Allen-Bradley 1606-XLS960E-3

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Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number:

1606-XLS960E-3

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 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.

Terminology and Abbreviations

egaP egaP

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. Efciency and Power Losses..............................11

13. Reliability ...........................................................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. Certications

.................................................. 18

23. Physical Dimensions and Weight .................... 19

24. Accessories ....................................................... 20

24.1. Wall mounting bracket - 1606-XLC......... 20

24.2. Buffer module - 1606-XLSBUFFER24........ 20

24.3. 1606-XLSRED80 - Redundancy Modules... 20

25. Application Notes.............................................

25.1. Repetitive Pulse Loading..........................21

25.2. Peak Current Capability ...........................22

25.3. External Input Protection.........................22

25.4. Using only 2 Legs of a 3-Phase System ....23

25.5. Charging Batteries ...............................24

25.6. Output Circuit Breakers............................24

25.7. Parallel Use to Increase Output Power....25

25.8. Parallel Use for Redundancy ....................25

25.9. Series Operation .......................................26

25.10. Inductive and Capacitive Loads................26

25.11. Back-feeding Loads ..................................26

25.12. Use in a Tightly Sealed Enclosure ............26

25.13. Mounting Orientations ............................27

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The Bulletin 1606 Switched Mode Power Supplies, specifically the 1606-XLS960E-3 model, are designed for industrial control applications, offering high efficiency and reliability.

Function Description:

The 1606-XLS960E-3 is a 3-phase switched-mode power supply that converts AC input voltage to a regulated DC output voltage. It is designed to provide a stable power source for various industrial loads, including those with high short-term power requirements. The unit incorporates an active inrush current limitation circuit to prevent high current peaks during turn-on. It also features a "BonusPower" function, allowing it to deliver higher short-term output power than its nominal rating, which is beneficial for starting loads with high inrush currents or for handling temporary overloads.

The power supply includes a DC-OK relay contact for remote monitoring of the output voltage status, indicating when the output voltage is above 90% of the adjusted value. A shut-down input allows for remote control of the unit, enabling it to be switched off or to adjust the output voltage. Internal data logging capabilities are integrated to store operational data and failure information, aiding in troubleshooting and maintenance.

The unit can be operated in "Single Use" mode or "Parallel Use" mode. In "Parallel Use" mode, multiple power supplies can be connected in parallel to increase the total output power or to provide redundancy for enhanced system availability. For redundancy, the unit supports N+1 configurations, where an additional power supply is added to ensure continuous operation even if one unit fails.

Important Technical Specifications:

Input (3AC 380-480V):

Nominal Input Voltage: 3AC 380-480V
AC Input Range: 3x 323-576Vac (continuous operation)
Allowed Voltage L to Earth: Max. 576Vac (continuous, IEC 60664-1)
Input Frequency: 50-60Hz ±6%
Turn-on Voltage: Typ. 3x 305Vac
Shut-down Voltage: Typ. 3x 275Vac
Input Current (at 24V, 40A): Typ. 1.65A (3AC 400V), 1.35A (3AC 480V)
Power Factor (at 24V, 40A): Typ. 0.88 (3AC 400V), 0.90 (3AC 480V)
Start-up Delay: Typ. 500ms (3AC 400V), 600ms (3AC 480V)
Inrush Current: Max. 6Apeak, Typ. 4.5Apeak (over entire temperature range)
Inrush Energy: Max. 1.5A²s
Inrush Delay: Typ. 500ms (3AC 400V), 600ms (3AC 480V)

Output (24V):

Nominal Output Voltage: 24V
Adjustment Range: 24-28V (min. 24V, max. 30V)
Factory Setting: Typ. 24.1V (single use), Typ. 25.1V (parallel use)
Nominal Output Current: 40A
BonusPower Current (short term 4s): Nom. 60A (at 24V), Nom. 51.5A (at 28V)
Peak Current Capability (up to 25ms): Typ. 110A (output voltage stays above 20V)
Nominal Output Power: 960W
BonusPower (short term): Nom. 1440W
BonusPower Time: Typ. 4s
Ripple and Noise Voltage: Max. 100mVpp (20Hz to 20MHz, 50Ohm)
Efficiency (at 24V, 40A): Typ. 95.3% (3AC 400V), 95.2% (3AC 480V)
Hold-up Time (at 24V, 40A, 3AC 400V): Typ. 50ms, Min. 20ms

General:

Weight: 1500g / 3.3lb
Dimensions (WxHxD): 110x124x127mm
Operating Temperature: -25°C to +70°C (derating above 60°C)
Storage Temperature: -40°C to +85°C
Humidity: 5 to 95% RH
Degree of Protection: IP20
Output Over-voltage Protection: Typ. 30Vdc, max. 32Vdc (output shut-down with automatic restart)
Over-temperature Protection: Output shut-down with automatic restart
MTBF (Calculated Lifetime Expectancy): 314,000h to 173,000h (at 24V, 40A, 25°C to 40°C)

Usage Features:

Output Voltage Adjustment: A multi-turn potentiometer on the front panel allows for precise adjustment of the output voltage between 24V and 28V.
Parallel Use Selector: A jumper on the front panel configures the unit for "Single Use" or "Parallel Use" mode, optimizing load sharing when multiple units are connected in parallel.
DC-OK Relay Contact: Provides a dry contact for remote signaling of the output voltage status, enabling integration into monitoring systems.
Shut-down Input: Allows for remote control of the power supply, either to switch it off or to adjust the output voltage (14Vdc to 28Vdc range).
LED Indicators:
- DC-OK LED (green): Indicates when the output voltage is above 90% of the adjusted value.
- Overload LED (red): Indicates output voltage below 90% of adjusted value, short circuit, or flashing for shut-down due to over-temperature or active shut-down input.
Mounting Orientations: The unit can be mounted in various orientations, though derating of output current may be required for non-standard orientations. Standard mounting (terminals on the bottom) allows for full output current.
Accessories: Available accessories include a wall mounting bracket (1606-XLC), a buffer module (1606-XLSBUFFER24) for extended hold-up time, and redundancy modules (1606-XLSRED80) for building redundant systems.
Two-Leg Operation: The power supply can be operated on two legs of a 3-phase system, though output power must be reduced, and EMC performance, hold-up time, and losses may differ. This mode is not UL approved.

Maintenance Features:

Internal Data Logging: A microcontroller continuously acquires and stores operational data (e.g., over-voltage transients, input voltage, internal temperature, overloads, missing input phases) and failure data. This data can be downloaded by service personnel to facilitate troubleshooting and accurate problem analysis, even if the unit is faulty.
Protection Features:
- Output Over-voltage Protection: Shuts down the output in case of an internal fault causing excessive output voltage, with automatic restart attempts.
- Over-temperature Protection: Shuts down the unit if internal temperature exceeds limits, with automatic restart.
- Input Transient Protection: Includes a Metal Oxide Varistor (MOV) to protect against input voltage transients.
- Internal Input Fuse: Included for protection.
Reliability: High calculated lifetime expectancy (MTBF) ensures long-term operation and reduced maintenance needs.
Certifications: Complies with various international standards (CE, C-Tick, UL 508, UL 60950-1, Marine RINA, SEMI F47, Marine GL, GOST R), indicating adherence to quality and safety requirements.