Rockwell Automation

1606-XLS480G 36V, 13A Single Phase Input

1606-XLS480G
36V,13A Single Phase Input
POWER SUPPLY
¾ Ultra-small size
¾ Extra-low inrush current
¾ Active power factor correction
¾ Wide range AC/DC input
¾ Superior reserve power (can support 150% rated power for five
seconds)
¾ Superior efficiency and temperature rating
¾ DC-OK and overload LED

1. GENERAL DESCRIPTION
The most outstanding features of this 1606-XLS Din-rail power supply are the high efficiency and the small size, which are
achieved by a synchronous rectification and further novel design details.
With short-term power capability of 150% and built-in large sized output capacitors, these features help start motors, charge
capacitors and absorb reverse energy. A wide range input voltage design and a negligible low input inrush current make
installation and usage simple. Diagnostics are easy due to the DC-ok relay, a green DC-ok and a red overload LED.
Unique quick-connect spring-clamp terminals allow a safe and fast installation. Many global approvals make this unit suitable
for nearly every situation.

2. SPECIFICATION QUICK 3. AGENCY APPROVALS

18WM
REFERENCE LISTED
IND. CONT. EQ.
Output voltage DC 36V UL 60950-1
UL 508
Adjustment range 36-42V
Output current 13.3A continuous, 36V R

20.0A for typ. 4s, 36V Class I Div 2 C US

182790
Output power 480W continuous, 36V
720W for typ. 4s, 36V
Output ripple < 100mVpp 20Hz to 20MHz
Input voltage AC 100-240V ±15% EMC, LVD
Line frequency 50-60Hz ±6%
AC Input current 4.56 / 2.48A at 120 / 230Vac
Power factor 0.95 / 0.90 at 120 / 230Vac
AC Inrush current typ. 9 / 7A peak at 120 / 230Vac 4. RELATED PRODUCTS
DC Input voltage DC 110-300V - -20%/+25% 1606-XLB Wall mount bracket
DC Input current 4.7 / 1.7A at 110 / 300Vdc 1606-XLSRED Redundancy Module
1606-XLBUFFER Buffer unit
Efficiency 92.5 / 94.0% at 120 / 230Vac
Losses 38.9 / 30.6W at 120 / 230Vac
Temperature range -25°C to +70°C operational
Derating 12W/°C +60 to +70°C
Hold-up time typ. 32 / 51ms at 120 / 230Vac
Dimensions 82x124x127mm WxHxD

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1606-XLS480G 36V, 13A Single Phase Input

INDEX PAGE INDEX PAGE

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

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

TERMINOLOGY AND ABBREVIATIONS

PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol .
Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”.
T.b.d. To be defined, value or description will follow later.
AC 230V A figure displayed with the AC or DC before the value represents a nominal voltage with standard
tolerances (usually ±20%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
As long as not otherwise stated, AC 100V and AC 230V parameters are valid at 50Hz and AC
120V parameters are valid at 60Hz mains frequency.
230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances
included.
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage

DISCLAIMER

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1606- XLS480G 36V, 13A Single Phase Input
The information presented in this document is believed to be accurate and reliable and may change without notice.

5. AC-INPUT
AC input nom. AC 100-240V wide-range input, see Fig. 5-1
AC input range min. 85-276Vac continuous operation
min. 60-85Vac full power for 200ms, no damage between 0 and 85Vac
min. 276-300Vac < 500ms
Input frequency nom. 50 – 60Hz ±6%
Turn-on voltage typ. 77Vac steady-state value, see Fig. 5-1
Shut-down voltage typ. 73Vac steady-state value, see Fig. 5-1
typ. 53Vac dynamical value

AC 100V AC 120V AC 230V

Input current typ. 5.47A 4.56A 2.48A at 36V, 13.3A, see Fig. 5-3
Power factor * typ. 0.96 0.95 0.90 at 36V, 13.3A, see Fig. 5-4
Crest factor ** typ. 1.6 1.7 2.05 at 36V, 13.3A
Start-up delay typ. 640ms 610ms 660ms see Fig. 5-2
Rise time typ. 80ms 80ms 80ms 0mF, 36V, 13.3A, see Fig. 5-2
typ. 85ms 85ms 85ms 13mF, 36V, 13.3A, see Fig. 5-2
Turn-on overshoot max. 75mV 75mV 75mV see Fig. 5-2
* The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
** The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.

Fig. 5-1 Input voltage range Fig. 5-2 Turn-on behavior, definitions
Rated
POUT input range max. Input
500ms Voltage
full
power
for
Shut -dow n
Turn-on

200ms
Output - 5%
Overshoot

Voltage
VIN Start-up Rise
delay Time
60V 85V 276V 300Vac

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1606- XLS480G 36V, 13A Single Phase Input

Fig. 5-3 Input current vs. output load at 36V Fig. 5-4 Power factor vs. output load at 36V
Input Current, typ. Power Factor, typ.
6A 1.0 100Vac
c
Va 120Vac
5 100 0.95
Va c
4 12 0 230Vac
0.9
3
ac
230V 0.85
2
1 0.8
Output Current Output Current
0 0.75
1.5 3 4.5 6 7.5 9 10.5 12 13.5A 1.5 3 4.5 6 7.5 9 10.5 12 13.5A

6. INPUT INRUSH CURRENT

DC input nom. DC 110-300V
DC input range min. 88-375Vdc continuous operation
DC input current typ. 4.7A / 1.7A 110Vdc / 300Vdc, 36V, 13.3A
Turn-on voltage typ. 74Vdc steady state value
Shut-down voltage typ. 69Vdc steady state value

Fig. 6-1 Wiring for DC Input

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

PE In case the –pole of the battery is not connected to

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

7. DC-INPUT
DC input nom. DC 110-300V
DC input range min. 88-375Vdc continuous operation
DC input current typ. 4.7A / 1.7A 110Vdc / 300Vdc, 36V, 13.3A
Turn-on voltage typ. 74Vdc steady state value
Shut-down voltage typ. 69Vdc steady state value

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1606- XLS480G 36V, 13A Single Phase Input

Fig. 7-1 Wiring for DC Input

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

PE In case the –pole of the battery is not connected to

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

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1606- XLS480G 36V, 13A Single Phase Input

8. OUTPUT
Output voltage nom. 36V
Adjustment range min. 36-42V guaranteed, multi turn potentiometer
max. 45V at clockwise end position of potentiometer
Factory setting 36.0V ±0.2%, at full load, cold unit
Line regulation max. 10mV 60 to 300Vac
Load regulation max. 100mV static value, 0A Æ 13.3A Æ 0A
Ripple and noise voltage max. 100mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 4 500µF

Continuous power capability

Output current nom. 13.3A at 36V, see Fig. 8-1
nom. 11.4A at 42V, see Fig. 8-1
Output power nom. 480W 36V, continuous
nom. 480W 42V, continuous
Short-circuit current min. 20A load impedance 50mOhm, up to 4s before hiccup mode
max. 27A starts, see Fig. 8-1 and Fig. 8-3

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. This Power-Boost is repeatedly available.
Detailed information can be found in chapter 27.1. If the power supply is loaded longer with the Power-Boost than shown in
the Boost-time diagram (see Fig. 8-2), the max. output power is automatically reduced to 480W.
If the power requirement is continuously above 480W and the voltage falls below approx. 30V (due to the current regulating
mode at overload), the unit shuts-off and makes periodical restart attempts. This behavior is called hiccup mode which is
described below. If the voltage is above 30V, the unit continuously delivers current.
Hiccup Mode:
Up to 4s of overloading, the power supply delivers continuous output current. After this, the output power is reduced to
nearly zero for approx. 17s before a new start attempt is automatically performed. If the overload has been cleared, the
device will operate normally. If the overload still exists, the output current will be delivered for 2 to 4s (depending on the
overload) again followed by a 17s rest time. This cycle is repeated as long as the overload exists. See Fig. 8-3. During the
off-period a small rest voltage and rest current is present on the output.

Output current nom. 20A at 36V, see Fig. 8-1

nom. 17.1A at 42V, see Fig. 8-1
Output power nom. 720W 36V, short term
nom. 720W 42V, short term
Short-circuit current min. 20A load impedance 50mOhm, up to 4s, see Fig. 8-1
max. 27A load impedance 50mOhm, up to 4s, see Fig. 8-1
Boost time typ. 4s at 36V, 20A, duration until the output voltage dips,
min 3.5s see Fig. 8-2
max. 4.5s

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1606- XLS480G 36V, 13A Single Phase Input

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

Output Voltage 10s

42V 9
8
36
B 7
30 6 m ax
24 C
5
A
18 4
A Short term <5s then auto 3 m in typ
12 switching to curve B + C 2
B Continuously available
6 C Below 30Vdc hiccup mode
Output 1 Output Power
Current
0 0
0 5 10 15 20 25A 528W 576W 624W 672W 720W 768W

Fig. 8-3 Short-circuit on output, hiccup mode, typical behavior at 36V

Output St art of End of

Current short circuit short circuit
25A

t
0
2s 17s 2s 17s 2s 17s

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

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

Input Short of
Output
Voltage
Output
Voltage
Output
Voltage
150% Bonus
Boost 150% Bonus
Boost
Power
Power Output Power
Pow er
100% Power 100%
Output
Power

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 36V to 30V at 27A for 20ms
typ. from 36V to 28V at 55A for 2ms
typ. from 36V to 26.6V at 55A for 5ms

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1606- XLS480G 36V, 13A Single Phase Input

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1606- XLS480G 36V, 13A Single Phase Input

9. HOLD-UP TIME
AC 100V AC 120V AC 230V
Hold-up Time typ. 32ms 32ms 51ms 13.3A, 36V, see Fig. 9-1
typ. 64ms 64ms 99ms 6.7A, 36V, see Fig. 9-1

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

100ms Hold-up t yp
.
90
Time A, Zero Transition
6.7
V,
80 36 min
. Input
A,
70 , 6.7 Voltage
36V
60 p.
ty
50 1 3.3A ,
36V,
40 A , m in . - 5%
36V, 13
.3 Output
30 Voltage
20 Hold-up Time
Input Voltage
10
85 120 155 190 230Vac

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
Isolation voltage See dielectric strength table in section 20

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 LED 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

Restrictions apply when using the DC-OK Contact in a Haz-Loc environment:

The DC-OK contact is intended to be used for a separately investigated nonincendive field wiring and/or field wiring
apparatus. The apparatus may be located in a Class I, Division 2 (Group A, B, C or D) hazardous (classified) location.
Non associated nonincendive field wiring apparatus shall not be connected in parallel unless this is permitted by the
associated nonincendive field wiring apparatus approval.

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1606- XLS480G 36V, 13A Single Phase Input
Selected barriers must have entity parameters such that Voc < V max, Isc < I max, Ca > Ci + Ccable, La > Li + Lcable.
For Ccable and Lcable, if the capacitance per foot or the inductance per foot is not known, then the following values shall be
used: Ccable = 60pF/foot and Lcable = 0.2uH/foot.

Fig. 10-2 DC-ok control drawing for use in Haz-Loc

environments

Contact current: I max = 50mA,

Hazardous Non Hazardous
- Contact voltage: V max. = 35V (DC or AC)
+

Location Location
Max. associated circuit capacitance Ca = 100nF
Output
Max. associated circuit inductance La = 20mH
13 Isc No polarity requirement
Power
Supply DC-
Voc Apparatus
ok

Input 14

L N PE

11. EFFICIENCY AND POWER LOSSES

AC 100V AC 120V AC 230V
Efficiency typ. 91.7% 92.5% 94.0% 13.3A, 36V
Power losses typ. 43.4W 38.9W 30.6W 13.3A, 36V
typ. 9.0W 9.2W 10.0W 0A

Fig. 11-1 Efficiency vs. output current at 36V Fig. 11-2 Losses vs. output current at 36V
Efficiency Power Losses
230Vac
94% 45W
120Vac 100Vac
93 40
120Vac
92 35
100Vac 230Vac
91 30
90 25
89 20
88 15
87 10
Output Current Output Current
86 5
2 4 6 8 10 12 14A 0 2 4 6 8 10 12 14A

Fig. 11-3 Efficiency vs. input voltage 36V, 13.3A Fig. 11-4 Losses vs. input voltage, 36V, 13.3A
Efficiency Power Losses
94% 50W
93 45
92 40
91 35
90 30
89 25
Input Voltage Input Voltage
88 20
85 120 155 190 225 260Vac 85 120 155 190 225 260Vac

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1606- XLS480G 36V, 13A Single Phase Input

12. FUNCTIONAL DIAGRAM

Fig. 12-1 Functional diagram

Output
Voltage
Regulator VOUT

L +
Input Fuse
+
N Input Filter
Input Rectifier
PFC
Converter
Power
Converter
Output
Filter
Active Inrush Limiter -
-
Overload
LED
DC-ok
LED
Temper- Output Output Output
ature Power Over- Voltage
Shut- Manager Voltage
down Protection Monitor DC-ok DC-ok
Relay contact

13. PRODUCT FACE LABEL

Fig. 13-1 Front side

Output Terminals Output voltage potentiometer

Quick-connect spring-clamp (multi turn potentiometer)
terminals, no tools required Open the flap to tune the output voltage.
+ Positive output pole Factory setting: 36.0V
- Negative output pole
Dual pins per pole DC-ok LED (green)
Overload LED (red)
DC ok Relay contact
(NO-contact) Overload DC-ok DC-ok
LED LED contact

480W Continuous power / Normal mode OFF ON Closed

720W Peak power Power Boost mode OFF ON Closed
Overload
OFF ON Closed
(VOUT > 90%)
Input Terminals
Quick-connect spring-clamp Overload
* OFF Open
terminals, no tools required (VOUT < 90%)
N … Neutral input Short-circuit
* OFF Open
L … Line (hot) input (VOUT = ca. 0V)
Over- temperature * OFF Open
... PE (Protective Earth)
See chapter 14 “Terminals and No input power OFF OFF Open
Wiring” to choose appropriate
wire gauges DC-ok LED and DC-ok contact
function synchronized

* Up to 4s of overloading, the power supply delivers continuous output current. After this, the output power is reduced to
nearly zero for approx. 17s before a new start attempt is automatically performed. If the overload has been cleared, the
device will operate normally. If the overload still exists, the output current will be delivered for 2 to 4s (depending on the
overload) again followed by a 17s rest time. This cycle is repeated as long as the overload exists.
The red overload LED is permanently on when the overload current is continuously flowing. During the 17s rest period, the
red LED is flashing with a frequency of approx. 1.3Hz.

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1606- XLS480G 36V, 13A Single 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.
Ferrules allowed, but not required
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)

Power terminals DC-OK-Signal terminals

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

Fig. 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. Close the lever d) Up to two stranded wires with the same cross
To disconnect wire: section are permitted in one connection point
reverse the procedure (except PE wire).
e) Do not use the unit without PE connection.

15. RELIABILITY

AC 100V AC 120V AC 230V

Lifetime expectancy min. 53 000h 61 000h 84 000h 40°C, 36V, 13.3A
min. 118 000h 127 000h 146 000h 40°C, 36V, 6.7A (=50% load)
min. 149 000h > 15 years > 15 years 25°C, 36V, 13.3A
MTBF SN 29500, IEC 61709 407 000h 441 000h 469 000h 40°C, 36V, 13.3A
749 000h 799 000h 840 000h 25°C, 36V, 13.3A
MTBF MIL HDBK 217F 204 000h 215 000h 229 000h 40°C, 36V, 13.3A, Ground Benign GB40
273 000h 288 000h 308 000h 25°C, 36V, 13.3A, Ground Benign GB25
The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime
expectancy of the built-in electrolytic capacitors.
Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s
manufacturer specification. The prediction model allows a calculation of up to 15 years from date of shipment.
MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates
reliability of a device. It is the statistical representation of the likelihood of the unit to fail and does not necessarily represent
the life of a product.

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1606- XLS480G 36V, 13A Single 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. The CE mark indicates conformance with EMC directive 89/336/EC, 93/68/EC and
2004/108/EC and the low-voltage directive (LVD) 73/23/EC, 93/68/EC, 2006/95/EC.

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

Electrostatic discharge EN 61000-4-2 Contact discharge 8kV Criterion A
Air discharge 15kV Criterion A
Electromagnetic RF field EN 61000-4-3 80MHz-1GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines 4kV Criterion A
Output lines 2kV Criterion A
Surge voltage on input EN 61000-4-5 LÆN 2kV Criterion A
N / L Æ PE 4kV Criterion A
Surge voltage on output EN 61000-4-5 +Æ- 500V Criterion A
+ / - Æ PE 500V Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 0% of 100Vac 0Vac, 20ms Criterion A
40% of 100Vac 40Vac, 200ms Criterion C
70% of 100Vac 70Vac, 500ms Criterion C
Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C
Voltage sags SEMI F47 0200 96Vac, 1000ms Criterion A
84Vac, 500ms Criterion A
60Vac, 200ms Criterion A
Input voltage swells RA internal standard 300Vac, 500ms Criterion A
Powerful transients VDE 0160 over entire load range 750V, 1.3ms Criterion C
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 Generic standards: EN 61000-6-3 and EN 61000-6-4

Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR
Class B, input lines
22
EN 55022 Class B, output lines
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 Fulfilled, active PFC
Voltage fluctuations, flicker EN 61000-3-3 Fulfilled
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may cause undesired operation.

Switching Frequencies The power supply has four converters with four different switching frequencies included. One
is nearly constant. The others are input voltage and load dependent.
Switching frequency 1 100kHz Resonant converter, nearly constant
Switching frequency 2 110kHz to 500kHz Boost converter, input voltage and load dependent
Switching frequency 3 73kHz to 114kHz PFC converter, input voltage and load dependent
Switching frequency 4 35-45kHz Aux. Converter, input voltage and load dependent

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1606- XLS480G 36V, 13A Single Phase Input

17. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) reduce output power above +60°C
Output de-rating 12W/°C 60-70°C (140°F to 158°F), see Fig. 17-1
Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation
Humidity 5 to 95% r.H. IEC 60068-2-30
Do not energize while condensation is present
Vibration sinusoidal 2-17.8Hz: ±1.6mm; IEC 60068-2-6
17.8-500Hz: 2g
2 hours / axis
0.5m2(s3) IEC 60068-2-64
Vibration random
2 hours / axis
Shock 30g 6ms, 20g 11ms IEC 60068-2-27
3 bumps / direction,
18 bumps in total
Altitude 0 to 6000m (0 to 20 000ft) Reduce output power or ambient temperature
above 2000m sea level.
Output de-rating (for altitude) 30W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 17-2
Over-voltage category III EN 50178, altitudes up to 2000m
II Altitudes from 2000m to 6000m
Degree of pollution 2 EN 50178, not conductive

Fig. 17-1 Output current vs. ambient temp., Fig. 17-2 Output current vs. altitude

Allowed Output Allowed Output

Current at 36V Current at 36V
20A 20A
f or t yp. 4s f or t yp. 4s
16.6 16.6
13.3 13.3 C
cont inuous cont inuous B
A
10 10
6.7 6.7
A... Tamb < 60°C
3.3 3.3 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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18. PROTECTION FEATURES

Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 50Vdc In case of an internal power supply defect, a redundant
max. 54Vdc circuitry limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Output over-current protection Electronically limited See Fig. 8-1
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm / >5mm top side / bottom side, e.g. screws, small parts
Over-temperature protection yes output shut-down with automatic restart
Input transient protection MOV (Metal Oxide Varistor)
Internal input fuse T10A H.B.C. not user replaceable
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. 0.23mA 100Vac, 50Hz, TN mains
typ. 0.34mA 120Vac, 60Hz, TN mains
typ. 0.58mA 230Vac, 50Hz, TN mains
< 0.31mA 110Vac, 50Hz, TN mains
< 0.45mA 132Vac, 60Hz, TN mains
< 0.80mA 264Vac, 50Hz, 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

Input DC-ok Type test 60s 2500Vac 3000Vac 500Vac 500Vac
L B Factory test 5s 2500Vac 2500Vac 500Vac 500Vac
N Field test 5s 2000Vac 2000Vac 500Vac 500Vac
Type tests and factory tests:
A D
B

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 L and N together as well as all output
-
poles.
The output voltage is floating and has no ohmic connection to ground.

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1606- XLS480G 36V, 13A Single Phase Input

21. APPROVALS

IECEE
IEC 60950-1 CB Scheme,
Information Technology Equipment
CB SCHEME
UL 508 18WM LISTED E198865
LISTED
IND. CONT. EQ.
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
Class I Div 2 RECOGNIZED E246877
Hazardous Location Class I Div 2 T4 Groups A,B,C and D
ANSI/ISA-12.12.01 (UL 1604)
The unit is suitable for use in Class I Division 2 Groups A, B, C, D 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.
CSA CSA approval for Canada
R
CAN/CSA C22.2 No 107-1; CAN/ CSA 60950-1-03; UL60950-1
C US
182790

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, IEC 62103 Electronic Equipment in Power Installations
SEMI F47 SEMI F47-0200, Ride-through compliance for semiconductor industry.
Full SEMI range compliance (Input: 120Vac or 208Vac, output: 480W)
UL1604 Hazardous Location Class I Div 2 T3C Groups A,B,C,D

23. USED SUBSTANCES

The unit does not release any silicone and is suitable for the use in paint shops.
The unit conforms to the RoHS directive 2002/96/EC
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.
The production material within our production does not include following toxic chemicals:
Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCT), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN),
Polybrom Biphenyll (PBB), Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated
Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO), Cadmium, Asbest, Mercury, Silicia

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1606- XLS480G 36V, 13A Single Phase Input

24. PHYSICAL DIMENSIONS AND WEIGHT

Weight 1200g / 2.65lb
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.

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. The tripping of an internal fuse is caused by an internal defect.

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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 slider 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

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. (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) For altitudes higher than 2000m reduce the pulse loading (30W/1000m) or the ambient temperature (5°C/1000m)

Fig. 27-1 Repetitive pulse loads, definitions Fig. 27-2 Max. Duty Cycle Curve

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

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

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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

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 27A for 50ms, typ. Fig. 27-4 Peak load 55A for 5ms, typ.

Output Output
36V Voltage 36V Voltage

28.7V 26.6V

55A
27A

Output Output
0A Current 0A Current

10ms/DIV 1ms/DIV
Peak load 27A (resistive) for 50ms Peak load 55A (nearly resistive) for 5ms
Output voltage dips from 36V to 29.0V. Output voltage dips from 36V to 26.6V.
Please note: The DC-OK relay triggers when the voltage dips more than 10% for longer than 1ms.

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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 48Vdc. The absorbing energy can be calculated according to the built-in large
sized output capacitor which is specified in chapter 8. If the feed back voltage gets higher than 48Vdc, the power supply
responds with a shut-down and a subsequent start-up attempt.

27.4. CHARGING OF BATTERIES

The power supply can be used for float-charging of lead-acid or maintenance free 36V VRLA batteries.
Instructions for charging batteries:
a) Set the output voltage, at disconnected load, very precisely to the end-of-charge voltage according to the expected
battery temperature.
End-of-charge voltage 41.7V 41.3V 40.7V 40.2V
Battery temperature 10°C 20°C 30°C 40°C
b) Use a 20A 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. 9mA at 38Vdc when the power supply is switched off.

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: 230Vac, load current: 0A
Supply I Tripping time shorter than 5s.
AC + + The following circuit breaker tripped during the test:
S1 Load A- or Z- Characteristic:: equal or smaller 20A*)
B- Characteristic: equal or smaller 16A*)
DC - -
C- Characteristic: equal or smaller 13A*)

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1606- XLS480G 36V, 13A Single Phase Input
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: 230Vac, 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:: ≤ 20A and R< 82mOhm*
B- Characteristic: ≤ 10A and R< 120mOhm*)
S1 Load
C- Characteristic: ≤ 6A and R< 180mOhm*)
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
120mOhm 3.3m 4.7m 6.7m 10.0m 16.7m 26.7m
180mOhm 5.0m 7.0m 10.0m 15.0m 25.1m 40.1m

* A list of the circuit breakers under test is available on request.

Example:
Which wire gauge must be used to trip a C-Characteristic circuit breaker with a rating of 6A? The load wire length is 21m.
Answer: A 6A C-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- XLS480G 36V, 13A Single Phase Input

27.6. EXTERNAL INPUT PROTECTION

The unit is tested and approved for branch circuits up to 20A. External protection is only required, if the supplying branch has
an ampacity greater than this. In some countries local regulations might apply. Check also local codes and local
requirements.
If an external fuse is necessary or utilized, a minimum value is required to avoid undesired tripping of the fuse.
B-Characteristic C-Characteristic
Ampacity max. 20A 20A
min. 10A 10A

27.7. PARALLEL USE TO INCREASE OUTPUT POWER

Power supplies can be paralleled to increase the output power.
Fig. 27-7 Schematic for parallel operation Instructions for parallel use:
Unit A a) Use only power supplies from the same series.
AC b) Adjust the output voltages of all power supplies to approximately
+ the same value (±750mV).
Otherwise, the DC-ok signal might not work properly.
-
DC c) A fuse (or diode) on the output is only required if more than
+ three units are connected in parallel.
Unit B
Load d) Do not continuously load the terminals with more than 25A.
AC Follow wiring instructions according to chapter 27.9
+ -
e) Keep an installation clearance of 15mm (left/right) between two
- power supplies and avoid installing the power supplies on top of
DC
each other.

27.8. 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 decoupling module 1606-XLSRED. (One Diode 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 LED 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.

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27.9. DAISY-CHAINING OF OUTPUTS

Daisy chaining (jumping from one power supply output to the next) is allowed as long as the max. current through one
terminal pin does not continuously exceed 20A. If the current is higher, use a separate distribution terminal.
Fig. 27-8 Daisy chaining of outputs Fig. 27-9 Using distribution terminals

max 20A!

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

Power Power Load

Power Power
Supply Supply Supply Supply

Input Input
Distribution
Input Input Terminals

27.10. SERIES OPERATION

The power supply can be put in series to increase the output voltage.
Fig. 27-10 Schematic for series operation Instructions for use in series:
a) It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed
Unit A 150Vdc.
AC b) Warning ! Voltages with a potential above 60Vdc are not SELV
+ any more and can be dangerous. Such voltages must be
- installed with a protection against touching.
DC c) For serial operation use power supplies of the same type.
+ d) Earthing of the output is required when the sum of the output
Unit B
Load voltage is above 60Vdc.
AC
+ - e) Keep an installation clearance of 15mm (left/right) between two
power supplies and avoid installing the power supplies on top of
- Earth each other.
DC
Note: Avoid return voltage (e.g. from a decelerating motor or battery)
which is applied to the output terminals.

27.11. INDUCTIVE AND CAPACITIVE LOADS

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

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27.12. OPERATION ON TWO PHASES

Fig. 27-11 Schematic for two phase operation

Power Supply Instructions for two phase operation:

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

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

Fuse
L3 N
to a hot wire.
240V

PE
Appropriate fuses or circuit breakers are specified in section 27.6
L2 DC “External Input Protection”.

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: Enclosure Type IP66 Box PK 9522 100, plastic, 254x180x165mm
Load: 36V, 10.6A; (=80%) load is placed outside the box
Input: 230Vac
Temperature inside enclosure: 49°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 24.3°C
Temperature rise: 19°C

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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 13.3A A1
Orientation A
Standard Orientation 10
Power
Supply 6.7
3.3
Ambient Temperature
INPUT 0
10 20 30 40 50 60°C

Fig. 27-13 Output Current

Mounting INPUT
13.3A
Orientation B
(Upside down) 10 A2
Supply
Power 6.7 A1

3.3
Ambient Temperature
0
OUTPUT

10 20 30 40 50 60°C

Fig. 27-14 Output Current

Mounting 13.3A
Orientation C
(Table-top mounting) 10 A2
6.7 A1
3.3
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 27-15 Output Current

Mounting 13.3A
Orientation D
(Horizontal cw) 10
OUTPUT
Supply
Power
INPUT

A2
6.7 A1
3.3
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 27-16 Output Current

Mounting 13.3A
Orientation E
(Horizontal ccw) 10
OUTPUT

Supply
Power

INPUT

A2
6.7 A1
3.3
Ambient Temperature
0
10 20 30 40 50 60°C

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