![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg1.png)
Reference Manual
1.
General Description ............................................1
2. Specication Quick Reference .............................1
3. Catalog Numbers .....................................................1
4. Certication Marks
...................................................1
5. Input ............................................................................3
6. Output in Normal Mode
........................................4
7. Output in Buer Mode
............................................5
8. Battery Input
..............................................................6
9. Buer Time ...............................................................7
10. Eciency and Power Losses .................................8
11. Functional Diagram .............................................8
12. Check Wiring and Battery Quality Tests
............9
13. End-of-Charge Voltage
..........................................9
14. Relay Contacts and Inhibit Input .....................10
15. Front Side User Elements ....................................11
16. Terminals and Wiring
...........................................12
17. Reliability .......................................................... 12
18. EMC ...................................................................... 13
19. Environment ................................................... 14
20. Protection Features .................................... 14
21. Safety .................................................................. 15
22. Certications
..................................................... 15
23. Environmental Compliance ......................... 16
24. Physical Dimensions and Weight
.............. 16
25. Installation Notes ......................................... 17
26. Accessories ........................................................ 18
27. Application Notes ......................................... 19
27.1. Battery Replacement Intervals
...... 19
27.2. Parallel and Serial Use
....................... 20
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.
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg2.png)
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
Typical setup of a DC-UPS system:
AC
24V
Power
Supply
e.g.:
as input voltage
24V
DC-UPS
12V
Battery
Normal mode
DC
24V
Load
e.g.: PLC
3. Catalog Numbers
DC UPS
Accessories 1606-XLSBAT2 Battery module 12V 26Ah
1606-XLSBATBR23 Mounting kit w/o battery
1606-XLS240-UPSE Controller
1606-XLB Panel/Wall mount bracket
4. Certication Marks
IND. CONT. EQ.
UL 508
C-Tick
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.
2 Rockwell Automation Publication 1606-RM013A-EN-P — March 2014
UL 60950-1
UL 508
GOST R
EMC, LVD
Marine RINA
Marine
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg3.png)
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 2014 3
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg4.png)
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
18 30 35V22.50
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
4 Rockwell 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.
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg5.png)
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
02 10
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
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 2014 5
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg6.png)
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
min. 17.9A Load impedance 100mOhm **)
max. 21A Load impedance 100mOhm **)
*) 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
A B
CD
D
Buffering will stop after 5s
Fig. 7-2 Transfert behavior, typ.
6 Rockwell 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.
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg7.png)
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
2.5 7.5 10 5.21A515
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 2014 7
![](/html/c5/c518/c518bce3c4b17f001cb6c57625fef9bf2f8663830053ea8df2a9901fb185287a/bg8.png)
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
40 50
0.5
1.0
1.5
2A
70 8060 90h30
A
B
A:
65Ah Battery
B:
100Ah Battery
Buffer Time (Hours)
30h
Buffer Current
0
5
2
4
6
8
10A
10 15 20 25
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).
8 Rockwell 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.