27.3. Using the Inhibit Input ..................... 21
27.4. Troubleshooting
................................. 21
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLS240-UPSE
Index
Terminology and Abbreviations
•DC UPS—Uninterruptible power supply with DC input.
•Normal mode—Describes a condition where the battery is charged, the input voltage is in range and the output is loaded within the
allowed limits..
•Buffer mode—Describes a condition where the input voltage is below the transfer threshold level, the unit is running on battery (buffering)
and the output is loaded within the allowed limits.
•Charging mode—Describes a condition where the battery is being charged, the input voltage is in range and the output is loaded within the
allowed limits.
•Inhibit mode—Describes a condition where buffering is disabled intentionally by using the inhibit input of the DC UPS (e.g. for service
actions or to save battery capacity).
•Buffer time—Equivalent to the term “hold-up time.”
•T.b.d.—To be defined, value or description will follow later.
Page 2
Bulletin 1606 Switched Mode Power Supplies
1. Description
This uninterruptible power supply (UPS) controller
1606-XLS240-UPSE is an addition to standard 24V
power supplies to bridge power failures or
emergency systems which must be kept fully in
operation for e.g. 72 hours.
The DC-UPS includes an internal temperature sensor
and a professional battery management system
which charges and monitors the battery to achieve
the longest battery service life as well as many
diagnostic functions that ensure a reliable operation
of the entire system.
A unique feature of the 1606-XLS240-UPSE is that only
one 12V battery is required to buer the 24V
output. This makes matching batteries unnecessary
and allows a precise battery charging and testing.
1606-XLS240-UPS Series
Related products
1606-XLS240-UPS
battery
included
larger
battery sizes
additional
12V output
1606-XLS240-UPSC
1606-XLS240-UPSE
1606-XLS240-UPSD
DC-UPS Control Unit
■
Requires Only One 12V Battery for a 24V Output
■
Allows Batteries Between 17Ah and 130Ah
■
Battery Charging with Temperature Tracking
■
Stable Output Voltage in Buer Mode
■
Superior Battery Management for Longest Battery Life
■
Comprehensive Diagnostic and Monitoring Functions
■
Replace Battery Signal Included
■
Electronically Overload and Short Circuit Protected
■
50% Power Reserves
■
3 Year Warranty
2. Specication Quick Reference
Input voltage nom. 24Vdc
range 22.5-30Vdc
Output current min.15A Normal mode
min. 10A Buer mode
Output voltage typ. 0.23V lower
22.25V Buer mode, 10A
Allowed batteries 17Ah to 130Ah VRLA lead acid
Temperature range -25 to +50°C
Dimensions 49x124x117mm WxHxD
Buer time (at 10A) typ. 55 minutes 26Ah battery
typ. 4 hours 100Ah battery
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
2Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
UL 60950-1
UL 508
GOST R
EMC, LVD
Marine RINA
Marine
Page 3
Bulletin 1606 Switched Mode Power Supplies
Intended Use
•This device may only be installed and put into operation by qualified personnel.
•This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office,
communication, and instrumentation equipment.
•Do not use this power supply in aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or
threaten human life.
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 20143
Page 4
Bulletin 1606 Switched Mode Power Supplies
5.Input
Input voltage
nom. DC 24V
Input voltage ranges
nom. 22.5 to 30Vdc Continuous operation, see Fig. 5-1
30 to 35Vdc Temporarily allowed, no damage to the DC-UPS *)
35Vdc Absolute maximum input voltage with no damage to the
DC-UPS
0 to 22.5Vdc The DC-UPS switches into buer mode and delivers
output voltage from the battery if the input was above
the turn-on level before and all other buer conditions
are fullled.
Allowed input voltage ripple
max. 1.5Vpp Bandwidth <400Hz
1Vpp Bandwidth 400Hz to 1kHz
Allowed voltage between input
and earth (ground)
max. 60Vdc or
42.4Vac
Turn-on voltage
typ. 22.8Vdc The output does not switch on if the input voltage does
not exceed this level.
max. 23Vdc
Input current **)
typ. 120mA Internal current consumption for the DC-UPS
typ.
max.
2.0A
2.7A
Current consumption for battery charging ***)
External capacitors on the input
No limitation
*) The DC-UPS shows “Check Wiring” with the red LED and buering is not possible.
**) The total input current is the sum of the output current,
the current which is required to charge the battery during the
charging process and the current which is need
ed to supply the DC-UPS itself. See also
Fig. 5-2 . This calculation does not apply
in overload situations where the DC-UPS limits the output current, therefore see Fig. 5-3.
***) Please note: This is the input current and not the current which ows into the battery during charging. The battery current can
be found in section 8.
Fig. 5-1 Input voltage range Fig. 5-2 Input current, denitions
A: Rated input voltage range
B: Temp. allowed, no harm to the unit
C: Absolute max. input voltage
D: Buffer mode
V
IN
183035V22.50
AB
C
D
V
OUT
Internal
current
consumption
Current
consumption
for battery
charging
Output
Current
Input
Current
Fig. 5-3 Input current and output voltage vs.
output current, typ. (battery fully charged)
Electric output current limitation
The DC-UPS is equipped with an electronic output
current limitation. This current limitation works
in a switching mode which reduces the power
losses and heat generation to a minimum. As a
result, the output voltage drops since there is not
enough current to support the load. A positive
eect of the current limitation in switching mode
is that the input current goes down despite an
increase in the output current resulting in less
stress for the supplying source.
0
0
5
10
15
20A
O
u
t
p
u
t
C
u
r
r
e
n
t
4812
20A
Output Voltage
15
20V
Overload
I
n
p
u
t
C
u
r
r
e
n
t
10
4Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 5
Bulletin 1606 Switched Mode Power Supplies
6.Output in Normal Mode
Output voltage in normal mode
nom. DC 24V The output voltage follows the input voltage reduced by
the input to output voltage drop.
Voltage drop between input and
output
max. 0.3V At 10A output current, see Fig. 6-1 for typical values
max. 0.45V At 15A output current, see
Fig. 6-1 for typical values
Ripple and noise voltage
max. 20mVpp 20Hz to 20MHz, 50Ohm *)
Output current nom. 15A Continuously allowed
Output power nom. 360W Continuo usly allowed
Short-circuit current
min. 17.9A Load impedance 100mOhm, see Fig. 6-2 for typical values
max. 21A Load impedance 100mOhm, see
Fig. 6-2 for typical values
Capacitive and inductive loads
No limitation
might be higher if the supplying source has a higher ripple and noise voltage.
Fig. 6-1 Input to output voltage drop, typ.
Fig. 6-2
Output voltage vs. output current in
normal mode at 24V input, typ.
Input to Output
Voltage drop
0
0210
0.1
0.15
0.25
18A
0.05
0.2
0.3
0.35
0.4V
Ou
t
p
u
t
C
u
r
r
e
n
t
468 121416
Output Voltage
0
05101520
4
8
12
28V
16
20
24
25
A
Output Current
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 20145
Page 6
Bulletin 1606 Switched Mode Power Supplies
7.Output in Buer Mode
If the input voltage falls below a certain value (transfer threshold level), the DC-UPS starts buering without any
interruption or voltage dips. Buering is possible even if battery not fully charged.
Output voltage in buer mode
nom. DC 24V Output voltage is stabilized and independent from
battery voltage
22.45V ±1%, at no load,
22.25V ±1%, at 10A output current
Transfer threshold for buering
typ. 80mV higher than the output voltage in buer mode
Ripple and noise voltage max. 20mVpp 20Hz to 20MHz, 50Ohm
Output current nom. 10A Continuously allowed
15A < 5s with full output voltage *)
Short-circuit current
*) If the output current is in the range between 10A and 15A for longer than 5s, a hardware controlled reduction of the
maximal output current to 10A occurs. If the 10A are not suci
ent to maintain the 24V, buering stops after another 5s.
Buering will again be possible as soon as the input voltage recovers.
**) If the nominal output voltage cannot be maintained in buer mode, the DC-UPS switches o after 5s to save battery
capacity.
Fig. 7-1 Buering transition, denitions
Buffer mode
Output
voltage
24V
28V
Input
voltage
t
t
Transfer
threshold
5
0
0
m
s
/
D
I
V
0
V
O
u
t
p
u
t
V
o
l
t
a
g
e
I
n
p
u
t
V
o
l
t
a
g
e
2
4
V
2
2
.
2
5
V
a
t
1
0
A
2
4
V
Fig. 7-3 Available output current in
buer mode
Fig. 7-4 Output voltage vs. output current
in buer mode, typ.
Output Current
0
05 Sec.
15A
10A
Time
5A
BonusPower
Output Voltage
A
B
C
Continuously available
Available for 5s then auto switching to curve
Buffering will stop after 5s
D
0
0
5101520
5
10
15
25V
20
25A
Output
Current
AB
CD
D
Buffering will stop after 5s
Fig. 7-2 Transfert behavior, typ.
6Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 7
8.Battery Input
The DC-UPS requires one 12V VRLA battery to buer the 24V output.
Battery voltage
nom. DC 12V Use one maintenance-free 12V VRLA lead acid battery or
one battery module which is listed in the Accessories
section.
Battery voltage range
9.0 – 15.0V Continuously allowed, except deep discharge protection
max. 35Vdc Absolute maximum voltage without any damage to the unit
typ. 7.4V Above this voltage level battery charging is possible
Allowed battery sizes
min. 17Ah max. 130Ah
Internal battery resistance
max. 100mOhm See individual battry data sheets for this value.
Battery charging method CC-CV Constant current, constant voltage mode
Battery charging current (CC-mode) nom. 3.0A Independent from battery size
max. 3.4A
End-of-charge-voltage (CV-mode)
13.0-14.4V See section 15.
Battery charging time typ. 9h *) For a 26Ah battery
typ. 34h *) For a 100Ah battery
Battery discharging current **)
typ. 21A Buer mode, 10A output
current, 11.5V on the battery
terminal of the DC-UPS, see Fig. 8-1 for other parameters
typ. 0.3A Buer mode, 0A output current
max. 50μA At no input, buering had switched o, all LEDs are o
typ. 270mA At no input, buering had switched o, yellow LED
shows “buer time expired” (max. 15 minutes)
Deep discharge protection ***)
typ. 10.5V At 0A output current
typ. 9.8V At 10A output current
*) The charging time depends on the duration and load current of the last buer event. The numbers in the table represent a
fully discharged battery.
**) The current between the battery and the DC-UPS is more than twice the output current. This is caused by boosting the 12V
battery voltage to a 24V level.This high current requires large wire gauges and short cable length for the longest possible
buer time. The higher the resistance of the connection between the battery and the DC-UPS, the lower the voltage on the
battery terminals which increases the discharging current. See also section 26 for more installation instructions.
***) To ensure longest battery lifetime, the DC-UPS has a battery deep discharge protection feature included. The DC-UPS stops
buering when the voltage on the battery terminals of the DC-UPS falls below a certain value. The yellow LED will show
“buer time expired” for a period of 15 minutes after the unit stopped buering.
Fig. 8-1 Battery discharging current
vs. output current, typ.
Battery Current
0
0
10
20
5
15
25
30A
2.57.5105.21A515
O
u
t
p
u
t
C
u
r
r
e
n
t
Voltage on
battery terminal
of the DC-UPS:
A:
10.5V
B:
11V
C:
12V
A B C
Bulletin 1606 Switched Mode Power Supplies
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 20147
Page 8
Bulletin 1606 Switched Mode Power Supplies
9.Buer Time
The buer time depends on the capacity and performance of the battery as well as the load current. The diagram
below shows the typical buer times of the standard battery modules.
Buer time with 26Ah battery (1606-XLSBATASSY2) min. 99’30’’ At 5A output current *)
min. 39’ At 10A output current *)
typ. 130’ At 5A output current, see
Fig. 9-1
**)
typ. 55’ At 10A output current, see
Fig. 9-1
**)
Buer time with 100Ah battery min. 62h 20’ At 0.5A output current *)
min. 3h At 10A output current *)
typ. 82h 20’ At 0.5A output current, see Fig. 9-1
**)
typ. 4h At 10A output current, see
Fig. 9-1 **)
*) Minimum value includes 20% aging of the battery and a cable length of 1.5m with a cross section of 2.5mm2 between the
battery and the DC-UPS and requires a fully charged (min. 24h) battery.
**) Typical value includes 10% aging of the battery and a cable length of 0.3m with a cross section of 2.5mm
2
between the battery
and the DC-UPS and requires a fully charged (min. 24h) battery.
Fig. 9-1 Buer time vs. output current with a 65Ah and a 100Ah battery
Buffer Current
0
4050
0.5
1.0
1.5
2A
70806090h30
A
B
A:
65Ah Battery
B:
100Ah Battery
Buffer Time (Hours)
30h
Buffer Current
0
5
2
4
6
8
10A
10152025
Buffer Time (Hours)
A
B
A:
65Ah Battery
B:
100Ah Battery
5
The battery capacity is usually specied in amp-hours (Ah) for a 20h discharging event. The battery discharge is nonlinear (due to the battery chemistry). The higher the discharging current, the lower the appropriate battery capacity.
The magnitude of the reduction depends on the discharging current as well as on the type of battery. High current
battery types can have up to 50% longer buer times compared to regular batteries when batteries are discharged
in less than one hour.
High discharging currents do not necessarily mean high power losses as the appropriate battery capacity is reduced
with such currents. When the battery begins to recharge after a discharging event, the process is completed much
faster since only the energy removed from the battery needs to be “relled.”
For this reason, the buer time cannot be calculated using the Ah capacity value. The equation “I x t” = capacity in
Ah generally leads to incorrect results when the discharging current is higher than C20 (discharging current for 20h).
8Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 9
Bulletin 1606 Switched Mode Power Supplies
10. Eciency and Power Losses
Eciency typ. 97.8% Normal mode, 10A output current, battery fully charged
Power losses typ. 2.9W Normal mode, 0A output current, battery fully charged
typ. 5.5W Normal mode, 10A output current, battery fully charged
typ. 7.2W During battery charging, 0A output current
typ. 18.5W Buer mode, 10A output current
Fig. 10-1 Eciency at 24V, typ.
Fig. 10-2 Losses at 24V, typ.
Efciency vs. output
current in normal mode
94.5
39
95.5
96.0
97.0
15A
95.0
96.5
97.5
98%
O
u
t
p
u
t
C
u
r
r
e
n
t
57 1113
Power losses versus output current
0
07.5
6
12
15A
3
9
15
18W
O
u
t
p
u
t
C
u
r
r
e
n
t
2.5510 12.5
A
B
A:
Buffer Mode
B:
Charging Mode
C:
Normal Mode
C
11. Functional Diagram
Fig. 11-1 Functional diagram
-
+
-
+
DC- UPS
24V
Power
Supply
Step-up
Converter
Battery
Charger
Electronic
Current
Limiter
Battery
Tester
+
-
12V Battery
+
-
Buffered
Load
Cut-off
Relay
InputOutput
Battery
Diagnosis LED
(yellow)
Status LED
(green)
Inhibit +
Controller
Check Wiring LED
(red)
Replace Battery
Buffering
Contact
Ready Contact
Battery Temperature
(7)
Inhibit -
(8)
(1)
(2)
(3)
(4)
(5)
(6)
Input Fuse
&
Reverse
Polarity
Protection
*
Temp.
*) Return current protection: this feature uses a Mosfet instead of a diode to minimize the voltage drop and power losses.
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 20149
Page 10
Bulletin 1606 Switched Mode Power Supplies
12. Check Wiring and Battery Quality Tests
The DC-UPS is equipped with an automatic “Check Wiring” and “Battery Quality” test.
“Check Wiring” test:
Under normal circumstances, an incorrect or bad connection from the battery to the DC-UPS or a missing (or blown)
battery fuse would not be recognized by the UPS when operating in normal mode. Only when backup is required
would the unit be unable to buer. Therefore, a “Check Wiring” test is included in the DC-UPS. This connection is
tested every 10 seconds by loading the battery and analyzing the response from the battery. If the resistance is too
high, or the battery voltage is not in range, the unit displays “Check Wiring” along with the red LED. At the same time,
the green “Ready” LED will turn o.
“Battery Quality” or “State of Health” (SoH) test:
The battery has a limited service life and needs to be replaced at xed intervals determined by the specied service
life (acc. to the Eurobat guideline), based on the surrounding temperature and the number of charging and
discharging cycles. If the battery is used longer than the specied service life, its capacity will degrade. Section 27-1
contains additional information on the topic. The battery quality test cannot identify a gradual loss in capacity.
However, it is able to detect a battery failure within the specied service life of the battery. Therefore a battery quality
test in included in the DC-UPS.
A battery problem is indicated by the yellow LED (replace battery pattern) and the relay contact “Replace Battery.”
Please note that it can take up to 170 hours (with the largest battery size) until a battery problem is reported. This
should avoid nuisance error messages as any urgent battery problems will be reported by the “Check Wiring” test and
create a warning signal.
When “Replace Battery” is indicated, we recommend replacing the battery as soon as possible.
13. End-of-Charge Voltage
The end-of-charge voltage depends on the temperature of the battery. An excessively high end-of-charge voltage may
damage the battery and shorten its lifetime. Therefore the DC-UPS includes an internal temperature sensor, which
regulates the end-of-charge voltage depending on the battery temperature. To achieve the longest lifetime,
the battery should be placed at the coldest location.
The temperature dierence between the DC-UPS and the battery requires a correction of the end-of-charge voltage.
This can be done with the selector on the front side of the unit. See section 15 for details.
10Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 11
Bulletin 1606 Switched Mode Power Supplies
14. Relay Contacts and Inhibit Input
The DC-UPS is equipped with relay contacts and signal inputs for remote monitoring and controlling of the unit.
Relay contacts:
Ready:
Contact is closed when battery is charged more than 85%, no wiring failure is recognized, input
voltage is sucient and inhibit signal is not active.
Buering: Contact is closed when unit is buering.
Replace Battery: Contact is closed when the unit is powered from the input and the battery quality test (SOH test)
reports a negative result.
Relay contact ratings max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
min 1mA at 5Vdc min.
Isolation voltage max 500Vac, signal port to power port
Signal input:
Inhibit: The inhibit input disables buering. In normal mode, a static signal is
required. In buer mode, a pulse with a minimum length of 250ms is
required to stop buering. The inhibit is stored and can be reset by
cycling the input voltage. See also section 27.3 for application hints.
7 +
5.1V
3mA
Inhibit
8
-
Signal voltage max. 35Vdc
Signal current max. 6mA, current limited
Inhibit threshold min. 6Vdc, buering is disabled above this threshold level
max. 10Vdc
Isolation nom. 500Vac, signal port to power port
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 201411
Page 12
Bulletin 1606 Switched Mode Power Supplies
15. Front Side User Elements
A
Power Port
Quick-connect spring-clamp terminals, connection for input voltage,
output voltage and battery
B
Signal Port
Plug connector with sc rew terminals, inserted from the bottom.
Connections for the Ready, Buering, Replace Battery contacts and for
the Inhibit input. See details in section 14..
C
Green Status LED
Ready: Battery is charged > 85%, no wiring failure is recognized, input
voltage is sucient and inhibit signal is not active.
Charging: Battery is charging and the battery capacity is below 85%. Buering: Unit is in buer mode.
Flashing pattern of the green status LED:
Ready
1
0
1
0
Charging
1
0
Buffering
D
Yellow Diagnosis LED
Overload: Output has switched o due to long overload in buer mode
or due to high temperatures.
Replace battery: Indicates a battery that failed the battery quality test (SoH test).
Battery should be replaced soon.
Inhibit active: Indicates that buering is disabled because of an active inhibit signal.
Flashing pattern of the yellow diagnosis LED:
1
0
Overload
1
0
Replace
Battery
1
0
Inhibit
active
E
Red Check Wiring LED
This LED indicates a failure in the installation (e..g. input voltage excessively low), wiring, battery or battery fuse.
F
Battery Temperature Selector
A: Same as this unit Temperature compensated end-of-charge voltage.
B: 10°C lower than this unit Temperature compensated end-of-charge voltage with an oset conditional upon tempera
C: 20°C lower than this unit Temperature compensated end-of-charge voltage with an oset conditional upon tempera
D: Battery temperature is 30°C Fixed end of charge voltage for 30°C battery temperature
E: Battery temperature is 20°C Fixed end of charge voltage for 20°C battery temperature
F: Battery temperature is 10°C Fixed end of charge voltage for 10°C battery temperature
C
D
E
12Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 13
16. Terminals and Wiring
Power terminals Signal terminals
Type Bi-stable, quick-connect spring-
clamp terminals. IP20 Fingertouch-proof. Suitable for eldand factory installation. Shipped
in open position.
Plug connector with screw terminal. Finger-touch-proof
construction with captive screws for 3.5mm slotted
screwdriver. Suitable for eld and factory installation.
Shipped in open position. To meet GL requirements,
unused terminal compartments should be closed.
Solid wire 0.5-6mm2 0.2-1.5mm2
Stranded wire 0.5-4mm2 0.2-1.5mm2
AWG 20-10AWG 22-14AWG
Ferrules Allowed, but not required Allowed, but not required
Pull-out force 10AWG:80N, 12AWG:60N,
Fig. 16-1 Spring-clamp terminals, connecting a wire
Insert wire
Close the lever
To disconnect wire, reverse the procedure.
Instructions:
a)Use appropriate copper cables that are designed
for an operating temperature of 60°C.
b)Follow national installation codes and regulations!
c)Ensure that all strands of a stranded wire are properly inserted in
the terminal connection!
d)Up to two stranded wires with the same cross-section are
permitted in one connection point.
17. Reliability
Lifetime expectancy min. 137 400h At 10A output current, 40°C
min. > 15 years At 5A output current, 40°C
min. > 15 years At 10A output current, 25°C
MTBF SN 29500, IEC 61709 886 000h At 10A output current, 40°C
1 482 000h At 10A output current, 25°C
MTBF MIL HDBK 217F 397 900 At 10A output current , 40°C, ground benign GB40
545 000 At 10A output current , 25°C, 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 specied in operational hours.
Lifetime expectancy is calculated according to the capacitor’s manufacturing specications. The prediction model
allows a calculation of up to 15 years from date of shipment.
MTBF stands for Mean Time Between Failures, which is calculated according to statistical device failures and indicates
reliability of a device. It is the statistical representation of the likelihood of failure of a specic unit and does not
necessarily represent the life of a product.
Bulletin 1606 Switched Mode Power Supplies
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 201413
Page 14
Bulletin 1606 Switched Mode Power Supplies
18. EMC
The unit is suitable for applications in industrial environments as well as in residencial, commercial and light industry
environment without any restrictions. The CE Mark indicates conformance with EMC guideline 89/336/EC, 93/68/EC and
2004/108/EC and the low-voltage directive (LVD) 73/23/EC, 93/68/EC and 2006/95/EC.
A detailed EMC report is avalaible upon request.
EMC Immunity
EN 61000-6-1, EN 61000-6-2 Generic standards
Electrostatic discharge EN 61000-4-2 Contact discharge
Air discharge
8kV
15kV
Criterion A*)
Criterion A*)
Electromagnetic RF eld EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Out- and Input lines
Signal lines **)
2kV
2kV
Criterion A
Criterion A
Surge voltage
EN 61000-4-5 + -
500V
500V
Criterion A
Criterion A
+ -
housing
500V
Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
*) DIN rail earthed
**) Tested with coupling clamp.
EMC Emission
EN 61000-6-3 and EN 61000-6-4 Generic standards
Conducted emission EN 55022Input lines Class B*)
Class B*)
Radiated emission EN 55011, EN 55022 Class B
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.
*) Informative measurement with voltage probe
Switching frequency
The DC-UPS has three converters with three different switching frequencies included.
Switching frequency of boost converter 100kHz Constant frequency
Switching frequency of electronic output current limitation 78kHz Constant frequency
Switching frequency of battery charger 19.5kHz Constant frequency
Output
Input
+
-
EN 55022
Output lines
14Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 15
Bulletin 1606 Switched Mode Power Supplies
19. Environment
Operational temperature -25°C to +50°C Full power, for the DC-UPS control unit.
Keep battery in a cooler environment!
Storage temperature -40 to +85°C Storage and transportation, except battery
Humidity 5 to 95% r.H. IEC 60068-2-30
Do not energize while condensation is present
Vibration sinusoidal 2-17.8Hz: ±1 .6mm; 17.8-500Hz: 2g IEC 60068-2-6
Shock 30g 6ms, 20g 11ms IEC 60068-2-27
Altitude 0 to 6000m Approvals apply only up to 2000m
Over-voltage category III EN 50178
II EN 50178 above 2000m altitude
Degree of pollution 2 EN 50178, not conductive
Fig. 19-1 Output current vs. ambient temperature
Fig. 19-2 Output current vs. ambient temperature
Allowable Output Current in Normal Mode
0
-2502030
50°C
2.5
5
7.5
10
12.5
15A
4010
Ambient Temperature
Allowable Output Current in Buffer Mode
0
-2502030
50°C
2.5
5
7.5
10
12.5
15A
1040
Ambient Temperature
c
o
n
t
i
n
u
o
u
s
f
o
r
t
y
p
.
5
s
The ambient temperature is dened 2cm below the unit.
20. Protection Features
Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection
in buer mode
typ. 32Vdc
max. 35Vdc
In case of an internal defect, a redundant circuitry
limits the maximum output voltage. The output
automatically shuts-down and makes restart attempts.
Degree of protection IP20 EN/IEC 60529
Penetration protection > 3.5mm E.g. screws, small parts
Reverse battery polarity protection yes Max. –35Vdc;
Wrong battery voltage protection yes Max. +35Vdc (e.g. 24V battery instead of 12V battery)
Battery deep discharge protection yes The limit is battery current dependent
Over temperature protection yes Out put shut-down with automatic restart
Input over-voltage protection yes Max. 35Vdc, no harm or defect of the unit
Internal input fuse 25A, blade type No user accessible part, no service part
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 201415
Page 16
Bulletin 1606 Switched Mode Power Supplies
21. Safety
Output voltage SELV IEC/EN 60950-1
PELV EN 60204-1, EN 50178, IEC 60364-4-41
Max. allowed voltage between any input, output or signal pin and ground:
60Vdc or 42.4Vac
Class of protection III PE (Protective Earth) connection is not required.
Isolation resistance > 5MOhm Power port to housing, 500Vdc
Dielectric strength 500Vac Power port to signal port
500Vac Power port / signal port to housing
Touch current (leakage current) The leakage current which is produced by the DC-UPS itself depends on the input
voltage ripple and need to be investigated in the nal application.
For a smooth DC input voltage, the produced leakage current is less than 100
μA.
22. Certications
EC Declaration of
Conformity
Complies with:
- CE EMC directive
- CE Low-voltage directive
UL 508
LISTED E56639 for the use in the U.S.A. (UL 508) and Canada
(C22.2 No. 14-95). Industrial Control Equipment
ISA 12.12.01, CSA
C22.2 No. 213
RECOGNIZED UNDER FILE NUMBER E244404 for use in the U.S.A.
(ISA 12.12.01) and Canada (C22.2 No. 213)
Hazardous Location Class I, Div. 2 - Groups A, B, C, D
GOST R
GOST R certication is applicable for products intended for sale and
use within Russia. See below for link to Certicate.
C-TICK
C-tick compliance is for products intended for sale and use within
the Australian market. See below for the link to the C-tick Declaration
of Conformity.
Marine GLGL (Germanischer Lloyd) classied for marine and offshore
applications. Environmental category: C, EMC2. See below for link
to Certicate.
Marine Rina
RINA (Registro Italiano Navale) certied. See below for the link to
the certicate.
UL 60950-1
RECOGNIZED E168663 for use in the U.S.A. (UL 60950-1)
and Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3
CSA C22.2 No. 213
ISA 12.12.01
CSA Certied under File Number 240020; CERTIFIED for use in the
U.S.A. (ISA 12.12.01) and Canada (C22.2 No. 213)
Hazardous Location Class I, Div. 2 - Groups A, B, C, D
Product certification information (including Certificates and Declarations of Conformity) can be found at www.ab.com/certifications.
16Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 17
Bulletin 1606 Switched Mode Power Supplies
23. Environmental Compliance
The unit does not release any silicone and is suitable for use in paint shops.
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The materials used in our production process do not include the following toxic chemicals:
Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated
Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated
Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica
24. Physical Dimensions and Weight
Width 49mm / 1.93’’
Height 124mm / 4.88’’ Plus height of signal connector plug
Depth 117mm / 4.61’’ Plus depth of DIN rail
Weight 545g / 1.2lb
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 (117mm) to calculate the total required installation
depth.
Fig. 24-1 Side view
Fig. 24-2 Front view
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 201417
Page 18
Bulletin 1606 Switched Mode Power Supplies
25. Installation Notes
Mounting:
The power terminal shall be located on top of the unit. An appropriate electrical and re end-product enclosure should
be considered in the end use application.
Cooling:
Convection cooled, no forced air cooling required. Do not obstruct air ow!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left side are recommended when loaded
permanently with more than 5A. Do not place heat sources next to the 1606-XLS240-UPSE
since it can inuence the function of rthe internal temperature sensor. Keep a minimum of
15mm from the adjacent device.
Risk of electrical shock, re, personal injury or death!
Turn power o and disconnect battery fuse before working on the DC-UPS. Protect against inadvertently 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 object from penetrating in the housing. Do not use in wet locations or in areas where
moisture and condensation can be expected.
Service parts:
The unit does not contain any service parts. The tripping of an internal fuse is caused by an internal fault. If damage or
malfunctioning should occur during operation, immediately turn power o and send unit to the factory for inspection.
Wiring and installation instructions:
(1) Connect the power supply to the input terminals of the DC-UPS.
(2)
Connect the battery to the battery terminals of the DC-UPS. Do not install the battery in airtight housings or cabinets.
(3) Connect the buered load to the output terminals of the DC-UPS. The output is decoupled from the input allowing load
(4)
Install the fuse upon completion of the wiring.
Fig. 25-1 Typical wiring diagram
24V
Power
Supply
+
-
NLPE
DC-UPS
1606-XLS240
-UPSE
24V
IN
24V
OUT
12V
BAT
+
-+-+-
12V
Battery
Module
+
-
Buffered
Load
+
-
Non-
buffered
Load
+
-
24V
buffered
branches
24V
Non-bufferd
branches
The battery should be installed according to EN50272-2, which includes sucient ventilation. Batteries store energy and
must be protected against energy hazards. Use a 30A battery fuse type ATO® 257 30 (Littelfuse) or similar in the battery path.
The battery fuse protects the wires between the battery and the DC-UPS. It also allows the disconnection of the battery from
the DC-UPS which we recommend when working on the battery or DC-UPS. Disconnect battery fuse before connecting the
battery. Please note: Excessively long or short wires between the DC-UPS and battery may shorten the buer time or result
in a malfunction of the DC-UPS. Do not use wires smaller than 2.5mm² (or 12AWG) and no longer than 2x1.5m (cord length
1.5m). Avoid voltage drops on this connection.
circuits to be easily split into buered and non-buered sections. Noncritical loads can be connected directly to the|
power supply and will not be buered. The energy of the battery can then be used in the circuits that require buering.
18Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 19
Bulletin 1606 Switched Mode Power Supplies
26. Accessories
Battery Modules
One pre-assembled battery module with a single 12V battery is available. As an option, the mounting bracket is also
available without battery. This option oers more exibility in selecting an approriate battery or can save shipping and
logistics costs. See individual datasheets for detailed information.
1606-XLSBATASSY2
Battery type High current version12V, 26Ah VRLA lead-acid maintenance free battery
Service life 10 to 12years According to EUROBAT guideline
Dimensions 214x179x158mm Width x height x depth
Weight 9.9kg
DIN Rail mountable no
Order number 1606-XLSBATASSY2Battery module
1606-XLSBATBR2 Mounting bracket without battery
1606-XLSBAT2Replacement battery only
Fig. 27-1
1606-XLSBATASSY2
1606-XLB Wall / Panel mounting bracket
Use this bracket to mount the DC UPS units onto a at surface without using a DIN rail. Both the aluminium brackets and the
black plastic slider of the DC UPS must be removed so that the two surface brackets may be mounted.
Fig. 26-2 1606-XLB Wall / Panel Mounting Bracket
Fig 26-3 Assembled Wall / Panel Mounting Bracket
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 201419
Page 20
Bulletin 1606 Switched Mode Power Supplies
27. Application Notes
27.1.Battery Replacement Intervals
Batteries have a limited lifetime. They degrade slowly beginning from the production and need to be replaced
periodically, The design life gures can be found in the indidividual battery datasheets and are usually specied according
to the Eurobat guideline or according to the manufacturer’s specications.
The design life is the estimated life based on laboratory condition, and is quoted at 20°C using the manufacturer’s
recommended oat voltage condition. According to the Eurobat guideline, design lives have been structured into the
following distinct groups:
3 - 5 years:
This group of batteries is very popular in stand-by applications and in small emergency equipment.
This represents a 4 years design life with a production tolerance of ±1 year.
6 - 9 years:
This group of batteries is generally used when an improved life is required.
This represents a 7.5 years design life with a production tolerance of ±1.5 years.
10 - 12 years:
This group of batteries is used in applications for which longest life and highest safety level are
required. This represents a 11 years design life with a production tolerance of ±1 year.
A battery failure within the specied design life of the battery usually results in complete loss of battery
function (broken cell, faulty connection, …) and will be detected and reported by the periodical battery tests
included in the 1606-XLS240-UPSE DC-UPS control unit.
If the operational parameters dier from those specied for the design life, earlier replacement of the battery may prove
necessary. The “real life” is called service life and is dened as the point at which the cell’s actual capacity has reached
80% of its nominal capacity. At the end of the service life, capacity degrades much more rapidly, so that further use of
the battery is not recommended.
Temperature eect
Temperature has the greatest impact on service life of a battery. The hotter the temperature, the earlier the wear-out phase of the
battery begins. The wear-out results in a degradation of battery capacity. See Fig 27-1 for details.
Eect of discharging cycles
The number as well as the depth of discharging cycles is limited. Replacing the battery may prove necessary earlier than the
calculated service life if the battery exceeds the numbers and values in Fig. 27-2.
Other factors shortening service life
Overcharging and deep discharging shortens the service life and should be avoided. Thanks to the single battery
concept of the 1606-XLS240-UPSE, the end-of-charge-voltage can be set very precisely to the required value, thereby
preventing unnecessary aging eects.
Charge retention is important to achieve the longest battery life. Stored batteries not fully charged age faster than
fully charged batteries. Batteries which are not in use should be recharged at least once a year.
Excessive oat charge ripple across the battery has the ect of reducing life and performance. The 1606-XLS240-UPSE
does not produce such a ripple voltage. This eect may therefore safely be ignored if you’re charging a battery with
your 1606-XLS240-UPSE.
Guidelines for long battery service life
Place the battery in a cool location, for instance near the bottom of the control cabinet.
Do not place the battery near heat generating devices.
Do not store discharged batteries.
Do not discharge the battery more than necessary. Set buer time limiter to the required buer time.
When choosing the battery capacity, always try to get the next higher capacity than the one you require.
The depth of discharge reduces the battery service life and limits the number of cycles. See Fig. 27-2.
20Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 21
Bulletin 1606 Switched Mode Power Supplies
Example for calculating the service life and the required replacement cycle:
Parameters for the example:
A 26Ah battery with a design life of 10-12 years is used.
The average ambient temperature is 30°C.
One buer event consumes approx. 25% of the achievable buer time.
One buer event every two days
Calculation:
Ambient temperature inuence:
According to Fig. 27-1 curve C, a 5 years service life can be expected for an ambient temperature of 30°C.
Number of discharging cycles: 5 years * 182 cycles = 910cycles in 5 years.
According to Fig. 27-2, curve C has to be used (only 25% of battery capacity is required). 910 cycles have only a
negligible inuence in a battery degradation and can be ignored.
Result:
The battery shall be replaced after 5 years.
Please note that the battery degrading begins from the production date (check date code on the battery) which may
shorten the replacement intervals.
Fig. 27-1 Service life versus ambient
temperatures, typ. *)
Fig. 27-2 Cell capacity degradation vs. discharging
cycles *)
20°C
10
30°C35°C
40°C
45°C
8
6
4
2
Ambient Temperature
25°C
1
3
5
7
9
Service Life in Years
Design Life
of Battery
A:
3-5 Years
B:
6-9 Years
C:
10-12 Years
A
B
C
0
120%
100%
40%
20%
Number of Discharging Cycles
200
60%
80%
Cell Capacity
Depth of
discharge
A:
100%
B:
50%
C:
30%
400600800 1000 1200
A
B
C
*) datasheet gures from battery manufacturer
27.2.Parallel and Serial Use
Do not use the DC-UPS in parallel to increase the output power. However, two units of the DC UPS can be paralleled
for 1+1 redundancy to gain higher system reliability.
Do not use batteries in parallel, since the battery quality test might create an error message.
Do not connect two or more units in series for higher output voltages.
Do not connect two or more units in a row to get longer hold-up times.
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Rockwell Automation Publication 1606-RM013A-EN-P — March 201421
Page 22
Bulletin 1606 Switched Mode Power Supplies
27.3.Using the Inhibit Input
The inhibit input disables buering. In normal mode, a static signal is required. In buer mode, a pulse with a
minimum length of 250ms is required to stop buering. The inhibit is stored and can be reset by cycling the input
voltage.
As long as the inhibit signal is active in normal mode, an internal relay contact will be opened and the battery will
no longer be charged.
For service purposes, the inhibit input can also be used to connect a service switch. Therefore, the inhibit signal can
be supplied from the output of the DC UPS.
Fig. 28-3 Wiring example for inhibit input
24V
Power
Supply
+
-
DC-UPS
1606XLS240-UPSE
24V
IN
24V
OUT
12V
BAT
+-+-+
-
Signal Port
Inhibit
+
-
12V
Battery
Module
+
-
Buffered
Load
+
-
Service
Switch
27.4.Troubleshooting
The LEDs on the front of the unit and relay contacts indicate about the actual or elapsed status of the DC-UPS. Please
see also section 15
.
The following guidelines provide instructions for xing the most common failures and problems. Always start with
the most likely and easiest-to-check condition. Some of the suggestions may require special safety precautions. See
notes in section
25
rst.
“Check wiring” LED is on Check correct wiring between the battery and the DC-UPS.
Check battery fuse. Is the battery fuse inserted or blown?
Check battery voltage (must be typically between 7.4V and 15.1V).
Check input voltage (must be typically between 22.8V and 30V).
Check battery polarity.
DC-UPS did not buer
Inhibit input was set.
Battery did not have enough time to be charged and is still below the deep discharge
protection limit.
DC-UPS stopped buering Deep discharge protection stopped buering
use a larger battery, or allow
sucient time for ch
arging the battery.
Output was overloaded or short circuit reduce load.
Output has shut down
Cycle the input power to reset the DC UPS.
Let DC UPS cool down, over-temperature protection may have triggered.
DC-UPS constantly switches between normal mode and buer mode
The supplying source on the input is too small and can not deliver sucient current.
Use a larger power supply or reduce the output load.
22Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise.
It is assumed that the input power source can deliver a sufficient output current.
Page 23
Page 24
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support
notes, sample code and links to software service packs, and a MySupport feature that you can customize to
make the best use of these tools. You can also visit our Knowledgebase at http://
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software updates, and to sign up for product notification updates.
, you can find technical manuals, technical and application
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConne ct
representative, or visit http://www.rockwellautomation.com/support/
SM
support programs. For more information, contact your local distributor or Rockwell Automation
.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in
this manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada1.440.646.3434
Outside United States or CanadaUse the Wor ldw ide Loc ator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local
Rockwell Automation representative.
New Product Satisfaction Return
Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from
the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these
procedures.
United StatesContact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your
Outside United StatesPlease contact your local Rockwell Automation representative for the return procedure.
distributor to complete the return process.
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