Rockwell Automation 1606-XL240-UPSE User Manual

Reference Manual

General Description ............................................1

2. Specication Quick Reference .............................1

3. Catalog Numbers .....................................................1

4. Certication Marks

...................................................1

5. Input ............................................................................3

6. Output in Normal Mode

........................................4

7. Output in Buer Mode

............................................5

8. Battery Input

..............................................................6

9. Buer Time ...............................................................7

10. Eciency 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. Certications

..................................................... 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.

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 buer 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 Buer 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. Specication Quick Reference

Input voltage nom. 24Vdc range 22.5-30Vdc Output current min.15A Normal mode min. 10A Buer mode Output voltage typ. 0.23V lower

22.25V Buer mode, 10A Allowed batteries 17Ah to 130Ah VRLA lead acid Temperature range -25 to +50°C Dimensions 49x124x117mm WxHxD Buer time (at 10A) typ. 55 minutes 26Ah battery typ. 4 hours 100Ah battery

Typical setup of a DC-UPS system:

24V Power Supply

e.g.:

as input voltage

24V

DC-UPS

12V

Battery

Normal mode

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. Certication 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

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

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 buer mode and delivers

output voltage from the battery if the input was above the turn-on level before and all other buer conditions are fullled.

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 buering 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, denitions

A: Rated input voltage range B: Temp. allowed, no harm to the unit C: Absolute max. input voltage D: Buffer mode

18 30 35V22.50

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 eect 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.

20A

4812

20A

Output Voltage

20V

Overload

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.

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

02 10

0.1

0.15

0.25

18A

0.05

0.2

0.3

0.35

0.4V

468 121416

Output Voltage

05101520

28V

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 2014 5

Bulletin 1606 Switched Mode Power Supplies

7. Output in Buer Mode

If the input voltage falls below a certain value (transfer threshold level), the DC-UPS starts buering without any interruption or voltage dips. Buering is possible even if battery not fully charged.

Output voltage in buer 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 buering

typ. 80mV higher than the output voltage in buer 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 suci

ent to maintain the 24V, buering stops after another 5s.

Buering will again be possible as soon as the input voltage recovers.

**) If the nominal output voltage cannot be maintained in buer mode, the DC-UPS switches o after 5s to save battery

capacity.

Fig. 7-1 Buering transition, denitions

Buffer mode

Output voltage

24V

28V

Input voltage

Transfer

threshold

Fig. 7-3 Available output current in buer mode

Fig. 7-4 Output voltage vs. output current in buer mode, typ.

Output Current

05 Sec.

15A

10A

Time

BonusPower

Output Voltage

A B C

Continuously available Available for 5s then auto switching to curve

Buffering will stop after 5s

5101520

25V

25A

Output Current

A B

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.

8. Battery Input

The DC-UPS requires one 12V VRLA battery to buer 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 Buer mode, 10A output

current, 11.5V on the battery

terminal of the DC-UPS, see Fig. 8-1 for other parameters

typ. 0.3A Buer mode, 0A output current

max. 50μA At no input, buering had switched o, all LEDs are o typ. 270mA At no input, buering had switched o, yellow LED

shows “buer 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 buer 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 buer 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

buering when the voltage on the battery terminals of the DC-UPS falls below a certain value. The yellow LED will show “buer time expired” for a period of 15 minutes after the unit stopped buering.

Fig. 8-1 Battery discharging current vs. output current, typ.

Battery Current

30A

2.5 7.5 10 5.21A515

Voltage on battery terminal of the DC-UPS:

10.5V

11V

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

Bulletin 1606 Switched Mode Power Supplies

9. Buer Time

The buer time depends on the capacity and performance of the battery as well as the load current. The diagram below shows the typical buer times of the standard battery modules.

Buer 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

**) Buer 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

between the battery

and the DC-UPS and requires a fully charged (min. 24h) battery.

Fig. 9-1 Buer time vs. output current with a 65Ah and a 100Ah battery

Buffer Current

40 50

0.5

1.0

1.5

70 8060 90h30

65Ah Battery

100Ah Battery

Buffer Time (Hours)

30h

Buffer Current

10A

10 15 20 25

Buffer Time (Hours)

65Ah Battery

100Ah Battery

The battery capacity is usually specied 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 buer 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 “relled.”

For this reason, the buer 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.

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