Rockwell Automation

1606-XLS480E-3 24V, 20A; Three Phase Input

1606-XLS480E-3
24V, 20A Three Phase Input
POWER SUPPLY
¾ Ultra-small size
¾ Extra-low inrush current
¾ Active power factor correction
¾ Wide range AC/DC input; auto select 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 3. AGENCY APPROVALS

REFERENCE
IND. CONT. EQ.
Output voltage DC 24V
UL 508 UL 60950-1
Adjustment range 24-28V
Output current 20A Continuous, 24V
30A For typ. 4s, 24V
Output power 480W Continuous, 24V Class I Div 2
720W For typ. 4s, 24V
Output ripple < 100mVpp 20Hz to 20MHz
EMC, LVD
Input voltage AC 380-480V ±15%
Line frequency 50-60Hz ±6%
AC Input current 0.79 / 0.65A At 3x400 / 480Vac
Power factor 0.94 / 0.95
AC Inrush current typ. 3A peak
At 3x400 / 480Vac
4. RELATED PRODUCTS
Conformal coated
Efficiency 95.0 / 94.8% At 3x400 / 480Vac 1606-XLS-480E-3C
unit
Losses 25.3 / 26.4W At 3x400 / 480Vac 1606-XLB Wall mount bracket
Temperature range -25°C to +70°C Operational Redundancy
1606-XLSRED
Derating 12W/°C +60 to +70°C Module
Hold-up time typ. 22 / 22ms At 3x400 / 480Vac 1606-XLBUFFER Buffer unit
Dimensions 65x124x127mm WxHxD
Output voltage DC 24V
Adjustment range 24-28V

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1606-XLS480E-3 24V, 20A; Three Phase Input

INDEX PAGE INDEX PAGE

1. General Description..............................................1 22. Fulfilled Standards ............................................. 15
2. Specification Quick reference ...............................1 23. Used Substances............................................... 15
3. Agency Approvals.................................................1 24. Physical Dimensions and Weight....................... 15
4. Related Products ..................................................1 25. Installation and Operation Instructions............... 16
5. AC-Input ...............................................................3 26. Accessories ....................................................... 17
6. DC-Input ...............................................................4 27. Application Notes............................................... 18
7. Input Inrush Current..............................................4 27.1. Repetitive Pulse Loading ......................... 18
8. Output...................................................................4 27.2. Peak Current Capability........................... 19
9. Hold-up Time ........................................................6 27.3. Back-feeding Loads................................. 19
10. DC-OK Relay Contact ..........................................8 27.4. Charging of Batteries............................... 19
11. Efficiency and Power Losses................................8 27.5. Output Circuit Breakers ........................... 20
12. Functional Diagram ..............................................9 27.6. External Input Protection ......................... 21
13. Product Face Label ............................................10 27.7. 2-Phase Operation .................................. 21
14. Terminals and Wiring..........................................11 27.8. Parallel Use to Increase Output Power.... 22
15. Reliability ............................................................11 27.9. Parallel Use for Redundancy ................... 22
16. EMC ...................................................................12 27.10. Daisy Chaining of Outputs ....................... 22
17. Environment .......................................................13 27.11. Series Operation...................................... 23
18. Protection Features ............................................14 27.12. Inductive and Capacitive Loads............... 23
19. Safety .................................................................14 27.13. Use in a Tightly Sealed Enclosure........... 23
20. Dielectric Strength ..............................................14 27.14. Mounting Orientations ............................. 24
21. Approvals............................................................15

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 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 disregarding whether it is full (13.7V) or flat (10V)
As long as not otherwise stated, AC 380V and AC 400V parameters are valid at 50Hz and AC
480V parameters are valid at 60Hz mains frequency.
400Vac 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- XLS480E-3 24V, 20A; Three Phase Input

5. AC-INPUT
AC input nom. 3AC 380-480V Wide-range input,, see Fig. 5-1
Consult factory if one phase is earthed.
AC input range min. 3x 323-552Vac Continuous operation
min. 3x 280-323Vac Full power for 200ms, no damage between 0 and 280Vac
For 2-phase operation see section 27.7
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 3x 263Vac Steady-state value, see Fig. 5-1
Shut-down voltage typ. 3x 242Vac Steady-state value, see Fig. 5-1

3AC 400V 3AC 480V

Input current typ. 0.79A 0.65A At 24V, 20A, all three phases equal voltage
See Fig. 5-3
Power factor * typ. 0.94 0.95 At 24V, 20A, see Fig. 5-4
Start-up delay typ. 350ms 290ms See Fig. 5-2
Rise time typ. 30ms 30ms 0mF, 24V, 20A, see Fig. 5-2
typ. 40ms 40ms 20mF, 24V, 20A, see Fig. 5-2
Turn-on overshoot max. 500mV 500mV See Fig. 5-2
* The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.

Fig. 5-1 Input voltage range Fig. 5-2 Turn-on behavior, definitions

POUT Rated input range Intput

full power
for 200ms Voltage
Shut -dow n

Turn-on

Output - 5% Overshoot
Voltage
VIN
Start-up Rise
delay Time
280V 323V 3x 552Vac

Fig. 5-3 Input current vs. output load at 24V Fig. 5-4 Power factor vs. output load
Input Current, typ. Power Factor, typ.
0.8A 1.0
c
Va
0.7 4 00 c 0.95 3x
0.6 3x 80Va 400Vac
4
0.5 3x 0.9
0.4
0.3 0.85
3x
0.2 480Vac
0.8
0.1 Output Current
Output Current
0 0.75
2 4 6 8 10 12 14 16 18 20A 2 4 6 8 10 12 14 16 18 20A

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1606- XLS480E-3 24V, 20A; Three Phase Input
6. DC-INPUT
The 1606-XLS480E-3 shall not be used with a DC-input voltage without consulting Rockwell Automation.
Check 1606-XLS480E-3 for DC-input voltage. (special version for intermediate bus systems, drive systems)

7. 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 microseconds after switch-on.

3AC 400V 3AC 480V

Inrush current max. 10Apeak 10Apeak -25°C to +70°C
typ. 3Apeak 3Apeak -25°C to +70°C
Inrush energy max. 1A2s 1A2s -25°C to +70°C
Inrush delay typ. 270ms 220ms

Fig. 7-1 Input inrush current, typical behavior

A: Inrush delay
B: Start-up delay
Input Current
Input: 3x400Vac
Output: 24V, 20A
A Ambient: 25°C
Upper curve: Input current 2A / DIV
Medium curve: Input voltage 1000V / DIV
Lower curve: Output voltage 50V / DIV
Input Voltage
Time basis: 100ms / DIV

B Output Voltage

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 320 to 552Vac
Load regulation max. 100mV Static value, 0A Æ 20A Æ 0A
Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 950µF The energy of the bulk capacitor on the input side will be
transferred to the output to supply short load peaks.

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1606- XLS480E-3 24V, 20A; Three Phase Input
Continuous power capability
Output current nom. 20A At 24V, see Error! Reference source not found.
nom. 17.5A At 28V, see Error! Reference source not found.
Output power nom. 480W 24V, continuous
nom. 490W 28V, continuous
Load impedance 50mOhm, see Error! Reference source not
Short-circuit current min. 20A
found.
Load impedance 50mOhm, see Error! Reference source not
max. 23A
found.

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 27.1 .
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. 30A At 24V, see Error! Reference source not found.
nom. 26A At 28V, see Error! Reference source not found.
Output power nom. 720W 24V, short term
nom. 728W 28V, short term
Load impedance 50mOhm, see Error! Reference source
Short-circuit current min. 30A
not found.
Load impedance 50mOhm, see Error! Reference source
max. 34A
not found.
Power-Boost time typ. 4s At 24V, 30A, duration until the output voltage dips,
min 3.5s See Error! Reference source not found.
max. 4.5s
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 27.2.
Peak current voltage dips typ. from 24V to 16V At 40A for 50ms
typ. from 24V to 19V At 80A for 2ms
typ. from 24V to 16.5V At 80A for 5ms

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 5s max.
24
4
20
min.
cont inuous

short -t erm

16 3
12 2
8
1
4
Output Current Output Power
0 0
0 5 10 15 20 25 30 35A 110 120 130 140 150 160%

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1606- XLS480E-3 24V, 20A; Three Phase Input

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

9. HOLD-UP TIME
3AC 400V 3AC 480V
20A, 24V, see Error! Reference source not
Hold-up Time typ. 22ms 22ms
found.
10A, 24V, see Error! Reference source not
typ. 44ms 44ms
found.

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

Hold-up Time
50ms 24V, 10A, t yp.
Zero Transition
Intput
40 Voltage
24V, 10A, min.
30
24V, 20A, t yp.
20 - 5%
24V, 20A, min. Output
10 Voltage
Input Voltage Hold-up Time
0
320 360 400 440 3x480Vac

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1606- XLS480E-3 24V, 20A; Three Phase Input

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1606- XLS480E-3 24V, 20A; Three Phase Input

10. 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 which is connected in parallel to the power supply output.

Contact closes As soon as the output voltage reaches 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
See dielectric strength table in section Error!
Isolation voltage
Reference source not found.

Fig. 10-1 DC-ok relay contact behavior

Note:
VOUT= VADJ
The DC-ok feature requires that the output voltage reaches
90% the nominal (=adjusted) level after turn-on in order to
10%
VADJ function according to specification. If this level cannot be
achieved, the overload lamp will be on and the DC-ok
< > contact will be open. The overload signal will only shut off
1ms 1ms 250ms
as soon as the adjusted voltage is reached. This is an
important condition to consider particularly, if the load is a
battery, the power supply is used in parallel or the power
supply is used for N+1 redundant systems.
open closed open closed

11. EFFICIENCY AND POWER LOSSES

3AC 400V 3AC 480V
Efficiency typ. 95.0% 94.8% 20A, 24V
Power losses typ. 25.3W 26.3W 20A, 24V
typ. 8.2W 10.0W 0A

Fig. 11-1 Efficiency vs. output current at 24V Fig. 11-2 Losses vs. output current at 24V
Efficiency Power Losses
96% 30W
95 25
94 3x
400Vac 3x
93 20 480Vac
92 15
3x
91 480Vac 10 3x
400Vac
90
89 5
Output Current Output Current
88 0
4 6 8 10 12 14 16 18 20A 0 2 4 6 8 10 12 14 16 18 20A

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1606- XLS480E-3 24V, 20A; Three Phase Input

Fig. 11-3 Efficiency vs. input voltage, 24V, 20A Fig. 11-4 Losses vs. input voltage, 24V, 20A
Efficiency Power Losses
95.4% 27W
95.2 26.5
95.0 26.0
94.8 25.5
94.6 25.0
94.4 24.5
Input Voltage Input Voltage
94.2 24.0
350 400 450 500 3x550Vac 350 400 450 500 3x550Vac

12. FUNCTIONAL DIAGRAM

Fig. 12-1 Functional diagram

Output
Voltage
Regulator VOUT
L1
L2 Input Filter +
Input Rectifier PFC
Inrush Limiter Converter Power Output +
L3 Transient Filter Converter Filter
-
-
Over-
load
DC
ok
Temper- Output Output Output
ature Power Over- Voltage
Shut- Manager Voltage
down Protection Monitor DC ok DC
Relay ok

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1606- XLS480E-3 24V, 20A; Three Phase Input

13. PRODUCT FACE LABEL

Fig. 13-1 Front side

Output Terminals Output voltage potentiometer

Quick-connect spring- (multi turn potentiometer)
clamp terminals, no Open the flap to tune the output voltage.
tools required Factory setting: 24.1V

+ Positive output DC-ok lamp (green)

- Negative Overload lamp (red)
(return) output
Dual pins per DC-
pole Overload DC-ok
ok
lamp contact
DC ok Relay contact lamp
(NO-contact)
480W Continuous Normal mode OFF ON Closed
power / Power-Boost
OFF ON Closed
720W Peak power mode
Overload
ON OFF Open
(VOUT < 90%)
Input Terminals
Quick-connect spring- Short-circuit
clamp terminals, no (VOUT = ca. ON OFF Open
0V)
tools required
Over-
ON OFF Open
temperature
L1, L2, L3 Line
inputs No input OFF OFF Open
power
... PE (Protective
Earth) input
See chapter Error!
Reference source
not found. “Terminals DC-ok lamp and DC-ok contact
and Wiring” to choose function synchronized
appropriate wire
gauges

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1606- XLS480E-3 24V, 20A; Three Phase Input

14. 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.
2
Solid wire 0.5-6mm
Stranded wire 0.5-4mm2
American wire gauge 20-10 AWG
Ferrules Allowed, but not required
Wire stripping length 10mm / 0.4inch
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)

Fig. 14-1 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.

15. RELIABILITY

3AC 400V 3AC 480V

Lifetime expectancy min. 51 000h 48 000h 40°C, 24V, 20A
min. 89 000h 86 000h 40°C, 24V, 10A
min. 144 000h 135 000h 25°C, 24V, 20A
MTBF SN 29500, IEC 61709 690 000h 670 000h 40°C, 24V, 20A
1 194 000h 1 159 000h 25°C, 24V, 20A
MTBF MIL HDBK 217F 284 000h 271 000h 40°C, 24V, 20A, Ground Benign GB40
389 000h 371 000h 25°C, 24V, 20A, 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 a unit to fail and does not necessarily represent
the life of a product.

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1606- XLS480E-3 24V, 20A; Three Phase Input
16. 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 L1 Æ L2, L2 Æ L3, 2kV Criterion A
L1 Æ L3
Surge voltage on input EN 61000-4-5 L1 / L2 / L3 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 380Vac 266Vac, 10ms Criterion A
Dip on all three phases 40% of 380Vac 152Vac, 100ms Criterion C
40% of 380Vac 152Vac, 1000ms Criterion C
Mains voltage dips EN 61000-4-11 70% of 380Vac 266Vac, 10ms Criterion A
Dip on one phase 40% of 380Vac 152Vac, 100ms Criterion A
40% of 380Vac 152Vac, 1000ms Criterion A
Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C
Voltage sags SEMI F47 0200 Dips on two phases 304Vac, 1000ms Criterion A
according to section 266Vac, 500ms Criterion A
7.2. (SEMI F47-200) 190Vac, 200ms Criterion A
Powerful transients VDE 0160 over entire load range 1300V, 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
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 Frequencies The power supply has three converters with three different switching frequencies included.
One is nearly constant. The other two are input voltage and load dependent.
Switching frequency 1 100kHz Nearly constant
Switching frequency 2 30kHz to 90kHz Input voltage and load dependent
Switching frequency 3 40kHz to 220kHz Input voltage and load dependent

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1606- XLS480E-3 24V, 20A; Three Phase Input

17. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) Reduce output power above +60°C
60-70°C (140°F to 158°F), see Error! Reference
Output de-rating 12W/°C
source not found.
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.
above 2000m, see Error! Reference source not
Output de-rating (for altitude) 30W/1000m or 5°C/1000m
found.
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. 17-1 Output current vs. ambient temp., Fig. 17-2 Output current vs. altitude

Allowed Output
Allowed Output Current at 24V Current at 24V
30A 30A
f or t yp. 4s
25 f or t yp. 4s
25
20 20 C
cont inuous B A B
15 cont inuous A
15
10 A... 2x 460 t o 552Vac
B... 2x 340 t o 460Vac 10
A... Tamb < 60°C
5 5 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- XLS480E-3 24V, 20A; Three Phase Input

18. PROTECTION FEATURES

Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 32Vdc In case of an internal power supply defect, a redundant
max. 35Vdc circuitry limits the maximum output voltage. The output
shuts-down and automatically attempts to restart.
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 Not included See section 27.6
Note: In case of a protection event, audible noise may occur.

19. 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. 0.38mA 3x 440Vac, 50Hz, TN mains
typ. 0.54mA 3x 528Vac, 60Hz, TN mains
< 0.47mA 3x 400Vac, 50Hz, TN mains
< 0.7mA 3x 480Vac, 60Hz, TN mains

20. 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. 20-1 Dielectric strength A B C D

Type test 60s 2500Vac 3000Vac 500Vac 500Vac
Input DC-ok
L1 B Factory test 5s 2500Vac 2500Vac 500Vac 500Vac
L2 Field test 5s 2000Vac 2000Vac 500Vac 500Vac
L3
Type tests and factory tests:
D
B

A Conducted by the manufacturer. Do not repeat test in field!

Output Rules for field test:
Earth
Use appropriate test equipment which applies the voltage with
C +
a slow ramp! Connect L1, L2 and L3 together as well as all
-
output poles.

The output voltage is floating and has no connection to ground.

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1606- XLS480E-3 24V, 20A; Three Phase Input
21. 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 T4A 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 (Dips on two phase: 304Vac for 1000ms,
266Vac for 500ms and 190Vac for 200ms)

22. 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

23. 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

24. PHYSICAL DIMENSIONS AND WEIGHT

Weight 870g / 1.92lb
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 (127mm) to calculate the total required installation
depth.

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1606- XLS480E-3 24V, 20A; Three Phase Input

Fig. 24-1 Front view Fig. 24-2 Side view

25. 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 27.14.
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.

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1606- XLS480E-3 24V, 20A; Three Phase Input

26. ACCESSORIES
1606-XLB Wall mounting bracket
This bracket is used to mount Dimension units onto a flat surface without utilizing a DIN-Rail. The two aluminum brackets
and the black plastic slide of the unit have to be detached, so that the two steel brackets can be mounted.
Fig. 26-1 1606-XLB Wall Mounting Bracket Fig. 26-2 Assembled Wall Mounting Bracket

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1606- XLS480E-3 24V, 20A; Three Phase Input
27. APPLICATION NOTES

27.1. 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 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 while. Use the max. duty cycle
curve (Fig. 27-2) to check if the average output current is below the nominal current.
d) The duty cycle must be below 0.75.
e) For altitudes higher than 2000m reduce the pulse loading (15W/1000m) or the ambient temperature (5°C/1000m)

Fig. 27-1 Repetitive pulse loads, definitions Fig. 27-2 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%

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
720W 480W 1s >25s 720W 240W 0.1s >0.16s
720W 0W 1s >1.3s 720W 240W 1s >1.6s
600W 240W 1s > 0,75s 720W 240W 3s >4.9s

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1606- XLS480E-3 24V, 20A; Three Phase Input
27.2. 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. 27-3 Peak load 40A for 50ms, typ. Fig. 27-4 Peak load 80A for 5ms, typ.

Output Output
24V Voltage 24V Voltage

18V 16.5V
40A 80A

Output Output
0A Current 0A Current
20ms/DIV 2ms/DIV

Peak load 40A (resistive) for 50ms Peak load 80A (resistive) for 5ms
Output voltage dips from 24V to 18V. Output voltage dips from 24V to 16.5V.
Please note: The DC-OK relay triggers when the voltage dips more than 10% for longer than 1ms.

27.3. 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 34Vdc. The absorbing energy can be calculated according to the built-in large
sized output capacitor which is specified in chapter Error! Reference source not found..

27.4. CHARGING OF 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 the battery) 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 25A 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. 16mA at 25Vdc when the power supply is switched off (except in case a
blocking diode is utilized).

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1606- XLS480E-3 24V, 20A; Three Phase Input
27.5. 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. 27-5 Branch protectors, test circuit 1

Circuit Parameters:
Power Breaker Input voltage:3x 400Vac, 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 25A
B- Characteristic: equal or smaller 16A
DC - -
C- Characteristic: equal or smaller 10A

Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 27-6 Branch protectors, test circuit 2 Parameters:
Input voltage: 3x 400Vac, load current: 0A
Circuit
Tripping time shorter than 5s.
Power Breaker
Supply I The following circuit breaker tripped during the test:
R
AC + + A- or Z- Characteristic:: ≤ 16A and R< 82mOhm
B- Characteristic: ≤ 6A and R< 180mOhm
S1 Load
C- Characteristic: ≤ 8A and R<= 150mOhm
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
82mOhm 2.3m 3.2m 4.6m 6.9m 11.4m 18.3m
150mOhm 4.2m 5.9m 8.4m 12.5m 20.9m 33.4m
180mOhm 5.0m 7.0m 10.0m 15.0m 25.1m 40.1m
Example:
Which wire gauge must be used to trip a B-Characteristic circuit breaker with a rating of 6A? The load wire length is 21m.
Answer: A 6A B-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.

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1606- XLS480E-3 24V, 20A; Three Phase Input

27.6. EXTERNAL INPUT PROTECTION

The unit is tested and approved for branch circuits up to 15A (U.S.A.) and 16A (IEC). 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. 16A (U.S.A.: 15A) 16A (U.S.A.: 15A)
min. 6A 3A

27.7. 2-PHASE OPERATION

The 1606-XLS480E-3 is specified to operate on two phases.

Instructions for 2-ph operation: Fig. 27-7 Wiring diagram 2-phase operation

Reduce output power according to curve. Exceeding the L1

limits results in a thermal shut-down. Fuse
L1
The specification for EMC performance, hold-up time, losses L3
L2
and output ripple will no longer be valid. Check suitability open L3
individually in the application. PE DC

L2

Fig. 27-8 2-phase operation, allowed output current Fig. 27-9 2-phase operation, Hold-up time
Allowed Output Current at 24V Hold-up Time (2-Ph)
30A 50ms
f or t yp. 4s 24V, 10A, t yp.
25 40
24V, 10A, min.
20
cont inuous 30
B A
15
20 24V, 20A, t yp.
10 A... 2x 460 t o 552Vac
B... 2x 340 t o 460Vac 24V, 20A, min.
5 10
Input Voltage Input Voltage
0 0
-25 0 20 40 60 70°C 320 360 400 440 2x480Vac

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1606- XLS480E-3 24V, 20A; Three Phase Input

27.8. PARALLEL USE TO INCREASE OUTPUT POWER

Power supplies can be paralleled to increase the output power.
Fig. 27-10 Schematic for parallel operation Instructions for parallel use:
Unit A
a) Use only power supplies from the same series (XLS).
Fuse *)
AC b) Adjust the output voltages of all power supplies to
+ approximately the same value (±500mV).
- Otherwise, the DC-ok signal might not work properly.
DC
c) A fuse (or diode) on the output is only required if more than
Unit B + three units are connected in parallel.
Fuse *)
AC Load
+ - d) Keep an installation clearance of 15mm (left / right) between
two power supplies and avoid installing the power supplies
- on top of each other.
DC

27.9. PARALLEL USE FOR REDUNDANCY

Power supplies can be paralleled for 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 XLS 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 10A are paralleled to build a 40A redundant system.
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 - virtually nearly impossible - case, the defect 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 redundancy module 1606-XLSRED. (One module per power supply)
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 already included in the units This
feature reports a faulty unit.
c) When possible, connect each power supply to different phases or circuits.
d) It is desirable to set the output voltages of all power supplies to the same value to avoid a false DC-ok signal.

27.10. 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. 27-11 Daisy chaining of outputs Fig. 27-12 Using distribution terminals

max 25A!

+ -
++ -- ++ -- -- -- -
Load ++ ++ +

Power Power Load

Power Power
Supply Supply Supply Supply

Input Input
Distribution
Input Input Terminals

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1606- XLS480E-3 24V, 20A; Three Phase Input
27.11. SERIES OPERATION
The power supply can be put in series to increase the output voltage.
Fig. 27-13 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.
Unit B + d) Earthing of the output is required when the sum of the output
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
(see notes)
Note: Avoid return voltage (e.g. from a decelerating motor or battery)
which is applied to the output terminals.

27.12. INDUCTIVE AND CAPACITIVE LOADS

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

27.13. 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: Typ IP66 Box PK 9519 100, plastic, 180x180x165mm
Load: 24V, 16A; (=80%) load is placed outside the box
Input: 3x 400Vac
Temperature inside enclosure: 55.9°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 24.9°C
Temperature rise: 31°C

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1606- XLS480E-3 24V, 20A; Three Phase Input

27.14. 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. 27-12 Output Current

Mounting OUTPUT
Orientation A 20A A1
Standard Orientation 16
Power 12
Supply
8
4
Ambient Temperature
INPUT 0
10 20 30 40 50 60°C

Fig. 27-13 Output Current

Mounting INPUT
Orientation B 20A
(Upside down) 16 A2
12
Supply
Power A1
8
4
Ambient Temperature
0
OUTPUT

10 20 30 40 50 60°C

Fig. 27-14 Output Current

Mounting
Orientation C 20A
A2
(Table-top mounting) 16
12 A1
8
4
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 27-15 Output Current

Mounting
Orientation D 20A
(Horizontal cw) 16 A2
OUTPUT
Supply
Power
INPUT

12
A1
8
4
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 27-16 Output Current

Mounting
Orientation E 20A
(Horizontal ccw) 16
OUTPUT

A2
Supply
Power

INPUT

12
8 A1
4
Ambient Temperature
0
10 20 30 40 50 60°C

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