peak detectors trigger due to an abnormal condition.
In such cases, the abnormal condition is properly captured.
Acquired data:
- Family name of unit (1606-XLS), revision of firmware
- Operational hours and expired portion of lifetime
- Operational data; latest 60 values with timestamps of the last 158 minutes of:
Number of over-voltage transients,
Average input voltage,
Peak input voltage,
Inside temperature,
Overloads > 2s,
Missing of one input phase (minimum output load required)
- Failure data; various errors such as:
Internal errors,
Over-temperature shut-down,
OVP,
Long-term overloads,
Remarkable temperatures inside the unit,
….
- Number of turn-on sequences and overvoltage transients

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
10 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

12. Efficiency and Power Losses

Efficiencies for 3-Phase operation:
3AC 400V 3AC 480V
Efficiency typ. 95.3% 95.2% at 24V, 40A
Average efficiency*) typ. 94.7% 94.6% 25% at 10A, 25% at 20A, 25% at 30A. 25%
at 40A
Power losses typ. 1.5W 1.5W with activated shut-down
typ. 9.5W 9.8W at 24V, 0A (no load)
typ. 24.1W 25.0W at 24V, 20A (half load)
typ. 47.3W 48.4W at 24V, 40A (full load)
*) 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.

Efficiencies when using only 2 legs of a 3-phase system:

2AC 400V 2AC 480V
Efficiency typ. 94.4%**) 94.7%**) at 24V, 40A
Power losses typ. 56.9W**) 53.7W**) at 24V, 40A (full load)
**) Curves can be found in section 25.4.

Fig. 12-1 Efficiency vs. output current at 24V, Fig. 12-2 Losses vs. output current at 24V,
typ. typ.
Efficiency Power Losses
96% 60W
3x400Vac 3x480Vac
50
95
3x480Vac 40
94 30 3x400Vac
20
93
10
Output Current Output Current
92 0
8 12 16 20 24 28 32 36 40A 0 4 8 12 16 20 24 28 32 36 40A

Fig. 12-3 Efficiency vs. input voltage at 24V, Fig. 12-4 Losses vs. input voltage at 24V, 40A,
40A, typ. typ.
Efficiency Power Losses
95.5% 50W
95.4 49
95.3 48
95.2 47
95.1 46
95.0 45
Input Voltage Input Voltage
94.9 44
350 400 450 500 3x550Vac 350 400 450 500 3x550Vac

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 11
Bulletin 1606 Switched Mode Power Supplies

13. Reliability
3AC 400V 3AC 480V
Calculated lifetime expectancy*) 314 000h*) 294 000h*) at 24V, 20A and 25°C
111 000h 104 000h at 24V, 20A and 40°C
179 000h*) 174 000h*) at 24V, 40A and 25°C
63 000h 62 000h at 24V, 40A and 40°C
MTBF**) SN 29500, IEC 61709 375 000h 369 000h at 24V, 40A and 40°C
685 000h 678 000h at 24V, 40A and 25°C
MTBF**) MIL HDBK 217F 158 000h 157 000h at 24V, 40A and 40°C; Ground Benign GB40
211 000h 210 000h at 24V, 40A and 25°C; Ground Benign GB25
*) The calculated lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the
lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours and is calculated according
to the capacitor’s manufacturer specification. The manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15
years (131 400h). Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices.
**) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a
device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.
The MTBF figure is a statistical representation of the likelihood of a device to fail. A MTBF figure of e.g. 1 000 000h means that
statistically one unit will fail every 100 hours if 10 000 units are installed in the field. However, it’s impossible to determine if the failing
unit has been running for 50 000h or only for 100h.

14. Functional Diagram

Fig. 14-1 Functional diagram

Single /
Output Parallel
Voltage
Regulator VOUT
L1
Input Fuses
L2 Input Filter +
PFC
Input Rectifier Converter Power Output +
L3 Inrush Limiter
Converter Filter
Transient Filter -
-
Overload
LED
DC-ok
LED
Temper- Output Output Output
ature Power Over-
Shut- Voltage Voltage
Manager Monitor DC ok 13
down Protection DC-ok
Relay Contact
14

Shut- 15 Shut-
Event Datalogger down
down
16 Input

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
12 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

15. Terminals and Wiring

The terminals are IP20, finger safe, constructed and suitable for field and factory wiring.
Input Output DC-OK, Shut-down
Type screw termination screw termination spring-clamp termination
Solid wire 0.5-6mm2 0.5-16mm2 0.15-1.5mm2
Stranded wire 0.5-4mm2 0.5-10mm2 0.15-1.5mm2
American Wire Gauge AWG 20-10 AWG 22-8 AWG 26-14
Max. wire diameter 2.8mm 5.2mm 1.5mm
(including ferrules) (including ferrules) (including ferrules)
Wire stripping length 7mm / 0.28inch 12mm / 0. 5inch 7mm / 0.28inch
Screwdriver 3.5mm slotted or cross- 3.5mm or 5mm slotted 3mm slotted
head No 2 or cross-head No 2 (to open the spring)
Recommended tightening torque 1Nm, 9lb.in 2.3Nm, 20.5lb.in Not applicable
Instructions:
a) Use appropriate copper cables that are designed for minimum operating temperatures of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum
90°C for ambient up to 70°C minimum.
b) Follow national installation codes and installation regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Do not use the unit without PE connection.
e) Unused terminal compartments should be securely tightened.
f) Ferrules are allowed.

Daisy chaining:
Daisy chaining (jumping from one power supply output to the next) is allowed as long as the average output current
through one terminal pin does not exceed 54A. If the current is higher, use a separate distribution terminal block as
shown in Fig. 15-2.
Fig. 15-1 Daisy chaining of outputs Fig. 15-2 Using distribution terminals

Distribution
Terminals
Power Power Power Power
Supply Supply Supply Supply
+ + - - + + - - Load - - - - Load
+ + + +
Output Output + - Output Output + -

max 54A!

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 13
Bulletin 1606 Switched Mode Power Supplies

16. Front Side and User Elements

Fig. 16-1 Front side

A Input Terminals (Screw terminals)
L1, L2, L3 Line input
...PE (Protective Earth) input
C D B Output Terminals (Screw terminals, two pins per pole)
+ Positive output
E – Negative (return) output
C “Parallel Use” “Single Use” Selector
F Set jumper to “Parallel Use” when power supplies are connected
in parallel to increase the output power. In order to achieve a
sharing of the load current between the individual power
supplies, the “parallel use” regulates the output voltage in such a
manner that the voltage at no load is approx. 4% higher than at
nominal load. See also section 25.7. A missing jumper is equal to
G a “Single Use” mode.
H D Output Voltage Potentiometer
Multi turn potentiometer;
Open the flap to set the output voltage.

A B Factory set: 24.1V at full output current, “Single Use” mode.

E DC-OK LED (green)
On, when the voltage on the output terminals is >90% of the
adjusted output voltage
F Overload LED (red)
- On, when the voltage on the output terminals is <90% of the
adjusted output voltage, or in case of a short circuit in the output.
- Flashing, when the shut-down has been activated or the unit has
switched off due to over-temperature.
- Input voltage is required
G DC-OK Relay Contact
The DC-OK relay contact is synchronized with the DC-OK LED.
See section 8 for details.
H Shut-down and Remote Control Input
Allows the power supply to be shut down. Can be activated with
a switch contact or an external voltage.
The remote control input allows adjusting the output voltage
between 14V and 28V. See sections 9 and 10 for details.

Indicators, LEDs
Overload LED DC-OK LED DC-OK Contact
Normal mode OFF ON Closed
During BonusPower OFF ON Closed
Overload (Vout < 90%) ON OFF Open
Output short circuit ON OFF Open
Temperature Shut-down flashing OFF Open
Active Shut-down input flashing OFF Open
No input power OFF OFF Open

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
14 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

17. EMC
The power supply is suitable for applications in industrial environment as well as in residential, commercial and light
industry environment without any restrictions. A detailed EMC report is available on request.

EMC Immunity According generic standards: EN 61000-6-1 and EN 61000-6-2

Electrostatic discharge EN 61000-4-2 contact discharge 8kV Criterion A
air discharge 15kV Criterion A
Electromagnetic RF field EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 input lines 4kV Criterion A
output lines 2kV Criterion A
DC-OK signal (coupling clamp) 2kV Criterion A
Surge voltage on input EN 61000-4-5 L1 L2, L2 L3, L1 L3 2kV Criterion A
L1 / L2 / L3 PE 4kV Criterion A
Surge voltage on output EN 61000-4-5 + - 1kV Criterion A
+ / - PE 1kV Criterion A
Surge voltage on DC-OK EN 61000-4-5 DC-OK signal PE 1kV Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 0% of 380Vac (0Vac) 0Vac, 20ms Criterion A,
(Dips on three phases) 0% of 480Vac (0Vac) 0Vac, 20ms Criterion A
Mains voltage dips EN 61000-4-11 40% of 380Vac (152Vac) 200ms Criterion A
(Dips on two phases) 40% of 480Vac (192Vac) 200ms Criterion A
70% of 380Vac (266Vac) 500ms Criterion A
70% of 480Vac (336Vac) 500ms Criterion A
Voltage interruptions EN 61000-4-11 0Vac 5000ms Criterion C
Voltage sags SEMI F47 0706 dips on two phases according to section 7.2. of the SEMI F47 standard
80% of 380Vac (304Vac) 1000ms Criterion A
70% of 380Vac (266Vac) 500ms Criterion A
50% of 380Vac (160Vac) 200ms Criterion A
Powerful transients VDE 0160 over entire load range 1550V, 1.3ms Criterion A
Criteria:
A: Power supply shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. The power supply will incur neither damage
nor hazard.

EMC Emission According generic standards: EN 61000-6-3 and EN 61000-6-4

Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B
input lines
Conducted emission IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 5dB higher than average limits
output lines for DC power port according EN
61000-6-3**)
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 fulfilled for class A equipment
Voltage fluctuations, flicker EN 61000-3-3 fulfilled*)
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.
*) Tested with constant current loads, non pulsing
**) 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.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 15
Bulletin 1606 Switched Mode Power Supplies

Switching Frequencies The power supply has three converters with three different switching frequencies
included. One is nearly constant. The others are variable.
Switching frequency 1 105kHz Resonant converter, nearly constant
Switching frequency 2 1kHz to 150kHz Boost converter, load dependent
Switching frequency 3 40kHz to 300kHz PFC converter, input voltage and load dependent

18. Environment
Operational temperature*) -25°C to +70°C (-13°F to 158°F) reduce output power according Fig. 18-1
Storage temperature -40 to +85°C (-40°F to 185°F) for storage and transportation
Output de-rating 24W/°C 60-70°C (140°F to 158°F)
Humidity**) 5 to 95% r.H. IEC 60068-2-30
Vibration, sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 1g***) IEC 60068-2-6
2 hours / axis
Shock 15g 6ms, 10g 11ms***) IEC 60068-2-27
3 bumps / direction, 18 bumps in total
Altitude 0 to 2000m (0 to 6 560ft) no restrictions
2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature,
see Fig. 18-2
IEC 62103, EN 50178, overvoltage category II
Altitude de-rating 60W/1000m or 5°C/1000m > 2000m (6500ft), see Fig. 18-2
Over-voltage category III IEC 62103, EN 50178, altitudes up to 2000m
II altitudes from 2000m to 6000m
Degree of pollution 2 IEC 62103, EN 50178, not conductive
LABS compatibility The unit does not release any silicone or other LABS-critical substances and is suitable for
use in paint shops.
*) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit. Curves and
figures for operation on only 2 legs of a 3-phase system can be found in section 25.4.
**) Do not energize in the presence of condensation.
***) Higher levels allowed when using the 1606-XLC wall mounting bracket.

Fig. 18-1 Output current vs. ambient temp. Fig. 18-2 Output current vs. altitude
Allowed Output Current at 24V Allowed Output Current at 24V
60A 60A
short-term (4s) short-term (4s)
50 50
continuous continuous
40 40 B
C
A
30 30
A... Tamb < 60°C
20 20 B... Tamb < 50°C
C... Tamb < 40°C
10 10
0 0
-25 0 20 40 60 70°C 0 2000 4000 6000m
Ambient Temperature Altitude

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
16 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

19. Protection Features

Output protection Electronically protected against overload, no-load and short-circuits*)
Output over-voltage protection typ. 30Vdc In case of an internal power supply defect, a redundant
max. 32Vdc circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 5mm e.g. screws, small parts
Over-temperature protection yes Output shut-down with automatic restart
Input transient protection MOV (Metal Oxide Varistor)
Internal input fuse included not user replaceable
*) In case of a protection event, audible noise may occur.

20. Safety Features

Input / output separation*) SELV IEC/EN 60950-1
PELV IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
double or reinforced insulation
Class of protection I PE (Protective Earth) connection required
Isolation resistance > 5MOhm input to output, 500Vdc
PE resistance < 0.1Ohm
Touch current (leakage current) typ. 0.35mA / 0.64mA 3x400Vac, 50Hz, TN-,TT-mains / IT-mains
typ. 0.45mA / 0.91mA 3x480Vac, 60Hz, TN-,TT-mains / IT-mains
max. 0.45mA / 0.78mA 3x440Vac, 50Hz, TN-,TT-mains / IT-mains
max. 0.60mA / 1.20mA 3x528Vac, 60Hz, TN-,TT-mains / IT-mains
*) double or reinforced insulation

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 17
Bulletin 1606 Switched Mode Power Supplies

21. Dielectric Strength

The output voltage is floating and has no ohmic connection to the ground. Type and factory tests are conducted by
the manufacturer. Field tests may be conducted in the field using the appropriate test equipment which applies the
voltage with a slow ramp (2s up and 2s down). Connect all phase terminals together as well as all output poles before
conducting the test. When testing, set the cut-off current settings to the value in the table below.
Fig. 21-1 Dielectric strength A B C D
Type test 60s 2500Vac 3000Vac 500Vac 500Vac
Input DC-ok Factory test 5s 2500Vac 2500Vac 500Vac 500Vac
L1 B*) 13
Field test 5s 2000Vac 2000Vac 500Vac 500Vac
L2 14
L3 Cut-off current setting > 10mA > 10mA > 40mA > 1mA
D
B

A
To fulfil the PELV requirements according to EN 60204-1 § 6.4.1, we
Earth Output recommend that either the + pole, the – pole or any other part of
+/-
C the output circuit shall be connected to the protective earth
Shut-down
15/16
system. This helps to avoid situations in which a load starts
unexpectedly or can not be switched off when unnoticed earth
faults occur.
B*) When testing input to DC-OK ensure 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.

22. Certifications
EC Declaration of Conformity Complies with CE EMC and CE Low Voltage Directives

C-Tick C-tick compliance is for products intended for sale and use
within the Australian market. See below for link to the C-tick
Declarations of Conformity.

UL 508 LISTED E56639 for use in the U.S.A. (UL 508) and Canada
(C22.2 No. 14-95)
IND. CONT. EQ. Industrial Control Equipment
UL 60950-1 RECOGNIZED E168663 for use in the U.S.A. (UL 60950-1) and
Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3
Marine RINA RINA (Registro Italiano Navale) certified. See below for link to
Certificate.

SEMI F47 SEMI F47-0706 Voltage Sag Immunity Compliance. See below
for link to the Certificate.

Marine GL GL (Germanischer Lloyd) classified for marine and offshore

applications. Environmental category: C, EMC2. See below
for link to the Certificate.
GOST R Certificate of Conformity for Russia and other GUS countries

Product certification information (including Certificates and Declarations of Conformity) can be found at www.ab.com/certifications.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
18 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

23. Physical Dimensions and Weight

Weight 1500g / 3.3lb
DIN rail Use 35mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN rail height must be added to the unit depth (127mm) to calculate the total required
installation depth.
Installation Clearances See Section 2.

Fig. 23-1 Front view Fig 23-2 Side view

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 19
Bulletin 1606 Switched Mode Power Supplies

24. Accessories

24.1. 1606-XLC Wall Mounting Bracket

This bracket is used to mount specific
units onto a flat surface without a DIN rail.

24.2. 1606-XLSBUFFER24 Buffer Module

This buffer unit is a supplementary device for DC 24V power supplies. It delivers
power to bridge typical mains failures or
extends the hold-up time after turn-off of Power Buffer
AC Supply Unit(s)
Load
the AC power. In times when the power
supply provides sufficient voltages, the +
DC
buffer unit stores energy in integrated -
electrolytic capacitors. In case of mains
voltage fault, this energy is released again in a regulated process. One buffer
module can deliver 20A. To buffer the full output current of 40A, two buffer
modules are needed in parallel.
The buffer unit does not require any control wiring. It can be added in parallel to
the load circuit at any given point. Buffer units can be added in parallel to increase
the output ampacity or the hold-up time.

24V Failure
40A
24.3. 1606-XLSRED80 Redundancy Modules Load Monitor

The 1606-XLSRED80 redundancy module is a unit in the 1606-XLS

series that is also suitable in combination with power supplies; 1606-XLS960E-3 1606-XLS960E-3
the latter have a continuous current overload behavior. 24-28V 960W
Power Supply
24-28V 960W
Power Supply
Output

The 1606-XLSRED80 is the preferred redundancy module for the Parallel Use
DC-
OK
1606-XLSRED80
Redundancy Parallel Use
DC-
OK
1606-XLS960E-3 power supply. It is equipped with two input Single Use Module Single Use

channels that are individually decoupled by using mosfet Input Input

24V, 40A 1 2 24V, 40A
technology. Using mosfets instead of diodes reduces the heat L1 L2 L3 PE + + - - + - + - L1 L2 L3 PE + + - -
generation and the voltage drop between input and output.

The 1606-XLSRED80 unit does not require additional auxiliary

voltage and is self-powered even in case of a short circuit I I I I I I
across the output. L1
L2
Due to the low power losses, the unit is very slender and only L3
requires 46mm width on the DIN rail. No space is needed PE

between the 1606-XLS power supply and the redundancy module.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
20 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

25. Application Notes

25.1. Repetitive Pulse Loading

Typically, a load current is not constant and varies over time. This power supply is designed to support loads with a
higher short-term power demand (=BonusPower). The short-term duration is hardware controlled by an output
power manager and is available on a repeated basis. If the BonusPower load lasts longer than the hardware
controller allows it, the output voltage will dip and the next BonusPower is available after the BonusPower recovery
time (see Section 6) has elapsed.
To avoid this, the following rules must be met:
a) The power demand of the pulse must be below 150% of the nominal output power.
b) The duration of the pulse power must be shorter than the allowed BonusPower time (see output section).
c) The average (R.M.S.) output current must be below the specified continuous output current.
If the R.M.S. current is higher, the unit will respond with a thermal shut-down after a period of time. Use the
maximum duty cycle curve (Fig. 25-2) to check if the average output current is below the nominal current.
d) The duty cycle must be below 0.75.

Fig. 25-1 Repetitive pulse loads, definitions Fig. 25-2 Max. duty cycle curve

Duty Cycle P0 = 10%

P0 = 50%
PPEAK TPEAK T0 0.75
P0 = 75%
max.
150%
0.6

100% 0.4

0.2 P0 = 100%
P0
PPEAK
0
100 110 120 130 140 150%
P0 Base load (W) Tpeak
DutyCycle =
PPEAK Pulse load (above 100%) Tpeak + T0
T0 Duration between pulses (s) Tpeak - (DutyCycle x Tpeak)
T0 =
TPEAK Pulse duration (s) DutyCycle

Example: A load is powered continuously with 480W (= 50% of the rated output load). From time to time a peak
power of 1440W (= 150% of the rated output load) is needed for 1 second.
The question is: How often can this pulse be supplied without overloading the power supply?
- Make a vertical line at PPEAK = 150% and a horizontal line where the vertical line crosses the P0 = 50%
curve. Read the max. duty cycle from the duty cycle-axis (= 0.37)
- Calculate the required pause (base load) length T0:
- Result: The required pause length = 1.7s Tpeak - (DutyCycle x Tpeak) 1s - (0.37 x 1s)
T0= = = 1.7s
- Max. repetition rate = pulse +pause length = 2.7s DutyCycle 0.37

More examples for pulse load compatibility:

PPEAK P0 TPEAK T0 PPEAK P0 TPEAK T0
1440W 960W 1s >25s 1440W 480W 0.1s >0.16s
1440W 0W 1s >1.3s 1440W 480W 1s >1.6s
1200W 480W 1s > 0.75s 1440W 480W 3s >4.9s

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 21
Bulletin 1606 Switched Mode Power Supplies

25.2. Peak Current Capability

The power supply can deliver peak currents (up to several milliseconds) which are higher than the specified short term
currents.
This 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 ensures the safe operation of subsequent circuit breakers of load circuits. The load
branches are often individually protected with circuit breakers or fuses. In case of a short or an overload in one branch
circuit, the fuse or circuit breaker need a certain amount of over-current to open in a timely manner. This 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. The capacitors get discharged during such an event, which causes a voltage dip on the output.
Both the following examples show typical voltage dips:

Fig. 25-3 Peak load with 2x the nominal Fig. 25-4 Peak load with 5x the nominal
current for 50ms, typ. current for 5ms, typ.

80A Peak load (resistive) for 50ms 200A Peak load (resistive) for 5ms
Output voltage dips from 24V to 20V. Output voltage dips from 24V to 12V.
Please note: The DC-OK relay triggers when the voltage dips more than 10% for longer than 1ms.

Peak current voltage dips typ. from 24V to 20V at 80A for 50ms, resistive load
typ. from 24V to 12V at 200A for 2ms, resistive load
typ. from 24V to 12V at 200A for 5ms, resistive load

25.3. External Input Protection

The unit is tested and approved for branch circuits up to 30A (U.S.A.) and 32A (IEC). An external protection is only
required if the supplying branch has an ampacity greater than this. Check also local codes and local requirements. In
some countries local regulations may apply.
If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of
the circuit breaker. A minimum value of 6A B- or C-Characteristic breaker should be chosen.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
22 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

25.4. Using Only Two Legs of a 3-Phase System

No external protection devices are required to protect against a phase-loss L1
L2 Power Supply
failure. L3
PE AC
This power supply can also be permanently operated on two legs of a 3-
L1
phase system. However, it is not recommended for this power class since the
L2
supplying 3-phase network can become unbalanced.
open L3
The output power must be reduced according to the curves below when DC
operation on only two legs of a 3-phase system. A long-term exceeding of
these limits will result in a thermal shut-down of the unit.
A use below 340Vac with more than 30A output current can also result in a thermal shut-down.
During power-on, some start-up attempts can occur until a permanent output power is available.
EMC performance, hold-up time, losses and output ripple differ from a three phase operation. Therefore, check
suitability of your individual application.
Such use is not included in the UL approval. Additional tests might be necessary when the complete system has to be
approved according to UL 508 or UL60950-1.
The screw of the terminal which remains unused must be securely tightened.

Fig. 25-5 Fig. 25-6

Output current vs. ambient temperature Hold-up time vs. input voltage

Allowed Output Current for Use on only Two Hold-up Time for Use on only Two Legs of a
Legs of a 3-Phase System Three Phase System
40A
C 50ms
24V, 20A, typ.
30 40
B A 24V, 20A, min.
A... 2x 460 to 552Vac
20 B... 2x 340 to 460Vac 30
C... max. 60 seconds 24V, 40A, typ.
20
10 24V, 40A, min.
10
0 Input Voltage
-25 0 20 40 60 70°C 0
Ambient Temperature 320 360 400 440 3x480Vac

Fig. 25-7 Fig. 25-8

Efficiency vs. output current at 24V Losses vs. output current at 24V

Efficiency for Use on only Power Losses for Use on only

Two Legs of a 3-Phase System Two Legs of a 3-Phase System

96% 60W
2x400Vac
2x480Vac 50
95
2x400Vac 40
94 2x480Vac
30
93 20
Output Current Output Current
92 10
8 12 16 20 24 28 32 36 40A 0 4 8 12 16 20 24 28 32 36 40A

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 23
Bulletin 1606 Switched Mode Power Supplies

25.5. Charging Batteries

The power supply can be used to charge lead-acid or maintenance free batteries. (Two 12V batteries in series.)
Instructions for charging batteries:
a) Set output voltage (measured at no load and at the battery end of the cable) very precisely to the end-of-charge
voltage.
End-of-charge voltage 27.8V 27.5V 27.15V 26.8V
Battery temperature 10°C 20°C 30°C 40°C
b) Use a 50A or 63A circuit breaker (or blocking diode) between the power supply and the battery.
c) Ensure that the output current of the power supply is below the allowed charging current of the battery.
d) Use only matched batteries when putting 12V types in series.
e) The return current to the power supply (battery discharge current) is typ. 35mA when the power supply is
switched off (except if using a blocking diode).

25.6. Output Circuit Breakers

Standard miniature circuit breakers (MCBs or UL1077 circuit breakers) are commonly used for AC-supply systems and
may also be used on DC branches.
MCBs are designed to protect wires and circuits. If the ampere value and the characteristics of the MCB are adapted to
the wire size that is used, the wiring is considered as thermally safe, whether the MCB opens or not.
To avoid voltage dips and under-voltage situations in adjacent 24V branches which are supplied by the same source, a
fast (magnetic) tripping of the MCB is desired. A quick shutdown within 10ms is necessary corresponding roughly to
the ride-through time of PLCs. This requires power supplies with high current reserves and large output capacitors.
Furthermore, the impedance of the faulty branch must be sufficiently small in order for the current to actually flow.
The best current reserve in the power supply does not help if Ohm’s law does not permit current flow. The following
table has typical test results showing which B- and C-Characteristic MCBs magnetically trip depending on the wire cross
section and wire length.
Fig. 25-9 Test circuit Maximal wire length*) for a fast (magnetic) tripping:
0.75mm² 1.0mm² 1.5mm² 2.5mm²
C-2A 28m 38m 54m 78m
C-3A 26m 35m 50m 74m
C-4A 19m 26m 38m 58m
Power Supply MCB Load
C-6A 12m 16m 24m 32m
AC + +
C-8A 9m 12m 17m 25m
Wire length
S1
C-10A 7m 10m 15m 21m
- C-13A 4m 5m 7m 11m
DC -
B-6A 19m 26m 35m 59m
S1... Fault simulation switch
B-10A 11m 17m 26m 37m
B-13A 10m 13m 21m 32m
B-16A 8m 11m 14m 24m
B-20A 4m 6m 8m 14m
*) Don’t forget to consider twice the distance to the load (or cable length) when calculating the total wire length (+ and – wire).

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
24 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

25.7. Parallel Use to Increase Output Power

Power supplies from the 16060-XLS series can be paralleled to increase Unit A

the output power. The output voltage shall be adjusted to the same value AC
(±100mV) 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, the -
DC
jumper on the front of the unit shall be moved from “Single use” to
“Parallel use” in order to achieve lo ad sharing. The “Parallel use” mode Unit B +
regulates the output voltage in such a manner that the voltage at no load is AC Load
approx. 4% higher than at nominal load. See also section 6. If no jumper is + -
plugged in, the unit is in “Single use” mode. Factory setting is also “Single -
use” mode. DC
If more than three units are connected in parallel, a fuse or circuit breaker with a rating of 50A or 63A is required on
each output. Alternatively, a diode or redundancy module can also be utilized.
Keep an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power
supplies on top of each other. Do not use power supplies in parallel in mounting orientations other than the standard
mounting orientation (terminals on the bottom of the unit) or in any other condition where derating of the output
current is required (e.g. altitude, above 60°C, …).
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.

25.8. 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 supplies in parallel. This is called a 1+1 redundancy. In case one power supply unit fails, the other one is
automatically able to support the load current without any interruption. Redundant systems for a higher power
demand are usually built in a N+1 method. E.g. five power supplies, each rated for 40A are paralleled to build a 160A
redundant system. For N+1 redundancy the same restrictions apply as for increasing the output power, see also
section 25.7.
Please note: This simple way to build a redundant system does not cover failures such as an internal short circuit in
the secondary side of the power supply. In such a case, the defective unit becomes a load for the other power supplies
and the output voltage can not be maintained any more. This can be avoided by using redundancy modules that include
have decoupling devices (diodes or mosfets). Further information and wiring configurations are provided in
section 24-3.
Recommendations for building redundant power systems:
a) Use separate input fuses for each power supply. A separate source for each supply when possible increases the
reliability of the redundant system.
b) Set the power supply into “Parallel Use” mode.
c) Monitor the individual power supply units. Therefore, use the DC-OK relay contact of the 1606 power supply.
d) It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting.

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 25
Bulletin 1606 Switched Mode Power Supplies

25.9. Series Operation

Unit A
Power supplies of the same type can be connected in series for higher
output voltages. It is possible to connect as many units in series as needed, AC
+
providing the sum of the output voltage does not exceed 150Vdc. Voltages
with a potential above 60Vdc are no longer SELV and can be dangerous. -
DC
Such voltages must be installed with a protection against touching.
Unit B +
Grounding of the output is required when the sum of the output voltage is
AC Load
above 60Vdc.
+ -
Avoid return voltage (e.g. from a decelerating motor or battery) which is
-
applied to the output terminals. DC Earth
(see notes)
Keep an installation clearance of 15mm (left / right) between two power
supplies and avoid installing the power supplies on top of each other. Do not use power supplies in series in mounting
orientations other than the standard mounting orientation (terminals on the bottom of the unit).
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.

25.10. Inductive and Capacitive Loads

The unit is designed to supply any kind of load, including capacitive and inductive loads.

25.11. Back-feeding Loads

Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called
return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force).
This power supply is resistant and does not show malfunctioning when a load feeds back voltage to the power supply.
It does not matter whether the power supply is on or off.
The maximum allowed feed-back-voltage is 35Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specified in section 6.

25.12. Use in a Tightly Sealed Enclosure

When the power supply is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher
than outside. In such situations, the inside temperature defines the ambient temperature for the power supply.
The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure.
The power supply is placed in the middle of the box, no other heat producing item is inside the box.
Enclosure: Rittal Typ IP66 Box PK 9522 100, plastic, 254x180x165mm
Load: 24V, 32A; (=80%) load is placed outside the box
Input: 230Vac
Temperature inside enclosure: 57.5°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 23.6°C
Temperature rise: 33.9K

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
26 Rockwell Automation Publication 1606-RM005A-EN-P - February 2014
 Bulletin 1606 Switched Mode Power Supplies

25.13. 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. Therefore, two different derating curves for continuous operation can be found below:
Curve A1 Recommended output current.
Curve A2 Max allowed output current (results in approximately half the lifetime expectancy of A1).

Fig. 25-10 Output Current

Mounting 40A A1
Orientation A
(Standard 30
orientation) Power
Supply 20
10
Ambient Temperature
INPUT OUTPUT 0
10 20 30 40 50 60°C

Fig. 25-11 Output Current

Mounting INPUT OUTPUT
40A
Orientation B
(Upside down) 30 A2
Supply
Power 20 A1

10
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 25-12 Output Current

Mounting 40A
Orientation C
(Table-top 30
A2
mounting)
20 A1

10
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 25-13 Output Current

Mounting 40A
Orientation D
INPUT OUTPUT

(Horizontal cw) 30 A2
Supply
Power

20 A1

10
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 25-14 Output Current

Mounting 40A
Orientation E
INPUT OUTPUT

(Horizontal ccw) 30 A2
Supply
Power

20 A1

10
Ambient Temperature
0
10 20 30 40 50 60°C

All parameters are specified at 24V, 40A, 3x400Vac, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.
Rockwell Automation Publication 1606-RM005A-EN-P - February 2014 27
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application
notes, sample code and links to software service packs, and a MySupport feature that you can customize to
make the best use of these tools. You can also visit our Knowledgebase at http://
www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums,
software updates, and to sign up for product notification updates.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConnectSM support programs. For more information, contact your local distributor or Rockwell Automation
representative, or visit http://www.rockwellautomation.com/support/.

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in
this manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada 1.440.646.3434
Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local
Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from
the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these
procedures.
United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your
distributor to complete the return process.
Outside United States Please contact your local Rockwell Automation representative for the return procedure.

Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to
improve this document, complete this form, publication RA-DU002, available at http://
literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf/
www.rockwellautomation.com/literature/.

Publication 1606-RM006A-EN-P - February 2014

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.