Switched Mode Power Supply

Catalog Number 1606-XLS960F

Reference Manual Original Instructions

Switched Mode Power Supply Reference Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.
These labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
The following icon may appear in the text of this document.

Identifies information that is useful and can help to make a process easier to do or easier to understand.

2 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

 Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Input Inrush Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hold-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DC-OK Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control of Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifetime Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mean Time Between Failure (MTBF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Certifications and Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . 17
Approximate Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Repetitive Pulse Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Peak Current Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Back-feeding Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Charging of Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Output Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
External Input Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parallel Use to Increase Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parallel Use for Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Daisy Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Series Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operation on Two Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Use in a Tightly Sealed Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 1

Table of Contents

Notes:

2 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Terminology and
Abbreviations Terms Descriptions
PE The abbreviation for Protective Earth. PE has the same meaning as the symbol.

The symbol for Protective Earth.

Earth, Ground This document uses the term “earth”, which is the same as the U.S. term “ground”.
A value that is displayed with the AC or DC before the value represents a nominal
AC 230V voltage with standard tolerances included. For example, DC 12V describes a 12V
battery, no matter if it is full (13.7V) or flat (10V).
A value with the unit (V AC or V DC) at the end is a momentary value without any
230V AC additional tolerances included.
50 Hz versus 60 Hz Unless otherwise stated, AC 230V parameters are valid at 50 Hz mains frequency.
Nom Indicates a nominal value.
Typ Indicates a typical value.
A dash alone in a table cell indicates that there is no information to be included in that
— cell.

All values in this document are specified under the following conditions unless
otherwise noted:
• 48V, 20 A, 230V AC input voltage
• 25 °C (77 °F) ambient temperature
• After a 5 minutes run-in time

Product Overview
The 1606-XLS960F is a high-efficiency
DIN rail power supply unit, which uses
a synchronous rectification, a
bridgeless PFC circuit, and additional
design details to achieve a compact
size.
Figure 1 - 1606-XLS960F
Large power reserves of 150% and built-
in large sized output capacitors
support the starting of heavy loads,
such as DC motors or capacitive loads.
Therefore, a unit from a lower wattage
class can be used.

The 1606-XLS960F power supply unit

has a high immunity to transients and
power surges, and has low
electromagnetic emissions.

The integrated input fuse, near-zero

input inrush current, and diagnostic
indicators simplify installation and
usage.

The 1606-XLS960F power supply unit

features a large international approval
package for various applications.
Product features include:
• AC 100…240V wide-range input
• Width 125 mm (4.9 in.)
• 95.0% full load and excellent partial load efficiencies
• 50% BonusPower, 1440 W for up to 4 s

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 3

 • 55 A high peak current for 10 ms, for easy fuse tripping
• Safe HiccupPLUS overload mode
• Active PFC (Power Factor Correction)
• Negligible low-input inrush current surge
• Full power -25…+60 °C (-13…+140 °F)
• Current sharing feature for parallel use
• Remote control of output voltage
• DC-OK relay contact
• Shut-down input
• ATEX and IECEx approved

Specifications
Attributes Values Notes
Output voltage DC 48V Nominal
Adjustment range 48…54V DC —
20…17.8 A Continuous
Output current
30…26.7 A Short term (4 s)
960 W Continuous
Output power
1440 W Short term (4 s)
Output ripple <150 mVpp 20 Hz…20 MHz
Input voltage AC 100…240V -15/+10%
Mains frequency 50…60 Hz ±6%
AC input current 8.6/4.5 A At 120/230V AC
Power factor 0.99/0.99 At 120/230V AC
AC inrush current 17/11 A peak At 120/230V AC
Efficiency 93.9/95.0% At 120/230V AC
Losses 62.4/50.5 W At 120/230V AC
Temperature range -25…+70 °C Operational
(-13…+158 °F)
24 W/1 °C
Derating 60…70 °C (140…158 °F)
(24 W/1.8 °F) (1)
Hold-up time 27/27 ms At 120/230V AC
125 x 124 x 127 mm
Dimensions (4.92 x 4.88 x 5 in.) WxHxD
Weight 1900 g (4.2 lb) —
(1) Between 85…90V AC. See Environment on page 15.

Catalog Numbers
Cat. No. Descriptions
Power supply
1606-XLS960F (48…54V standard unit)
1606-XLC Wall mount bracket
1606-XLSBUFFER48 Buffer unit
1606-XLSRED40HF Redundancy module

4 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

AC Input
Attributes Values Notes
Input voltage Nom AC 100…240V Suitable for TN, TT, and IT mains networks
— 90…264V AC Continuous operation
<55 °C (131 °F) ambient temperature
— 85…90V AC continuously allowed
>55 °C (131 °F) ambient temperature short term
Input voltage range or with output derating, see Figure 27 on page 16
— 60…85V AC Full power for up to 200 ms
— 0…85V AC No damage to the unit
— 264…300V AC <500 ms
Allowed voltage L or N to earth Max 300V AC Continuous, IEC 62103
Input frequency Nom 50…60Hz ±6%
Steady-state value, load independent, see
Turn-on voltage Typ 80V AC
Figure 2
Shut-down voltage Typ 74V AC Steady-state value, load independent, see
Figure 2
External input protection — See External Input Protection on page 24.

Values
Attributes Notes
AC 100V AC 120V AC 230V
Input current Typ 10.5 A 8.6 A 4.5 A At 48V, 20 A, see Figure 4
Power factor (1) Typ 0.99 0.99 0.99 At 48V, 20 A, see Figure 5
Crest factor (2) Typ 1.47 1.53 1.56 At 48V, 20 A
Startup delay Typ 800 ms 750 ms 700 ms See Figure 3
Typ 16 ms 16 ms 16 ms At 48V, 20 A, resistive load, 0 mF, see Figure 3
Rise time
Typ 55 ms 55 ms 55 ms At 48V, 20 A, resistive load, 20 mF, see Figure 3
Turn-on overshoot Max 100 mV 100 mV 100 mV See Figure 3
(1) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
(2) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.

Figure 2 - Input Voltage Range Figure 3 - Turn-on Behavior, Definitions

P OUT Rated Input Range Input

Voltage
Shut-down

Turn-on

Output - 5%
Voltage

Overshoot
V IN
Start-up Rise
Delay Time
74 80 85 264V AC

Figure 4 - Input Current Versus Output Load at 48V Figure 5 - Power Factor Versus Output Load at 48V

Input Current, Typ Power Factor, Typ

12 A 1.0 A

10 A: 100 V AC A B
B: 120 V AC 0.95
8 C: 230 V AC B
0.9
6 A: 100V AC
C
0.85 B: 120V AC
4 C: 230V AC
C
2 0.8
Output Current Output Current
0 0.75
2 4 6 8 10 12 14 16 18 20 A 2 4 6 8 10 12 14 16 18 20 A

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 5

Input Inrush Current The power supply unit is equipped with an active inrush current limitation
circuit, which limits the input inrush current after turn-on to a negligible low
value. The input current is smaller than the steady state input current.
Values
Attributes Notes
AC 100V AC 120V AC 230V
Max 25 Apeak 22 Apeak 16 Apeak
Inrush current (1) Over the entire temperature range; mains
Typ 20 Apeak 17 Apeak 11 Apeak interruptions >1 s
Inrush energy Max 5 A2 s 5 A2 s 5 A2 s
(1) The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.

Figure 6 - Typical Turn-on Behavior at Nominal

Load - 25 °C (77 °F) Ambient
Temperature

Input Current 5 A/DIV

Input

230V AC

100 ms/DIV 48V DC

Output

DC Input Do not operate this power supply unit with DC-input voltage. Use the
1606-XLE480FP-D unit instead. It can be necessary to run two
1606-XLE480EP-D units in parallel.

Output
Attributes Values Notes
Output voltage Nom DC 48V —
— 48…54V DC Guaranteed
Adjustment range
Max 56V DC (1) At clockwise end position of potentiometer
Typ 48.0V DC ±0.2%, at full load, cold unit, in Single Use mode
Factory setting Typ 46.0V DC ±0.5%, at full load, cold unit, in Parallel Use mode
Typ 48.0V DC At no load, cold unit, in Parallel Use mode
Line regulation Max 10 mV 85…300V AC
In Single Use mode: static value, 0 A  20 A, see Figure 7 on
Max 50 mV
page 7
Load regulation
In Parallel Use mode: static value, 0 A  20 A, see Figure 8 on
Typ 2000 mV
page 7
Ripple and noise voltage Max 150 mVpp 20 Hz…20 MHz, 50 Ω
Continuously available at 48V, see Figure 7 on page 7 and Figure 8
Nom 20 A on page 7
Continuously available at 54V, see Figure 7 on page 7 and Figure 8
Nom 17.8 A on page 7

Nom 30 A Short-term available BonusPower (2), at 48V for typical 4 s, see

Output current Figure 7 on page 7 and Figure 8 on page 7

Nom 26.7 A Short-term available BonusPower (2), at 54V for typical 4 s, see
Figure 7 on page 7 and Figure 8 on page 7
Up to 10 ms, output voltage stays above 40V, see Figure 10 on
Typ 55 A page 7. This peak current is available once every second. See Peak
Current Capability on page 22.

6 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

 Attributes Values Notes
Nom 960 W Continuously available at 48…54V
Output power
(2)
Nom 1440 W Short-term available BonusPower (2) at 48…54V
BonusPower time Typ 4s Duration until the output voltage dips, see Figure 11 on page 8
Overload free time to reset power manager, see Figure 12 on
BonusPower recovery time Typ 7s
page 8
— Continuous current Output voltage >40V DC, see Figure 7
Overload behavior
— HiccupPLUS mode (3) Output voltage <40V DC, see Figure 7
Min 30 A (4) Load impedance 50 mΩ, see Figure 9
Max 35 A (4) Load impedance 50 mΩ, see Figure 9
Short-circuit current
Max 11.5 A Average (RMS) current, load impedance 50 mΩ, see Figure 9
Typ 62 A Up to 10 ms, load impedance <10 mΩ, see Figure 10
Output capacitance Typ 3700 µF Included in the power supply
(1) Max output voltage that can occur at the clockwise end position of the potentiometer, due to tolerances. It is not a
guaranteed value that can be achieved. The typical value is about 55V.
(2) BonusPower, short-term power capability (up to typ 4 s): The power supply unit 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. This BonusPower is repeatedly available. See Repetitive Pulse Loading on page 20. If the power supply unit is
loaded longer with the BonusPower than shown in Figure 11 on page 8, the maximum output power is automatically reduced
to 960 W. If the power requirement is continuously above 960 W and the voltage falls below approximately 40V (due to the
current regulating mode at overload), the unit shuts off and makes periodical restart attempts. This behavior is called
HiccupPLUS mode, see Figure 9. If the voltage is above 40V, the unit continuously delivers current.
(3) For up to 4 s of overloading, the power supply unit delivers continuous output current. After overloading, the output power
reduces to nearly zero for approximately 17 s before a new start attempt is automatically performed. If the overload is
cleared, the device operates normally. If the overload still exists, the output current is delivered for 2…4 s (depending on the
overload) again followed by a 17 s rest time. This cycle repeats as long as the overload exists. During the off-period, a small
rest voltage and a rest current are present on the output.
(4) Discharge current of output capacitors is not included.

Figure 7 - Output Voltage Versus Output Current in Figure 8 - Output Voltage Versus Output Current in
Single Use Mode, Typ Parallel Use Mode, Typ

Output Voltage Adjustment Range

Output Voltage (Parallel Use, Typ)
56V 56V
A B Adjustment Range
48 54V
A B
40 52V
32 50V Continuously Bonus
A Continuously allowed Power
24 available 48V
Hiccup
16 B Short-term (4 s)
then switching Mode 46V Factory
to curve A setting
8 44V
0 42V
0 5 10 15 20 25 30 35 A 0 5 10 15 20 25 30 A
Output Current Output Current

Figure 9 - Short-circuit on Output, HiccupPLUS Mode, Figure 10 - Dynamic Overcurrent Capability, Typ
Typ
g y
g

Output Voltage (dynamic behavior, < 10 ms)

Output
Current 54V Adjustment
Normal Normal
operation Short -circuit operation Range
48
35 A
40
32
t
0
24
2s 17 s 2s 17 s 2s 17 s
16
8
Output Current
0
0 10 20 30 40 50 60 70 A

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 7

 Figure 11 - Bonus Time Versus Output Power Figure 12 - BonusPower Recovery Time
g

Bonus Time
Limitation by
5s max Power Power Manager
Demand
4 100%

3 min
t

2 Bonus Recovery Time

Time Bonus Power disabled
Output
1 Voltage
Output Power
0 t
100 110 120 130 140 150 160 170%

The BonusPower is available when power comes on and after the end of an
output short circuit or output overload.
Figure 13 - BonusPower After Input Turn-on Figure 14 - BonusPower After Output Short

Input Short of
Voltage Output

Output
Voltage
Output
Voltage
150% Bonus 150% Bonus
Power Output Power
100%
Output Power 100%
Power

Hold-up Time
Values
Attributes Notes
AC 100V AC 120V AC 230V
Typ 54 ms 54 ms 54 ms
At 48V, 10 A, see Figure 15
Min 45 ms 45 ms 45 ms
Hold-up Time
Typ 27 ms 27 ms 27 ms
At 48V, 20 A, see Figure 15
Min 23 ms 23 ms 23 ms

Figure 15 - Hold-up Time Versus Input Voltage Figure 16 - Shutdown Behavior Definitions

Hold-up Time
60 ms Zero Transition
48V, 10 A, typ
Input
50 48V, 10 A, min Voltage
40
30 48V, 20 A, typ

20 - 5%
48V, 20 A, min Output
Voltage
10
Input Voltage Hold-up Time
0
90 120 155 190 230V AC

8 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

DC-OK Relay Contact This feature monitors the output voltage that the power supply unit produces.
It is independent of any back-fed voltage from a unit that is connected in
parallel to the power supply unit output.
Action Notes
Contact closes Once the output voltage reaches 90% of the adjusted output voltage

Contact opens Once the output voltage dips more than 10% below the adjusted output voltage. Short dips are extended
to a signal length of 250 ms. Dips shorter than 1 ms are ignored.
Contact recloses Once the output voltage exceeds 90% of the adjusted voltage
Max 60V DC at 0.3 A, 30V DC at 1 A, 30V AC at 0.5 A Resistive load
Contact ratings
Min 1 mA at 5V DC Min permissible load
Isolation voltage See Dielectric Strength on page 16.

Figure 17 - DC-OK Relay Contact Behavior

g y

V OUT = VADJ

10% 0.9* VADJ

< >
1 ms 1 ms 250 ms

open closed open closed

Shutdown Input This feature allows a switch-off of the output of the power supply unit with a
signal switch or an external voltage. The shutdown occurs immediately, while
the turn-on is delayed up to 350 ms. In a shut-down condition, the output
voltage is <4V and the output power is <0.5 W.

The voltage between different minus pole output terminals must be below 1V
when units are connected in parallel. In a series operation of multiple power
supply units, only wiring option A with individual signal switches is allowed.

IMPORTANT Option C requires a current sink capability of the voltage source. Do not
use a blocking diode.
The shut-down function has no safety feature included.

Figure 18 - Activation of the Shut-down Input

g

Option A: Option B: Option C:

(via open NC 15 Shut- NC 15 Shut-
15 Shut- down (via external down
down collector) 16 Input
I voltage 16 Input
16 Input +

OFF: linked OFF: U < 1V U

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

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 9

Remote Control of Output You can use the shut-down input to adjust the output voltage remotely,
typically between 44…54V DC. All other functions of the shut-down input
Voltage remain the same.

The control voltage is referenced to the main ground (negative output voltage).
.

Figure 19 - Remote Control of the Output Voltage Figure 20 - Applying the Control Voltage
Output Voltage
56V Potentiometer:
54V setting
52 48V setting
48 15 Shut-
44 down
+ 16 Input
40 Control NC
36 Voltage
32 -
28
24
0 5 10V
Control Voltage

To set the shutdown input to adjust the output voltage remotely:

1. Set the unit into Single Use mode.
2. Set the output voltage adjustment (48…54V) to the maximum desired
voltage.
3. Apply a control voltage to reduce the output voltage.

Efficiency and Power

Losses Attributes
Values
Notes
AC 100V AC 120V AC 230V
Efficiency Typ 93.5% 93.9% 95.0% At 48V, 20 A
Average efficiency (1) Typ 92.9% 93.3% 93.9% 25% at 5 A, 25% at 10 A, 25% at 15 A, 25% at 20 A
Typ 3.6 W 3.5 W 3.3 W With activated shut-down
Typ 13.5 W 12.8 W 12.8 W At 48V, 0 A (no load)
Power losses
Typ 35.6 W 34.0 W 30.1 W At 48V, 10 A (half load)
Typ 66.7 W 62.4 W 50.5 W At 48V, 20 A (full load)
(1) An assumption for a typical application where the power supply unit is loaded with 25% of the nominal load for 25% of the
time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of the time, and with
100% of the nominal load for the rest of the time.

Figure 21 - Efficiency Versus Output Current at 48V, Figure 22 - Losses Versus Output Current at 48V, Typ
Typ
y
Efficiency Power Losses
96% 80 W
230V AC 100V AC
95 70
120V AC 120V AC
94 60
100V AC 230V AC
93 50
92 40
91 30
90 20
89 10
Output Current Output Current
88 0
4 6 8 10 12 14 16 18 20 A 0 2 4 6 8 10 12 14 16 16 20 A

10 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

 Figure 23 - Efficiency Versus Input Voltage at 48V, Figure 24 - Losses Versus Input Voltage at 48V, 20 A,
20 A, Typ Typ

Efficiency Power Losses

95% 80 W
94 70
93 60
92 50
91 40
90 30
Input Voltage Input Voltage
89 20
85 120 155 190 225 260V AC 85 120 155 190 225 260V AC

Functional Diagram Figure 25 - Functional Diagram

Single /
Output Parallel
Voltage
Regulator V OUT
L
Input Fuse Bridgeless +
N Input Filter PFC
Power Output +
Inrush Limiter Converter Filter
Converter
-
-
Overload
LED
DC-ok
LED
Temperature Output Output Output
Shutdown Power Overvoltage Voltage
Manager Protection Monitor 13
DC-OK DC-OK
Relay Contact
14

Event Datalogger 15 Shut-down

Shutdown Input and
Remote
16 Control

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 11

Front Side and User
Elements
Figure 26 - Front Side User Elements
Input terminals (screw terminals)
A N, L Line input
…PE (protective earth) input
Output terminals (screw terminals, two pins per pole)
B + Positive output
- Negative (return) output
Parallel Use/Single Use selector
Set the jumper to Parallel Use when the power supply units are
D connected in parallel to increase the output power. To achieve a
sharing of the load current between the individual units, the Parallel
C 48- C
Parallel Use
54V
Use regulates the output voltage in such a manner that the voltage at
Single Use
E DC ok no load is approximately 4% higher than at nominal load. See Parallel
F OVL Use to Increase Output Power on page 24. A missing jumper is equal to
Allen-Bradley
a Single Use mode.
QUALITY

Output voltage potentiometer

D Multi-turn potentiometer; open the flap to set the output voltage.
1606-XLS Factory setting is 48V at full output current, Single Use mode.
DC-OK status indicator (green)
POWER SUPPLY
1606-XLS960F

13
E Shows on when the voltage on the output terminals is >90% of the
18WM
IND.CONT.EQ.
DC ok
14
G adjusted output voltage.
Shut- 15 Overload status indicator (red)
Down H
16
• Shows on when the voltage on the output terminals is <90% of the
adjusted output voltage, or if there is a short circuit in the output.
F
Input DC 48V / 20A • Flashes when the shutdown is activated or the unit is switched off
AC 200-240V
+ + due to over-temperature.
N L B • Input voltage is required.
A
DC-OK relay contact
G The DC-OK relay contact is synchronized with the DC-OK status
indicator. See DC-OK Relay Contact on page 9.
Shutdown and Remote Control input
Allows the power supply unit to be shut down; can be activated with a
H switch contact or an external voltage. The remote control input allows
for adjustment of the output voltage between 44…54V. See Shutdown
Input on page 9 and Remote Control of Output Voltage on page 10.

Indicators (LEDs) Overload LED DC-OK LED DC-OK Contact

Normal mode OFF ON Closed
During BonusPower OFF ON Closed
Overload (Hiccup mode) Flashing OFF Open
Output short circuit Flashing OFF Open
Temperature shut-down Flashing OFF Open
Active shut-down input Flashing OFF Open
No input power OFF OFF Open

12 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field and
factory wiring.
Values
Attributes
Input Output DC-OK, Shutdown
Type Screw termination Screw termination Spring clamp termination
2 2
Solid wire 0.5…6 mm 0.5…16 mm 0.15…1.5 mm2
Stranded wire 0.5…4 mm2 0.5…10 mm2 0.15…1.5 mm2
American Wire Gauge 20…10 AWG 22…8 AWG 26…14 AWG
Max wire diameter 2.8 mm (0.11 in.) (1) 5.2 mm (0.2 in.) (1) 1.5 mm (0.06 in.) (1)
Wire stripping length 7 mm (0.28 in.) 12 mm (0.5 in.) 7 mm (0.28 in.)
3.5 mm (0.138 in.) or 5 mm
Screwdriver 3.5 mm (0.138 in.), slotted (0.2 in.), slotted or 3 mm (0.12 in.), to open
or cross-head, No 2 the spring
cross-head, No 2
Recommended torque 1 N•m (9 lb•in) 2.3 N•m (20.5 lb•in) —
(1) Includes ferrules.

Wiring instructions:
• Use the appropriate copper cables that are designed for the minimum
operating temperatures:
- 60 °C (140 °F) for an ambient temperature up to 45 °C (113 °F).
- 75 °C (167 °F) for an ambient temperature up to 60 °C (140 °F).
- 90 °C (194 °F) for an ambient temperature up to 70 °C (158 °F).
• Follow national installation codes and installation regulations.
• Confirm that all strands of a stranded wire enter the terminal
connection.
• Do not use the unit without PE connection.
• Unused terminal compartments must be securely tightened.
• Ferrules are allowed.

Lifetime Expectancy
Values
Attribute Notes
AC 100V AC 120V AC 230V
299,000 hr (1) 305,000 hr (1) 327,000 hr (1) At 48V, 10 A and 25 °C (77 °F)
106,000 hr 108,000 hr 116,000 hr At 48V, 10 A and 40 °C (104 °F)
Calculated lifetime expectancy (1)
180,000 hr (1) 193,000 hr (1) 253,000 hr (1) At 48V, 20 A and 25 °C (77 °F)
64,000 hr 68,000 hr 90,000 hr At 48V, 20 A and 40 °C (104 °F)
(1) The minimum operating hours (service life). The lifetime expectancy of the built-in electrolytic capacitors determines the
service life. Lifetime expectancy is specified in operational hours and is calculated according to the manufacturer
specification of the capacitor. The manufacturer of the electrolytic capacitors lists a maximum life of up to 15 years (131,400
hr). Any number that exceeds this value is a calculated theoretical lifetime, which can be used to compare devices.

Mean Time Between Failure MTBF is calculated according to statistical device failures, and indicates the
reliability of a device. It is the statistical representation of the likelihood of a
(MTBF) unit to fail; it does not necessarily represent the life of a product. An MTBF
value of, for example, 1,000,000 hr means that statistically one unit fails every
100 hours if 10,000 units are installed in the field. However, the running time
of individual failed units cannot be determined.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 13

 Values
Attribute Notes
AC 100V AC 120V AC 230V
491,000 hr 481,000 hr 537,000 hr At 48V, 20 A and 25 °C (77 °F)
MTBF SN 29500, IEC 61709
274,000 hr 269,000 hr 300,000 hr At 48V, 20 A and 40 °C (104 °F)
At 48V, 20 A and 25 °C (77 °F);
170,000 hr 171,000 hr 183,000 hr Ground Benign GB25
MTBF MIL HDBK 217F
Ground Benign At 48V, 20 A and 40 °C (104 °F);
126,000 hr 127,000 hr 137,000 hr
Ground Benign GB40

36,000 hr 36,000 hr 39,000 hr At 48V, 20 A and 25 °C (77 °F);

MTBF MIL HDBK 217F Ground Fixed GF25
Ground Fixed At 48V, 20 A and 40 °C (104 °F);
27,000 hr 27,000 hr 30,000 hr Ground Fixed GF40

Electromagnetic The power supply unit is suitable for applications in an industrial environment
and in a residential, commercial, and light industry environment without any
Compatibility restrictions.
EMC Immunity According to Generic Standards EN 61000-6-1 and EN 61000-6-2
Attributes Standards Values Criteria (1)
Contact discharge 8 kV Criterion A
Electrostatic discharge EN 61000-4-2
Air discharge 15 kV Criterion A
Electromagnetic RF field EN 61000-4-3 80 MHz…2.7 GHz 20V/m Criterion A
Input lines 4 kV Criterion A
Fast transients (burst) EN 61000-4-4 Output lines 2 kV Criterion A
Signal lines (coupling clamp) 2 kV Criterion A
LN 2 kV Criterion A
Surge voltage on input EN 61000-4-5
L  PE, N  PE 4 kV Criterion A
+- 1 kV Criterion A
Surge voltage on output EN 61000-4-5
+ / -  PE 1 kV Criterion A
DC-OK signal  PE 1 kV Criterion A
Surge voltage on signal lines EN 61000-4-5
Shut-down input  PE Not relevant due to wire length (2)
Conducted disturbance EN 61000-4-6 0.15…80 MHz 20V Criterion A
0% of 100V AC 0V AC, 20 ms Criterion A
40% of 100V AC 40V AC, 200 ms Criterion C
70% of 100V AC 70V AC, 500 ms Criterion A
Mains voltage dips EN 61000-4-11
0% of 200V AC 0V AC, 20 ms Criterion A
40% of 200V AC 80V AC, 200 ms Criterion A
70% of 200V AC 140V AC, 500 ms Criterion A
Voltage interruptions EN 61000-4-11 0% of 200V AC (=0V) 5000 ms Criterion C
Dips on the input voltage according to SEMI F47 standard
80% of 120V AC (96V AC) 1000 ms Criterion A
Voltage sags SEMI F47
70% of 120V AC (84V AC) 500 ms Criterion A
50% of 120V AC (60V AC) 200 ms Criterion A
Powerful transients VDE 0160 Over entire load range 750V, 1.3 ms Criterion B (3)
(1) Criterion A: Power supply shows normal operation behavior within the defined limits.
Criterion B: Output voltage dips between 48…42V for 5 ms.
Criterion C: Temporary loss of function is possible. The power supply unit can automatically shut down and restart
without damage or hazards to itself.
(2) Do not use longer wires than 30 m (98.42 ft) for the shutdown input or use an additional protection.
(3) Criterion A is fulfilled for output current up to 15 A.

14 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

 EMC Emission According to Generic Standards EN 61000-6-3 and EN 61000-6-4
Attributes Standards Notes

Conducted emission input lines EN 55011, EN 55032, FCC Part 15, Class B
CISPR 11, CISPR 32
10 dB higher than average limits for DC power port
Conducted emission output lines IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
according to EN 61000-6-3 (1)
Radiated emission EN 55011, EN 55032 Class B
Harmonic input current EN 61000-3-2 Fulfilled for class A equipment
Voltage fluctuations, flicker EN 61000-3-3 Fulfilled (2)
This device complies with FCC Part 15 rules.
Operation is subjected to following conditions:
• This device must not cause harmful interference.
• This device must accept any interference received, including interference that can cause undesired operation.
(1) Restrictions apply for applications in residential, commercial, and light-industrial environments where local DC power
networks, according to EN 61000-6-3, are involved. No restrictions for all kinds of industrial applications.
(2) Tested with constant current loads, non-pulsing.

The power supply unit has four converters with four different switching
frequencies, which are included. One frequency is nearly constant; others are
input voltage and load dependent.
Switching Frequency
Switching Frequency Values Notes
1 105 kHz Resonant converter, nearly constant
2 1...150 kHz Boost converter, input voltage, and load dependent
3 1...100 kHz PFC converter, input voltage, and load dependent
4 25...45 kHz Auxiliary converter, input voltage, and load dependent

Environment
Attributes Values Notes
Operational temperature (1) -25…+70 °C (-13…+158 °F) Reduce output power according to Figure 27 on page 16
Storage temperature -40…+85 °C (-40…+185 °F) For storage and transportation
Output derating 24 W/1 °C (24 W/1.8 °F) Between 60…70 °C (140…158 °F)
(2) 5…95% r.H. IEC 60068-2-30
Humidity
2…17.8 Hz: ±1.6 mm (0.063 in.) (3)
Vibration sinusoidal 17.8…500 Hz: 1 g (0.04 oz) IEC 60068-2-6
2 hours/axis
15 g (0.53 oz) 6 ms,
Shock 10 g (0.35 oz) 11 ms (3) IEC 60068-2-27
3 bumps/direction,
18 bumps in total
0…2000 m (0…6560 ft) Without any restrictions
Altitude Reduce output power or ambient temperature, see Figure 28
2000…6000 m (6560…20,000 ft) on page 16
IEC 62103, EN 50178, overvoltage category II
60 W/1000 m (7.5 W/3280 ft), or
Altitude derating >2000 m (6500 ft), see Figure 28 on page 16
5 °C/1000 m (9 °F/3280 ft)
III IEC 62103, EN 50178, altitudes up to 2000 m (6500 ft)
Overvoltage category
II Altitudes from 2000…6000 m (6500…20,000 ft)
Degree of pollution 2 IEC 62103, EN 50178, not conductive
(1) The same as the ambient temperature and is defined as the air temperature 20 mm (0.79 in.) below the unit.
(2) Do not energize while condensation is present.
(3) Higher levels are allowed when using the 1606-XLC wall mounting bracket.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 15

 Figure 27 - Output Current Versus Ambient
Figure 28 - Output Current Versus Altitude
Temperature

Allowed Output Current at 48V Allowed Output Current at 48V

30 A 30 A
short-term (4 s) short-term (4 s)
25 25
A
20 20 C
continuous B continuous B
A
15 A: 90…264V AC
15
B: 85…90V AC
10 10
A: Tamb <60 °C
5 5 B: Tamb <50 °C
C: Tamb <40 °C Altitude
Ambient Temperature
0 0
-25 0 20 40 60 70 °C 0 2000 4000 6000 m

Protection Features
Attributes Values Notes
Output protection Electronically protected against overload, no-load, and short-circuits (1)
58.8V DC typ If there is an internal power supply anomaly, a redundant circuit limits
Output overvoltage protection the maximum output voltage. The output shuts down and automatically
60V DC max attempts to restart.
Degree of protection IP 20 EN/IEC 60529 (2)
Penetration protection >5 mm (0.2 in.) For example, screws and small parts
Over-temperature protection Yes Output shutdown with automatic restart
Input transient protection MOV Metal Oxide Varistor
Internal input fuse Included Not user-replaceable
(1) An audible noise occurs if there is a protection event.
(2) For use in a controlled environment according to CSA 22.2 No 107.1-01.

Safety Features
Attributes Values Notes
SELV IEC/EN 60950-1
Input/output separation (1)
PELV IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
Class of protection I PE connection not required.
Isolation resistance >100 MΩ Input to output, 500V DC
PE resistance <0.1 Ω —
Typ 0.39 mA/1.0 mA 100V AC, 50 Hz, TN-, TT-mains/IT-mains
Typ 0.56 mA/1.43 mA 120V AC, 60 Hz, TN-, TT-mains/IT-mains
Touch current Typ 0.90 mA/2.25 mA 230V AC, 50 Hz, TN-, TT-mains/IT-mains
(leakage current) Max 0.50 mA/1.21 mA 110V AC, 50 Hz, TN-, TT-mains/IT-mains
Max 0.71 mA/1.73 mA 132V AC, 60 Hz, TN-, TT-mains/IT-mains
Max 1.18 mA/2.28 mA 264V AC, 50 Hz, TN-, TT-mains/IT-mains
(1) Double or reinforced insulation.

Dielectric Strength The output voltage is floating and has no ohmic connection to the ground. The
manufacturer conducts type and factory tests. Field tests can be conducted
with the appropriate test equipment, which applies the voltage with a slow
ramp (2 s up and 2 s down). Connect all input terminals together and connect
all output poles before conducting the test. When testing, set the cutoff
current settings to the values in the following table.

16 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

 Figure 29 - Dielectric Strength Test or Setting Time A B C D
Type test 60 s 2500V AC 3000V AC 500V AC 500V AC
Factory test 5s 2500V AC 2500V AC 500V AC 500V AC
Input DC-OK Field test 5s 2000V AC 2000V AC 500V AC 500V AC
L B (a) 13
Cutoff current setting — >20 mA >20 mA >40 mA >1 mA
N 14

B
A To fulfill the PELV requirements according to
Output EN60204-1 § 6.4.1, we recommend that you connect
Earth, PE
C
+/- the protective earth system to the + pole, the – pole,
Shut-down or any other part of the output circuit. This
15/16
connection helps to avoid situations in which a load
starts unexpectedly or cannot be switched off when
unnoticed earth faults occur.
(a) When input to DC-OK is tested, confirm that the max voltage between DC-OK
and the output is not exceeded (column D). We recommend connecting DC-OK
pins and the output pins together when performing the test.

Certifications and
Standards Compliance
Names Symbols Notes (1)

UL Certificate
Listed equipment for category NMTR - Industrial Control
UL 508 Equipment
IND. CONT. EQ. Applicable for US and Canada

UL Certificate
UL 60950-1 Recognized component for category QQGQ - Information
Technology Equipment
Applicable for US and Canada

Agency Certificate (Bureau Veritas) (1)

EN 60079-0 Explosive atmospheres - General requirements
ATEX EN 60079-7, EN 60079-15 Equipment protection by type of
protection "e" and "n"
Temperature Code: T3
Type of Protection: nA nC
IECEx Certificate (1)
IEC 60079-0 Explosive atmospheres - General requirements
IECEx IEC 60079-7, IEC 60079-15 Equipment protection by type of
protection "e" and "n"
Temperature Code: T3
Type of Protection: nA nC
CSA Certificate
Power Supplies for Hazardous Location
Applicable for Canada and US
Class I Div 2 CSA Class: 5318-01 (Canada), 5318-81 (US)
Temperature Code: T3
Groups: A, B, C, and D
DNV-GL Certificate
DNV-GL Type approved product
Temperature: Class D
Marine (DNV GL) Humidity: Class B
Vibration: Class C
EMC: Class A
Enclosure: Class A

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 17

 Names Symbols Notes (1)

The CE marking indicates conformance with the following:

EC Declaration of Conformity – EMC Directive
– Low Voltage Directive (LVD)
– RoHS directive

Manufacturer's Statement
REACH Directive EU-Directive regarding the Registration, Evaluation,
Authorization, and Restriction of Chemicals

EAC TR Registration Registration for the Eurasian Customs Union market (Russia,
Kazakhstan, Belarus)

(1) Product certification information (including Certificates and Declarations of Conformity) can be found at rok.auto/certifications.

Approximate Dimensions
and Weight Attributes Values and Descriptions
Width 125 mm (4.92 in.)
Height 124 mm (4.88 in.)
Depth 127 mm (0.5 in.) (1)
Weight 1900 g (4.2 lb)
Use 35 mm (1.38 in.) DIN rails according to EN 60715 or EN 50022 with a height of
DIN rail 7.5 mm (0.30 in.) or 15 mm (0.59 in.).
Housing material Aluminum body, steel cover
Top: 40 mm (1.57 in.)
Installation clearances Bottom: 20 mm (0.79 in.)
Left/right: 5 mm (0.2 in.) (2)
(1) Add the DIN rail height to the unit depth to calculate the total required installation depth.
(2) Increase the 5 mm (0.2 in.) to 15 mm (0.59 in.) in case the adjacent device is a heat source. When the
device is permanently loaded with less than 50%, the 5 mm (0.2 in.) can be reduced to zero.

Figure 30 - Front View [mm (in.)] Figure 31 - Side View [mm (in.)]
Height 124 (4.88)

40 (1.57) 19.1 (0.75)

Width 127 (5.0)
75.4 (2.97) 40.5 (1.54)
DIN Rail Depth
Width 125 (4.92)

18 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Accessories 1606-XLC Wall Mounting Bracket
This bracket is used to mount specific units onto a flat surface without using a
DIN rail.
Figure 32 - Wall Mounting Bracket Attached
Figure 33 - Wall Mounting Bracket
to Unit

1606-XLSBUFFER48 Buffer Module

This buffer module is a supplementary device for DC 48V power supply units.
The module delivers power to bridge typical mains failures or extends the hold-
up time after turn-off of the AC power. In times when the power supply unit
provides sufficient voltages, the buffer module stores energy in integrated
electrolytic capacitors. If there is a mains voltage fault, this energy is released
again in a regulated process.

The buffer module does not require any control wiring. It can be added in
parallel to the load circuit at any given point. Buffer modules can be added in
parallel to increase the output ampacity or the hold-up time.
Figure 34 - Buffer Module Figure 35 - Buffer Module in Parallel

p pp p

Power Buffer
AC Supply Unit(s)
Load

+
DC
-

1606-XLSRED40HF Redundancy Module

The 1606-XLSRED40HF redundancy module is equipped with two input
channels of 20 A each, which are individually decoupled by using mosfet
technology. The output current is up to 40 A.

Mosfets are used instead of diodes to reduce the heat generation and voltage
drop between input and output.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 19

 The 1606-XLSRED40HF redundancy module does not require an additional
auxiliary voltage and is self-powered, even if there is a short circuit across the
output.
Due to the low-power losses, the module is slender and only requires a
46 mm (1.81 in.) wide DIN rail.
Figure 37 - Typical 1+1 Redundant Configuration for 20 A with a Dual
Figure 36 - Redundancy Module
Redundancy Module

48V Failure
20 A
Load Monitor

1606-XLS960F 1606-XLS960F
48…54V 960 W + - 48…54V 960 W
Power Supply Output Power Supply
DC-
OK
1606-XLSRED40HF DC-
OK
Parallel Use Redundancy Parallel Use
Single Use Module Single Use

Input Input
AC Input 48V, 20A AC Input 48V, 20 A
- - - -
1 2
L N PE + + + - + - L N PE + +

I I

L
N
PE

Repetitive Pulse Loading A load current is not typically constant and varies over time. The power supply
unit is designed to support loads with a higher short-term power requirement
without damage or shutdown, or BonusPower. An output power manager
controls the short-term duration. BonusPower is repeatedly available. If the
BonusPower load lasts longer than the hardware controller allows, the output
voltage will dip and the next BonusPower is available after the BonusPower
recovery time has elapsed (see Output on page 6).

To avoid voltage dips, follow the following rules:

• The power demand of the pulse must be below 150% of the nominal
output power.
• The duration of the pulse power must be shorter than the allowed
BonusPower time (see Output on page 6).
• The average (RMS) output current must be below the specified
continuous output current. If the RMS current is higher, the unit
responds with a thermal shutdown after a time. Use the maximum duty
cycle curve in Figure 39 on page 21 to check if the average output current
is below the nominal current.
• The duty cycle must be below 0.75.

20 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Figure 38 - Repetitive Pulse Loads, Definitions Figure 39 - Maximum Duty Cycle Curve
g
Duty Cycle P 0 = 10%
P 0 = 50%
0.75
PPEAK TPEAK T0 P 0 = 75%
max 0.6
150%
0.4
100%
0.2 P 0 = 100%
P0 P PEAK
0
1 100 110 120 130 140 150%
1

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

Example Repetitive Pulse Calculation

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

Tpeak - (DutyCycle x Tpeak) 1 s - (0.37 x 1 s)

T0 = = = 1.7 s
DutyCycle 0.37

Additional Examples for Pulse Load Compatibility

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

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 21

Peak Current Capability The power supply unit can deliver peak currents (up to several milliseconds)
which are higher than the specified short-term currents.

Peak current capability helps to start current-demanding loads. Solenoids,

contactors, and pneumatic modules often have a steady state coil and a
pick-up coil. The inrush current demand of the pick-up coil is several times
higher than the steady-state current and usually exceeds the nominal output
current (including the BonusPower). The same situation applies when starting
a capacitive load.

The peak current capability also achieves the safe operation of subsequent
circuit breakers of load circuits. The load branches are often individually
protected with circuit breakers or fuses. If there is a short or an overload in one
branch circuit, the fuse or circuit breaker needs a certain amount of
overcurrent to open in a timely manner. This safety avoids voltage loss in
adjacent circuits.

The extra current (peak current) is supplied by the power converter and the
built-in large-sized output capacitors of the power supply unit. The capacitors
get discharged during such an event, which causes a voltage dip on the output.
Figure 40 and Figure 41 show typical voltage dips.
Figure 40 - Peak Loading with 2x the Nominal Figure 41 - Peak Loading with 5x the Nominal
Current for 50 ms, Typ Current for 5 ms, Typ

48V 48V
40 A 37.9V
28.9V
100 A

0A 0A
10 ms/DIV 1 ms/DIV

Peak load 40 A (resistive load) for 50 ms. Peak load 100 A (resistive load) for 5 ms.
Output voltage: 48V dips to 37.9V Output voltage: 48V dips to 28.9V

IMPORTANT The DC-OK relay triggers when the voltage dips more than 10% for
longer than 1 ms.

Peak Current Voltage Dips

Attributes Values Notes
Typ 48…37.9V At 40 A for 50 ms, resistive load
Typ 48…34.9V At 100 A for 2 ms, resistive load
Typ 48…28.9V At 100 A for 5 ms, resistive load

Back-feeding Loads Loads such as decelerating motors and inductors can feed voltage back to the
power supply unit. This feature is also called return voltage immunity, or
resistance against Back Electromagnetic Force (Back EMF).

This power supply unit is resistant and does not show malfunctions when a
load feeds back voltage to the unit, regardless of whether the unit is on or off.

The maximum allowed feed back voltage is 63V DC. The absorbing energy can
be calculated according to the built-in large-sized output capacitor, which is
specified in Output on page 6.

22 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Inductive and Capacitive The unit is designed to supply any kind of loads, including unlimited
capacitive and inductive loads. If extreme large capacitors, such as EDLCs
Loads (electric double layer capacitors or UltraCaps) with a capacitance of >1F are
connected to the output, the unit can charge the capacitor in the HiccupPLUS
mode (see Output on page 6).

Charging of Batteries This power supply unit is not recommended to charge lead-acid or
maintenance free batteries. The recommended end-of-charge voltage of 55V at
20 °C (68 °F) for four 12V VRLA lead-acid batteries in series cannot be supplied
from the 1606-XLS960F power supply unit.

Output Circuit Breakers Standard miniature circuit breakers, such as MCB or UL1077, are commonly
used for AC-supply systems and can be used on DC branches.

MCB circuit breakers are designed to protect wires and circuits. If the ampere
value and the characteristics of the MCB circuit breaker are adapted to the wire
size that is used, the wiring is considered thermally safe, regardless of whether
the MCB opens.

To avoid voltage dips and undervoltage situations in adjacent 48V branches

that are supplied by the same source, a fast magnetic tripping of the MCB
circuit breaker is desired. A shutdown within 10 ms is necessary, which
corresponds roughly to the ride-through time of the PLC. A quick shutdown
requires power supply units with high current reserves and large output
capacitors. Furthermore, the impedance of the faulty branch must be
sufficiently small for the current to flow. The following table contains typical
test results that show which B- and C-characteristic MCB circuit breakers
magnetically trip, depending on the wire cross section and wire length.
Figure 42 - Test Circuit
Power Supply MCB Load

AC + +

Wire length
S1

DC - -
S1 Fault simulation switch

Maximal Wire Length for a Fast Magnetic Tripping [m (ft)] (1)

Wire Length by Gauge
MCB
0.75 mm² (18 AWG) 1.0 mm² (17 AWG) 1.5 mm² (16 AWG) 2.5 mm² (14 AWG)
C-2A 68 (223.1) 89 (292) >100 (328.1) >100 (328.1)
C-3A 53 (173.9) 75 (246.1) >100 (328.1) >100 (328.1)
C-4A 44 (144.4) 57 (187) 88 (288.7) >100 (328.1)
C-6A 18 (5901) 25 (82) 38 (124.7) 58 (190.3)
C-8A 9 (29.5) 12 (39.4) 18 (59.1) 24 (78.7)
C-10A 8 (26.2) 11 (36.1) 16 (52.5) 23 (75.5)
C-13A 4 (13.1) 5 (16.4) 8 (26.2) 12 (39.4)
B-6A 39 (128) 50 (164.0) 74 (242.8) >100 (328.1)
B-10A 21 (68.9) 29 (95.1) 44 (144.4) 68 (223.1)
B-13A 13 (42.7) 21 (68.9) 34 (111.5) 52 (170.6)
B-16A 7 (23) 9 (29.5) 13 (42.7) 17 (55.8)
B-20A 2 (6.6) 3 (9.8) 4 (13.1) 5 (16.4)
(1) Consider twice the distance to the load or cable length when calculating the total wire length
(+ and – wire).

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 23

External Input Protection The unit is tested and approved for branch circuits up to 30 A (US) and 32 A
(IEC). An external protection is required only if the supplying branch has an
ampacity greater than the approved circuit amperage. Check local codes and
local requirements. In some countries, local regulations might apply.
If an external fuse is used, minimum requirements must be considered to
avoid nuisance tripping of the circuit breaker. A minimum value of 16 A B- or
C-characteristic breaker must be used, when the unit is used at AC 100V and
AC 120V mains voltages (including AC 230V). If the unit is used only at AC 230V
mains, a 10 A B- or C-characteristic breaker is sufficient.

Parallel Use to Increase Power supply units from the same series can be paralleled to increase the
output power. The output voltage must be adjusted to the same value
Output Power (±100 mV) in Single Use mode with the same load conditions on all units, or
the units can be left with the factory settings. After the adjustments, move the
jumper on the front of the unit from Single Use to Parallel Use to achieve load
sharing. The Parallel Use mode regulates the output voltage so that the voltage
at no load is approximately 4% higher than at nominal load. See Output on
page 6. If no jumper is plugged in, the unit is in Single Use mode. The factory
setting is also Single Use mode.
Figure 43 - Parallel Use to Increase Output Power
Unit A
AC
+
-
DC
+
Unit B
Load
AC
+ -
-
DC

If more than three units are connected in parallel, a fuse or circuit breaker with
a rating of 30 A or 32 A is required on each output. Alternatively, use a diode or
redundancy module.

Energize all units simultaneously to avoid the overload HiccupPLUS mode. If

the output was in HiccupPLUS mode due to overload or short circuits and the
required output current is higher than the current of one unit, turn off the
power for at least 5 seconds.

Keep a left and right installation clearance of 15 mm (0.59 in.) between the two
power supply units and avoid installing the units on top of each other. Do not
use power supply units in parallel in mounting orientations other than in the
standard mounting orientation (terminals on the bottom of the unit). Do not
use the power supply units in parallel in any other condition where a derating
of the output current is required, such as in altitudes above 60 °C (140 °F).
Understand that leakage current, EMI, inrush current, and harmonics
increase when using multiple power supply units.

24 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Parallel Use for Redundancy Power supplies can be paralleled for redundancy to gain higher system
availability. Redundant systems require a certain amount of extra power to
support the load in case one power supply unit fails. The simplest way is to put
two power supply units in parallel. This type of redundancy is called a 1+1
redundancy. In case one power supply unit fails, the other unit automatically
supports the load current without any interruption. Redundant systems for a
higher power demand are built in an N+1 method. For example, five power
supply units, each rated for 20 A, are paralleled to build an 80 A redundant
system. For N+1 redundancy, the same restrictions apply as for increasing the
output power, see Parallel Use to Increase Output Power on page 24.

IMPORTANT This redundant system does not cover failures such as an internal short
circuit in the secondary side of the power supply unit. In such a case,
the defective unit becomes a load for the other power supply units and
the output voltage cannot be maintained. This defective unit load can
only be avoided by using redundancy modules that include decoupling
devices, such as diodes or mosfets. See 1606-XLSRED40HF Redundancy
Module on page 19.

Recommendations for building redundant power systems:

• Use separate input fuses for each power supply unit to increase the
reliability of the redundant system.
• Set the unit into Parallel Use mode.
• Monitor the individual units. Use the DC-OK relay contact of the
1606-XLS960F power supply unit.
• Set the output voltages of all units to the same value (±100 mV) or leave
output voltages at the factory setting.

Daisy Chain A daisy chain (a jump from one power supply unit output to the next) is
allowed as long as the average output current through one terminal pin does
not exceed 54 A. If the current is higher, use a separate distribution terminal
block as shown in Figure 45.
Figure 44 - Daisy Chain of Outputs Figure 45 - Using Distribution Terminals

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

Max 25 A
Continuous

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 25

Series Operation
Figure 46 - Series Operation
Power supplies of the same type can
Unit A be connected in series for higher
AC output voltages. Connect as many
+
units in series as needed, providing
- the sum of the output voltage does
DC
+ not exceed 150V DC. Voltages with
Unit B
Load a potential above 60V DC can be
AC dangerous and are no longer SELV.
+ - Such voltages must be installed
- with a protection against being
DC Earth touched.

Earthing of the output is required when the sum of the output voltage is above
60V DC.

Avoid return voltage (for example, from a decelerating motor or battery) which
is applied to the output terminals.
Keep a left and right installation clearance of 15 mm (0.59 in.) between two
power supply units and avoid installing the units on top of each other. Do not
use power supply units in series in mounting orientations other than the
standard mounting orientation (terminals on the bottom of the unit).

Understand that leakage current, EMI, inrush current, and harmonics

increase when using multiple power supply units.

Operation on Two Phases

Figure 47 - Operation on Two Phases

Power Supply
L1 AC
internal
The power supply unit can be used
on two phases of a three-phase
max

fuse
L
system, as long as the supplying
L3
+10%

N
voltage is below 240V+10%.
PE
240V

L2 DC

26 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

Use in a Tightly Sealed When the power supply unit is installed in a tightly sealed enclosure, the
temperature inside the enclosure is higher than outside of the enclosure. In
Enclosure such situations, the inside temperature defines the ambient temperature for
the power supply unit.
The following measurement results can be used as a reference to estimate the
temperature rise inside the enclosure. These measurements are taken with the
power supply unit in the middle of the enclosure, with no other heat-
producing items inside the enclosure.
Attributes Values
254 x 180 x 165 mm
(4.88 x 7.09 x 6.50 in.)
Enclosure size Rittal Typ IP66 Box
PK 9522 100, plastic
Input voltage 230V AC
Load 48V, 16 A; (=80%) (1)
Temperature inside enclosure 65.6 °C (150.08 °F) (2)
Temperature outside enclosure 24.1 °C (75.38 °F)
Temperature rise 41.5K
(1) The load is placed outside the box.
(2) Temperature in the middle of the right side of the
power supply unit with a distance of 20 mm (0.79 in.).

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 27

Mounting Orientations Mounting orientations, other than all terminals on the bottom, require a
reduction in continuous output power or a limitation in the maximum allowed
ambient temperature. The amount of reduction influences the lifetime
expectancy of the power supply unit.
Figure 48…Figure 52 on page 28 show two derating curves for continuous
operation.
• Curve A1: Recommended output current.
• Curve A2: Max allowed output current (results in approximately half the
lifetime expectancy of A1).

Output Current
20 A A1

15
Figure 48 - Mounting Orientation A: Power
Standard Orientation Supply 10
5
Ambient Temperature
INPUT OUTPUT 0
10 20 30 40 50 60 °C

Output Current
20 A
OUTPUT INPUT

15 A2
Figure 49 - Mounting Orientation B: Supply
Upside Down Power 10 A1

5
Ambient Temperature
0
10 20 30 40 50 60 °C

Output Current
20 A
15
Figure 50 - Mounting Orientation C: A2
A1
Table-top Mounting 10
5
Ambient Temperature
0
10 20 30 40 50 60 °C

Output Current
20 A
INPUT

15
Figure 51 - Mounting Orientation D:
Supply
Power

A2
Horizontal CW 10
A1
OUTPUT

5
Ambient Temperature
0
10 20 30 40 50 60 °C

Output Current
20 A
OUTPUT

15
Figure 52 - Mounting Orientation E: A2
Supply

Horizontal CCW
Power

10
A1
INPUT

5
Ambient Temperature
0
10 20 30 40 50 60 °C

28 Rockwell Automation Publication 1606-RM028A-EN-P - September 2021

 Switched Mode Power Supply Reference Manual

Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.

Resource Description
Switched Mode Power Supply Specifications Technical Data, publication Provides specifications for Bulletin 1606 products and applications.
1606-TD002
1606-XLS960F Installation Instructions, publication 1606-IN029 Provides basic specifications and installation instructions.
Provides guidance on how to conduct security assessments, implement Rockwell
System Security Design Guidelines Reference Manual, SECURE-RM001 Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Industrial Components Preventive Maintenance, Enclosures, and Contact Provides a quick reference tool for Allen-Bradley® industrial automation controls and
Ratings Specifications, publication IC-TD002 assemblies.
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
Safety Guidelines for the Application, Installation, and Maintenance of general guidelines for the application, installation, and maintenance of solid-state control in
Solid-State Control, publication SGI-1.1 the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at rok.auto/literature.

Rockwell Automation Publication 1606-RM028A-EN-P - September 2021 29

Rockwell Automation Support
Use these resources to access support information.
Technical Support Center Find help with how-to videos, FAQs, chat, user forums, and product notification updates. rok.auto/support
Knowledgebase Access Knowledgebase articles. rok.auto/knowledgebase
Local Technical Support Phone Numbers Locate the telephone number for your country. rok.auto/phonesupport
Literature Library Find installation instructions, manuals, brochures, and technical data publications. rok.auto/literature
Product Compatibility and Download Center Download firmware, associated files (such as AOP, EDS, and DTM), and access product rok.auto/pcdc
(PCDC) release notes.

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Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our
content, complete the form at rok.auto/docfeedback.

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At the end of life, this equipment should be collected separately from any unsorted municipal waste.

Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.

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