Rockwell Automation

1606-XLS80E 24V, 3.4A; Single Phase Input

1606-XLS80E
24V,3.4A Single Phase Input
POWER SUPPLY
¾ Ultra-small size
¾ Extra-low inrush current
¾ Active power factor correction
¾ Wide range AC/DC input
¾ Superior reserve power (can support 150% rated power for five
seconds)
¾ Superior efficiency and temperature rating
¾ DC-OK and overload LED

1. GENERAL DESCRIPTION
The most outstanding features of this 1606-XLS DIN-rail power supply are the high efficiency and the small size, which are achieved by a
synchronous rectification and further novel design details.
With short-term peak power capability of 150% and built-in large sized output capacitors, these features help start motors, charge capacitors
and absorb reverse energy and often allow a unit of a lower wattage class to be used.
High immunity to transients and power surges as well as low electromagnetic emission makes usage in nearly every environment possible.
The integrated output power manager, a wide range input voltage design and virtually no input inrush current make installation and usage
simple. Diagnostics are easy due to the dry DC-ok contact, a green DC-ok LED and red overload LED.
Unique quick-connect spring-clamp terminals allow a safe and fast installation and a large international approval package for a variety of
applications makes this unit suitable for nearly every situation.

2. SPECIFICATION QUICK REFERENCE

3. AGENCY APPROVALS
Output voltage DC 24V
Adjustment range 24-28V
IND. CONT. EQ.
Output current 3.4A continuous, 24V
UL 508 UL 60950-1
5A for typ. 4s, 24V
Output power 80W continuous, 24V
120W for typ. 4s, 24V
Output ripple < 50mVpp 20Hz to 20MHz Class I Div 2
Input voltage AC 100-240V ±15%
Line frequency 50-60Hz ±6%
AC Input current 1.42 / 0.82A at 120 / 230Vac EMC, LVD
Power factor 0.53 / 0.47 at 120 / 230Vac
AC Inrush current typ. 5 / 10A peak at 120 / 230Vac
DC Input voltage DC 110-300V - -20%/+25%
DC Input current 0.8 / 0.29A at 110 / 300Vdc
Efficiency 88.7 / 90.0% at 120 / 230Vac 4. RELATED PRODUCTS
Losses 10.4 / 9.1W at 120 / 230Vac Wall mount
1606-XLB
bracket
Temperature range -25°C to +70°C operational
Redundancy
Derating 2W/°C +60 to +70°C 1606-XLSRED
Module
Hold-up time typ. 41 / 174ms at 120 / 230Vac 1606-XLBUFFER Buffer unit
Dimensions 32x124x102mm WxHxD

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1606-XLS80E 24V, 3.4A; Single Phase Input

INDEX PAGE INDEX PAGE

1. General Description..............................................1 21. Fulfilled Standards ............................................. 13
2. Specification Quick reference ...............................1 22. Used Substances............................................... 13
3. Agency Approvals.................................................1 23. Physical Dimensions and Weight....................... 14
4. Related Products ..................................................1 24. Installation and Operation Instructions............... 14
5. AC-Input ...............................................................3 25. Accessories ....................................................... 15
6. Input Inrush Current..............................................4 26. Application Notes............................................... 16
7. DC-Input ...............................................................4 26.1. Repetitive Pulse Loading ......................... 16
8. Output...................................................................5 26.2. Peak Current Capability........................... 17
9. Hold-up Time ........................................................7 26.3. Back-feeding Loads................................. 17
10. Efficiency and Power Losses................................7 26.4. Charging of Batteries............................... 17
11. Functional Diagram ..............................................8 26.5. Output Circuit Breakers ........................... 18
12. Product Face label................................................8 26.6. External Input Protection ......................... 18
13. Terminals and Wiring............................................9 26.7. Parallel Use to Increase Output Power.... 19
14. Reliability ..............................................................9 26.8. Parallel Use for Redundancy ................... 19
15. EMC ...................................................................10 26.9. Daisy Chaining of Outputs ....................... 19
16. Environment .......................................................11 26.10. Series Operation...................................... 20
17. Protection Features ............................................12 26.11. Inductive and Capacitive Loads............... 20
18. Safety .................................................................12 26.12. Operation on Two Phases ....................... 20
19. Dielectric Strength ..............................................12 26.13. Use in a Tightly Sealed Enclosure........... 20
20. Approvals............................................................13 26.14. Mounting Orientations ............................. 21

INTENDED USE
Those responsible for the application and use of the products must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and safety requirements, including and applicable
laws, regulation , codes, and standards.

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 230V A figure displayed with the AC or DC before the value represents a nominal voltage with standard
tolerances (usually ±20%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
As long as not otherwise stated, AC 100V and AC 230V parameters are valid at 50Hz and AC
120V parameters are valid at 60Hz mains frequency.
230Vac A figure with the unit (Vac) at the end is a value without any additional tolerances included.
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage

DISCLAIMER
The information presented in this document is believed to be accurate and reliable and may change without notice.

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1606-XLS80E 24V, 3.4A; Single Phase Input
5. AC-INPUT
AC input nom. AC 100-240V see Fig. 5-1
AC input range min. 85-276Vac continuous operation
min. 60-85Vac full power for 200ms, no damage between 0 and 85Vac
min. 276-300Vac < 500ms
Input frequency nom. 50 – 60Hz ±6%
Turn-on voltage typ. 61Vac steady-state value, see Fig. 5-1
Shut-down voltage typ. 58Vac steady-state value, see Fig. 5-1

AC 100V AC 120V AC 230V

Input current typ. 1.67A 1.42A 0.82A at 24V, 3.4A, see Fig. 5-3
Power factor * typ. 0.55 0.53 0.47 at 24V, 3.4A, see Fig. 5-4
Crest factor ** typ. 3.33 3.9 3.88 at 24V, 3.4A
Start-up delay typ. 355ms 350ms 330ms see Fig. 5-2
Rise time typ. 6ms 5ms 7ms 0mF, 24V, 3.4A, see Fig. 5-2
typ. 20ms 20ms 22ms 3.4mF, 24V, 3.4A, see Fig. 5-2
Turn-on overshoot max. 50mV 50mV 50mV See Fig. 5-2
* 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. 5-1 Input voltage range Fig. 5-2 Turn-on behavior, definitions
Rated
POUT input range max. Intput
500ms Voltage
full
power
for
Shut -dow n
Turn-on

200ms
Output - 5% Overshoot
Voltage
VIN Start-up Rise
delay Time
60V 85V 276V 300Vac

Fig. 5-3 Input current vs. output load at 24V Fig. 5-4 Power factor vs. output load at 24V
Power
1.8A Input 0.6 Factor, typ.
ac
Current, typ.
1.5 0V Vac
10 c
0.55
10 0
Va
1.2 120 ac
0.5 120V
0.9 ac
230V
0.6
0.45 230Vac

0.3 0.4
Output Current Output Current
0 0.35
0.5 1.0 1.5 2.0 2.5 3.0 3.5A 0.5 1.0 1.5 2.0 2.5 3.0 3.5A

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1606-XLS80E 24V, 3.4A; Single Phase Input
6. INPUT INRUSH CURRENT
An active inrush limitation circuitry limits the input inrush current after turn-on of the input voltage and after short input
voltage interruptions.
The charging current into EMI suppression capacitors is disregarded in the first milliseconds after switch-on.

AC 100V AC 120V AC 230V

Inrush current max. 6Apeak 7Apeak 13Apeak -25°C to +70°C
typ. 4.5Apeak 5Apeak 10Apeak -25°C to +70°C
Inrush energy max. 2A2s 2A2s 2A2s -25°C to +70°C

Fig. 6-1 Input inrush current, typical behavior

Input Current Input: 230Vac

Output: 24V, 3.4A
Ambient: 25°C
Upper curve: Input current 5A / DIV
Input Voltage Medium curve: Input voltage 500V / DIV
Lower curve: Output voltage 20V / DIV
Time basis: 100ms / DIV

Output Voltage

7. DC-INPUT
DC input nom. DC 110-300V
DC input range min. 88-375Vdc continuous operation
DC input current typ. 0.8A / 0.29A 110Vdc / 300Vdc, 24V, 3.4A
Turn-on voltage typ. 61Vdc steady state value
Shut-down voltage typ. 47Vdc steady state value

Fig. 7-1 Wiring for DC Input

Battery
Power Supply Instructions for DC use:
+ AC a) Use a battery or similar DC source.
internal
fused b) Connect +pole to L and –pole to N.
L
+ c) Connect the PE terminal to a earth wire or to
N Load the machine ground.
-
Fuse

PE When the –pole of the battery is not connected to

earth, use an appropriate fuse to protect the N
- DC
terminal.

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1606-XLS80E 24V, 3.4A; Single Phase Input

8. OUTPUT
Output voltage nom. 24V
Adjustment range min. 24-28V guaranteed, multi turn potentiometer
max. 30V at clockwise end position of potentiometer
Factory setting 24.1V ±0.2%, at full load, cold unit
Line regulation max. 10mV 60 to 300Vac
Load regulation max. 100mV static value, 0A Æ 3.4A Æ 0A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 1 500µF

Continuous power capability

Output current nom. 3.4A at 24V, see Fig. 8-1
nom. 3.0A at 28V, see Fig. 8-1
Output power nom. 80W 24V, continuous
nom. 84W 28V, continuous
Short-circuit current min. 3.5A load impedance 250mOhm, see Fig. 8-1
max. 4.2A load impedance 250mOhm, see Fig. 8-1

Power-Boost , 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. The Power-Boost is repeatedly available.
Detailed information can be found in chapter 26.1 .
Once Power-Boost has been stopped by the output power limiter, a timer disables the next Power-Boost capability. The
recovery timer will start as soon as the output voltage reaches the adjusted value again, which usually happens after the
load has been reduced.
Output current nom. 5A at 24V, see Fig. 8-1
nom. 4.5A at 28V, see Fig. 8-1
Output power nom. 120W 24V, short term
nom. 126W 28V, short term
Short-circuit current min. 5.2A load impedance 250mOhm, see Fig. 8-1
max. 6.0A load impedance 250mOhm, see Fig. 8-1
Power-Boost time typ. 4s at 24V, 5A, duration until the output voltage dips,
min 3s see Fig. 8-2
max. 5s
Power-Boost recovery time typ. 7s overload free time to reset power manager, see Fig. 8-3

Peak current capability (up to several ms)

The power supply can deliver a peak current which is higher than the specified short term current. This helps to start current
demanding loads or to safely operate subsequent circuit breakers.
The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be
discharged and causes a voltage dip on the output. Detailed curves can be found in chapter 26.1.
Peak current voltage dips typ. from 24V to 20V at 6.8A for 10ms
typ. from 24V to 12.5V at 13.5A for 2ms
typ. from 24V to 7.5V at 13.5A for 5ms

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1606-XLS80E 24V, 3.4A; Single Phase Input

Fig. 8-1 Output voltage vs. output current, typ. Fig. 8-2 Power-Boost time vs. output power

Output Voltage Adjustment Bonus

BoostTime
Time
Range
28V 10s
24 9
8
20 7
con t inu ous

6 m ax
u p t o 4s

16
5
12 4
8 3 m in
2
4 1
Output Current Output Power
0 0
0 1 2 3 4 5 6A 110 120 130 140 150 160%

Fig. 8-3 Power-Boost recovery time

Limitation by
Power <150% Power Manager
Demand 100%

Boost
Bonus Recovery Time
Time Bonus Power disabled
Boost

Output
Voltage

Power-Boost is available as soon as power comes on and immediately after the end of an output short circuit.

Fig. 8-4 Power-Boost after input turn-on Fig. 8-5 Power-Boost after output short

Intput Short of
Output
Voltage
Output
Voltage
Output
Voltage
150% Bonus
Boost 150% Bonus
Boost
Power
Power Output Power
Power
100% Power 100%
Output
Power

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1606-XLS80E 24V, 3.4A; Single Phase Input
9. HOLD-UP TIME
AC 100V AC 120V AC 230V
Hold-up Time typ. 28ms 41ms 174ms 3.4A, 24V, see Fig. 9-1
typ. 58ms 88ms 347ms 1.7A, 24V, see Fig. 9-1

Fig. 9-1 Hold-up time vs. input voltage Fig. 9-2 Shut-down behavior, definitions

190ms Hold-up
Time Zero Transition
170
24V, 1.7A, min.
150 24V, 1.7A, typ.
Intput
130 Voltage
110
90 24V, 3.4A, min.
70 - 5%
24V, 3.4A, typ. Output
50 Voltage
30 Hold-up Time
Input Voltage
10
85 120 155 190 230Vac
Note: At no load, the hold-up time can be up to one minute. The green DC-ok lamp is on during this time.

10. EFFICIENCY AND POWER LOSSES

AC 100V AC 120V AC 230V
Efficiency typ. 91.2% 92.3% 93.0% 10A, 24V
Power losses typ. 23.1W 20.0W 18.1W 10A, 24V
typ. 5.6W 5.7W 5.9W 0A

Fig. 10-1 Efficiency vs. output current at 24V Fig. 10-2 Losses vs. output current at 24V
Efficiency Power Losses
94% 24W
230Vac 100Vac
93 21
92 120Vac
91 100Vac 18 120Vac
90 15
89 12 230Vac
88
87 9
Output Current Output Current
86 6
2 3 4 5 6 7 8 9 10A 0 1 2 3 4 5 6 7 8 9 10A

Fig. 10-3 Efficiency vs. input voltage, 24V, 10A Fig. 10-4 Losses vs. input voltage, 24V, 10A
Efficiency Power Losses
94% 27W
93 24
92 21
91 18
90 15
89 12
Input Voltage Input Voltage
88 9
85 120 155 190 225 260Vac 85 120 155 190 225 260Vac

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1606-XLS80E 24V, 3.4A; Single Phase Input

11. FUNCTIONAL DIAGRAM

Fig. 11-1 Functional diagram

Output
Voltage
Regulator VOUT

+
L Input Fuse
+
Input Filter Power Output
N Input Rectifier Converter Filter
-
Inrush Limiter
Transient Filter -

Over-
Temper- Output Output load
ature Output Over- Voltage
Shut- Power Voltage Monitor DC
down Manager Protection ok

12. PRODUCT FACE LABEL

Fig. 12-1 Front side

Output Terminals Output voltage potentiometer

Quick-connect spring-clamp (multi turn potentiometer)
terminals, no tools required Open the flap to tune the output voltage.
Factory setting: 24.1V
+ Positive output
- Negative (return) output DC-ok lamp (green)
Dual pins per pole Overload lamp (red)
Overload DC-ok
LED LED
80W Continuous power / Normal mode OFF ON
120W Peak power Power-Boost mode OFF ON
Overload
ON ON
(VOUT < 90%, > 80%)
Input Terminals
Quick-connect spring-clamp Overload
ON OFF
terminals, no tools required (VOUT < 80%)
N … Neutral input Short-circuit
ON OFF
L … Line (hot) input (VOUT = ca. 0V)
Over- temperature Intermitted Intermitted
... PE (Protective Earth) input
No input power OFF OFF
See chapter 13 “Terminals and Voltage fed back to
Wiring” to choose appropriate the output OFF ON
wire gauges terminals

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1606-XLS80E 24V, 3.4A; Single Phase Input
13. TERMINALS AND WIRING
Type Bi-stable, quick-connect spring clamp terminals. IP20 Finger safe construction.
Suitable for field- and factory installation. Shipped in open position.
Ferrules allowed, but not required
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)

Input terminals Output terminals

2
Solid wire 0.5-6mm 0.3-4mm2
Stranded wire 0.5-4mm2 0.3-2.5mm2
American wire gauge 20-10 AWG 26-12 AWG
Wire stripping length 10mm / 0.4inch 6mm / 0.25inch

Fig. 13-1 Connecting a wire Instructions:

a) Use appropriate copper cables that are designed
for an operating temperature of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum.
b) Follow national installation codes and installation
regulations!
c) Ensure that all strands of a stranded wire enter the
terminal connection!
1. Insert the wire 2. Snap the lever d) Up to two stranded wires with the same cross
To disconnect wire: same procedure section are permitted in one connection point
vice versa (except PE wire).
e) Do not use the unit without PE connection.

14. RELIABILITY

AC 100V AC 120V AC 230V

Lifetime expectancy min. 48 000h 62 000h 79 000h 40°C, 24V, 3.4A
min. 117 000h 126 000h 114 000h 40°C, 24V, 1.7A
min. 136 000h 15 years 15 years 25°C, 24V, 3.4A
MTBF SN 29500, IEC 61709 1 191 000h 1 265 000h 1 451 000h 40°C, 24V, 3.4A
2 061 000h 2 155 000h 2 436 000h 25°C, 24V, 3.4A
MTBF MIL HDBK 217F 581 000h 631 000h 643 000h 40°C, 24V, 3.4A, Ground Benign GB40
812 000h 889 000h 912 000h 25°C, 24V, 3.4A, Ground Benign GB25

The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime
expectancy of the built-in electrolytic capacitors.
Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s
manufacturer specification. The prediction model allows a calculation of up to 15 years from date of shipment.
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 the unit to fail and does not necessarily represent
the life of a product.

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1606-XLS80E 24V, 3.4A; Single Phase Input
15. EMC
The power supply is suitable for applications in industrial environment as well as in residential, commercial and light industry
environment without any restrictions. CE mark is in conformance with EMC guideline 89/336/EEC and 93/68/EEC and the
low-voltage directive (LVD) 73/23/EWG.

EMC Immunity EN 61000-6-1 EN 61000-6-2 Generic standards

Electrostatic discharge EN 61000-4-2 Contact discharge 8kV Criterion A
Air discharge 15kV Criterion A
Electromagnetic RF field EN 61000-4-3 80MHz-1GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines 4kV Criterion A
Output lines 2kV Criterion A
Surge voltage on input EN 61000-4-5 LÆN 2kV Criterion A
N / L Æ PE 4kV Criterion A
Surge voltage on output EN 61000-4-5 +Æ- 500V Criterion A
+ / - Æ PE 500V Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 70% of 100Vac 70Vac, 10ms Criterion A
40% of 100Vac 40Vac, 100ms Criterion C
40% of 100Vac 40Vac, 1000ms Criterion C
Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C
Voltage sags SEMI F47 0200 96Vac, 1000ms Criterion A
84Vac, 500ms Criterion A
60Vac, 200ms Criterion A
Input voltage swells RA internal standard 300Vac, 500ms Criterion A
Powerful transients VDE 0160 over entire load range 750V, 1.3ms Criterion A
Criterions:
A: Power supply shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. Power supply might shut-down and restarts by itself. No damages or hazards for the power supply occur.

EMC Emission EN 61000-6-3 and EN 61000-6-4 Generic standards

Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR
Class B, input lines
22
EN 55022 Class A, output lines
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 Fulfilled, active PFC
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.

Switching Frequency 65 to 270kHz load and input voltage dependent

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1606-XLS80E 24V, 3.4A; Single Phase Input

16. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) reduce output power above +60°C
Output de-rating 2W/°C 60-70°C (140°F to 158°F), see Fig. 16-1
Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation
Humidity 5 to 95% r.H. IEC 60068-2-30
Do not energize while condensation is present
Vibration sinusoidal 2-17.8Hz: ±1.6mm; IEC 60068-2-6
17.8-500Hz: 2g
2 hours / axis
0.5m2(s3) IEC 60068-2-64
Vibration random
2 hours / axis
Shock 30g 6ms, 20g 11ms IEC 60068-2-27
3 bumps / direction,
18 bumps in total
Altitude 0 to 6000m (0 to 20 000ft) Reduce output power or ambient temperature
above 2000m sea level.
Output de-rating (for altitude) 5W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 16-2
Over-voltage category III EN 50178, altitudes up to 2000m
II Altitudes from 2000m to 6000m
Degree of pollution 2 EN 50178, not conductive

Fig. 16-1 Output wattage vs. ambient temp., Fig. 16-2 Output wattage vs. altitude

Allowed Output Allowed Output

Wattage at 24V Wattage at 24V
120W 120W
f or t yp. 4s f or t yp. 4s
100 100
80 80 C
cont inuous cont inuous B
A
60 60
40 40
A... Tamb < 60°C
20 20 B... Tamb < 50°C
Ambient Temperature C... Tamb < 40°C Altitude
0 0
-25 0 20 40 60 70°C 0 2000 4000 6000m

The ambient temperature is defined as the air temperature 2cm below the unit.

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1606-XLS80E 24V, 3.4A; Single Phase Input
17. PROTECTION FEATURES
Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 34Vdc In case of an internal power supply defect, a redundant
max. 36Vdc circuitry limits the maximum output voltage. The output
shuts-down and automatically attempts to restart.
Output over-current protection Electronically limited See Fig. 8-1
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm e.g. screws, small parts
Over-temperature protection yes output shut-down with automatic restart
Input transient protection MOV (Metal Oxide Varistor) and active transient filter
Internal input fuse T6.3A H.B.C. not user replaceable
Note: In case of a protection event, audible noise may occur.

18. SAFETY
Input / output separation SELV IEC/EN 60950-1
PELV EN 60204-1, EN 50178, 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 between housing and PE terminal
Touch current (leakage current) typ. 0.19mA 100Vac, 50Hz, TN mains
typ. 0.29mA 120Vac, 60Hz, TN mains
typ. 0.53mA 230Vac, 50Hz, TN mains
< 0.25mA 110Vac, 50Hz, TN mains
< 0.38mA 132Vac, 60Hz, TN mains
< 0.74mA 264Vac, 50Hz, TN mains

19. DIELECTRIC STRENGTH

To fulfill the PELV requirements according to EN60204-1 § 6.4.1, we recommend that either the + pole, the – pole or any
other part of the output circuit shall be connected to the protective earth system. This helps to avoid situations in which a
load starts unexpectedly or can not be switched off any more when unnoticed earth faults occur.
Fig. 19-1 Dielectric strength A B C
Input Type test 60s 2500Vac 3000Vac 500Vac
L Factory test 5s 2500Vac 2500Vac 500Vac
N B
Field test 5s 2000Vac 2000Vac 500Vac
Output
+
Type tests and factory tests:
A
-
Conducted by the manufacturer. Do not repeat test in field!
C Rules for field test:
Earth, PE
Use appropriate test equipment which applies the voltage with
a slow ramp! Connect L and N together as well as all output
poles.
The output voltage is floating and has no ohmic connection to ground.

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1606-XLS80E 24V, 3.4A; Single Phase Input
20. APPROVALS

IECEE
IEC 60950-1 CB Scheme,
Information Technology Equipment
CB SCHEME
UL 508 LISTED E198865 listed for use in U.S.A. (UL 508) and Canada (C22.2
IND. CONT. EQ.
No. 14-95)
Industrial Control Equipment
UL 60950-1 RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-
1) and Canada (C22.2 No. 60950)
Information Technology Equipment, Level 5
UL 1604 RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and
Canada (C22.2 No. 213-M1987)
Hazardous Location Class I Div 2 T4 Groups A,B,C,D and
Class I Zone 2 Groups IIA, IIB and IIC
The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations as well as for Class I
Zone 2 Groups IIA, IIB and IIC locations. Substitution of components may impair suitability for
Class I Division 2 environment. Do not disconnect equipment unless power has been switched off.
Wiring must be in accordance with Class I, Division 2 wiring methods of the National Electrical
Code, NFPA 70, and in accordance with other local or national codes.
SEMI F47 SEMI F47-0200 Power Quality Star
Ride-through compliance for semiconductor industry.
Full SEMI range compliance (Input: 120Vac or 208Vac, output: 240W)

21. FULFILLED STANDARDS

EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN/IEC 61131-2 Programmable Controllers
EN 50178 Electronic Equipment in Power Installations

22. USED SUBSTANCES

The unit does not release any silicone and is suitable for the use in paint shops.
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The production material within our production does not include following toxic chemicals:
Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCT), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN),
Polybrom Biphenyll (PBB), Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated
Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO), Cadmium, Asbest, Mercury, Silicia

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1606-XLS80E 24V, 3.4A; Single Phase Input

23. PHYSICAL DIMENSIONS AND WEIGHT

Weight 440g / 0.97lb
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 depth (102mm) to calculate the total required installation
depth.

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

24. INSTALLATION AND OPERATION INSTRUCTIONS

Hazardous voltage inside device. Risk of electric shock, severe burns, or death.
• Do not use the unit without proper earth connection (Protective Earth). Use the pin on the terminal block for earth
connection and not one of the screws on the housing.
• Turn power off before working on the power supply. Protect against inadvertent re-powering.
• Make sure the wiring is correct by following all local and national codes.
• Do not open, modify or repair the unit.
• Use caution to prevent any foreign objects from entering into the housing.
• Do not use in wet locations or in areas where moisture or condensation can be expected.

Mounting Orientation:
Output terminal must be located on top and input terminal on the bottom. For other orientations see section 26.14.
Cooling:
Convection cooled, no forced cooling required. Do not cover ventilation grid (e.g. cable conduits) by more than 30%!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently with full
power. In case the adjacent device is a heat source, 15mm clearance is recommended.
Service parts:
The unit does not contain any serviceable parts. The tripping of an internal fuse is caused by an internal defect.

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1606-XLS80E 24V, 3.4A; Single Phase Input
25. ACCESSORIES
1606-XLB Wall mounting bracket
This bracket is used to mount 1606 units onto a flat surface without utilizing a DIN-Rail. The two aluminum brackets and the
black plastic slider of the unit have to be detached, so that the two steel brackets can be mounted.
Fig. 25-1 1606-XLB Wall Mounting Bracket Fig. 25-2 Assembled Wall Mounting Bracket

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1606-XLS80E 24V, 3.4A; Single Phase Input
26. APPLICATION NOTES

26.1. REPETITIVE PULSE LOADING

Typically, a load current is not constant. It varies over time. For pulse load compatibility, following rules must be met:
a) The pulse power demand must be below 150% of the nominal power.
b) The duration of the pulse power must be shorter than the allowed Power-Boost. (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 might respond with a thermal shut-down after a while. Use the max. duty cycle
curve (Fig. 26-2) to check if the average output current is below the nominal current.
d) For altitudes higher than 2000m reduce the pulse loading (15W/1000m) or the ambient temperature (5°C/1000m)

Fig. 26-1 Repetitive pulse loads, definitions Fig. 26-2 Max. Duty Cycle Curve

1.0 DutyCycle
P0 = 10%
PPEAK TPEAK T0 0.8 P0 = 50%
max. P0 = 75%
150% 0.6
100%
0.4

P0 0.2 P0 = 100%
PPEAK
0
100 110 120 130 140 150%

Tpeak
P0 Base load (W) DutyCycle =
Tpeak + T0
PPEAK Pulse load (above 100%)
T0 Duration between pulses (s) Tpeak - (DutyCycle x Tpeak)
T0 =
TPEAK Pulse duration (s) DutyCycle

Utilizing the Max. Duty Cycle Curve:

Example to determine the repetition rate of pulses without dipping of the output voltage:
Parameters of application: Determining the repetition rate:
1) make a vertical line at PPEAK = 150%
Pulse length is TPEAK = 1s 2) make a horizontal line where the vertical line crosses the P0 = 50% curve
3) Read the Max. Duty Cycle from the Duty Cycle-axis (= 0.37)
Steady state load P0=120W 4) Calculate the min. pause (base load) length T0 :
(= 50% of IRATED)
Tpeak - (DutyCycle x Tpeak) 1s - (0.37 x 1s)
T0 = = = 1.7s
Peak load PPEAK = 360W DutyCycle 0.37
(= 150% of IRATED) 5) Pulse length = 1s, min. pause length = 1.7s
6) Max. repetition rate = pulse length +pause length = 2.7s

More examples for pulse load compatibility:

PPEAK P0 TPEA T0 PPEAK P0 TPEA T0
K K
120W 80W 1s >25s 120W 40W 0.1s >0.16s
120W 0W 1s >1.3s 120W 40W 1s >1.6s
100W 40W 1s > 0,75s 120W 40W 3s >4.9s

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1606-XLS80E 24V, 3.4A; Single Phase Input
26.2. PEAK CURRENT CAPABILITY
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 Power-Boost) The same situation applies, when starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit, the
fuse needs a certain amount of over-current to trip or to blow. The peak current capability ensures the safe operation of
subsequent circuit breakers.
Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the power
supply can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The following two examples
show typical voltage dips:
Fig. 26-3 Peak load 6.8A for 50ms, typ. Fig. 26-4 Peak load 13.5A for 5ms, typ.

Output
24V Voltage 24V
Output
Voltage
18.5V

6.8A
13.5A
7.5V

Output Output
0A Current 0A Current

10ms/DIV 1ms/DIV
Peak load 6.8A (resistive) for 50ms Peak load 13.5A (resistive) for 5ms
Output voltage dips from 24V to 18.5V. Output voltage dips from 24V to 7.5V.

26.3. 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 chapter 8.

26.4. CHARGING OF BATTERIES

The power supply can be used for float-charging of lead-acid or maintenance free 24V VRLA batteries.
Instructions for charging batteries:
a) Set the output voltage, at disconnected load, very precisely to the end-of-charge voltage according to the expected
battery temperature.
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 15A or16A 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 is typ. 6.3mA at 25Vdc when the power supply is switched off (except in case a
blocking diode is utilized).

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1606-XLS80E 24V, 3.4A; Single Phase Input
26.5. OUTPUT CIRCUIT BREAKERS
Standard miniature circuit breakers (MCBs) can be used for branch protection. Ensure that the MCB is rated for DC voltage,
too. The following tests show which circuit breakers the power supply typically trips.
Circuit breakers have huge tolerances in their tripping behavior. Therefore, these typical tests can only be used as a
recommendation or for comparing two different power supplies. Furthermore, the loop impedance has a major influence on
whether a breaker trips or not. Two tests were performed, representing typical situations:

Test 1: Short circuit with S1 on the power supply end of the cable (loop impedance approx. 20mOhm)
Fig. 26-5 Branch protectors, test circuit 1

Circuit Parameters:
Power Breaker Input voltage: 230Vac, load current: 0A
Supply I Tripping time shorter than 5s.
AC + + The following circuit breaker tripped during the test:
S1 Load A- or Z- Characteristic:: equal or smaller 6A
DC - - C- Characteristic: equal or smaller 1A

Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 26-6 Branch protectors, test circuit 2 Parameters:
Circuit Input voltage: 230Vac, load current: 0A
Power Breaker Tripping time shorter than 5s.
Supply I The following circuit breaker tripped during the test:
R
AC + + A- or Z- Characteristic:: ≤ 6A and R< 180mOhm
S1 Load C- Characteristic: ≤ 1A and R< 390mOhm
DC - -
What does this resistance mean in wire length?
2 2 2 2 2 2
0.5mm 0.7mm 1.0mm 1.5mm 2.5mm 4.0mm
180mOhm 10.9m 15.2m 21.7m 32.6m 54.3m 86.9m
220mOhm 6.1m 8.6m 12.3m 18.4m 30.6m 49.0m

Example:
Which wire gauge must be used to trip a Z-Characteristic circuit breaker with a rating of 6A? The load wire length is 21m.
Answer: A 6A Z-Characteristic circuit breaker requires a loop impedance of less than 180mOhm (test results). The wire
length table shows that up to 25.1m wire with a cross section of 2.5mm2 are below 180mOhm. A wire not smaller than
2
2.5mm shall be used.

26.6. EXTERNAL INPUT PROTECTION

The unit is tested and approved for branch circuits up to 20A. External protection is only required, if the supplying branch has
an ampacity greater than this. In some countries local regulations might apply. Check also local codes and local
requirements.
If an external fuse is necessary or utilized, a minimum value is required to avoid undesired tripping of the fuse.

B-Characteristic C-Characteristic
Ampacity max. 20A 20A
min. 6A 6A

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1606-XLS80E 24V, 3.4A; Single Phase Input
26.7. PARALLEL USE TO INCREASE OUTPUT POWER
Power supplies can be paralleled to increase the output power.
Unit A a) Use only power supplies from the same series.
AC b) A fuse (or diode) on the output is only required if more than
+ three units are connected in parallel.
- c) Do not load terminals with more than 25A. Follow wiring
DC instructions according to chapter 0
+ d) Keep an installation clearance of 15mm (left/right) between two
Unit B
Load power supplies and avoid installing the power supplies on top of
AC each other.
+ -
-
DC

26.8. PARALLEL USE FOR REDUNDANCY

Power supplies can be paralleled for 1+1 redundancy to gain a 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 1606-
XLS80E power supplies in parallel. In case one power supply unit fails, the other one is automatically able to support the
load current without any interruption. This simple way to build a redundant system has two major disadvantages:
a. The faulty power supply can not be recognized. The green LED will still be on since it is reverse-powered from the other
power supply.
b. It does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a (nearly
impossible) case, the defective unit becomes a load for the other power supplies and the output voltage can not be
maintained any more.
This can only be avoided by utilizing decoupling diodes which are included in the decoupling module 1606-XLSRED or
redundancy module 1606-XLERED with alarm contacts.
Recommendations for building redundant power systems:
a) Use separate input fuses for each power supply.
b) Monitor the individual power supply units. A DC-ok lamp and a DC-ok contact is included in the redundancy module
1606-XLERED. This feature reports a faulty unit.
c) When possible, connect each power supply to different phases or circuits.

26.9. DAISY CHAINING OF OUTPUTS

Daisy chaining (jumping from one power supply output to the next) is allowed as long as the maximum current through one
terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.
Fig. 26-7 Daisy chaining of outputs Fig. 26-8 Using distribution terminals

max 25A!

+ -
++ -- ++ -- ++ -- ++ -- + -
Load
Load
Power Power Power Power
Supply Supply Supply Supply
L N PE L N PE
Distribution
Input Input Terminals

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1606-XLS80E 24V, 3.4A; Single Phase Input
26.10. SERIES OPERATION
The power supply can be put in series to increase the output voltage.

Fig. 26-9 Schematic for series operation Instructions for use in series:
a) It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed
Unit A 150Vdc.
AC b) Warning ! Voltages with a potential above 60Vdc are not SELV
+ any more and can be dangerous. Such voltages must be
- installed with a protection against touching.
DC c) For serial operation use power supplies of the same type.
+ d) Earthing of the output is required when the sum of the output
Unit B
Load voltage is above 60Vdc.
AC
+ - e) Keep an installation clearance of 15mm (left/right) between two
power supplies and avoid installing the power supplies on top of
- Earth each other.
DC
Note: Avoid return voltage (e.g. from a decelerating motor or battery)
which is applied to the output terminals.

26.11. INDUCTIVE AND CAPACITIVE LOADS

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

26.12. OPERATION ON TWO PHASES

Fig. 26-10 Schematic for two phase operation

Power Supply Instructions for two phase operation:

L1 AC a) A phase to phase connection is allowed as long as the
supplying voltage is below 240V(+15%).
max.

internal
fused
L b) Use a fuse or a circuit breaker to protect the N input. The N
input is internally not protected and is in this case connected
+15%

Fuse
L3 N
to a hot wire.
240V

PE
Appropriate fuses or circuit breakers are specified in section 0
L2 DC “External Input Protection”.

26.13. 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. The inside temperature defines the ambient temperature for the power supply.
Results from such an installation:
Power supply is placed in the middle of the box, no other heat producer inside the box
Enclosure: Type IP66 Box PK 9516 100, plastic, 110x180x165mm
Load: 24V, 3.4A; (=100%) load is placed outside the box
Input: 230Vac
Temperature inside enclosure: 41.3°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 25.1°C
Temperature rise: 16.2°C

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1606-XLS80E 24V, 3.4A; Single Phase Input
26.14. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous
output power or a limitation in the max. 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 approx. in half the lifetime expectancy of A1).

Fig. 26-11 Output Current

Mounting OUTPUT
Orientation A 3.5A A1
Standard Orientation 2.8
Power 2.1
Supply
1.4
0.7
Ambient Temperature
INPUT 0
10 20 30 40 50 60°C

Fig. 26-12 Output Current

Mounting INPUT
Orientation B 3.5A A2
(Upside down) 2.8 A1
2.1
Supply
Power
1.4
0.7
Ambient Temperature
0
OUTPUT

10 20 30 40 50 60°C

Fig. 26-13 Output Current

Mounting
Orientation C 3.5A A2
(Table-top mounting) 2.8 A1
2.1
1.4
0.7
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 26-14 Output Current

Mounting
Orientation D 3.5A A2
(Horizontal cw) 2.8 A1
OUTPUT
Supply
Power
INPUT

2.1
1.4
0.7
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 26-15 Output Current

Mounting
Orientation E 3.5A A2
(Horizontal ccw) 2.8 A1
OUTPUT

Supply
Power

INPUT

2.1
1.4
0.7
Ambient Temperature
0
10 20 30 40 50 60°C

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