Rockwell Automation 1606-XLDC92D User Manual

Reference Manual

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1.

Intended Use .......................................................3

2. Installation Requirements...................................3

3. Input Voltage ......................................................4

4. Soft-start and Input Inrush Current Surge .........5

5. Output .................................................................6

6. Hold-up Time.......................................................7

7. Efciency and Power Losses................................8

8. Functional Diagram.............................................9

9. Front Side and User Elements.............................9

10. Terminals and Wiring ........................................10

11. Reliability ...........................................................10

12. EMC ....................................................................11

13. Environment ......................................................12

14. Protection Features ...........................................12

15. Safety Features ..................................................13

16. Dielectric Strength ............................................13

17. Environmental Compliance .............................13

18. Certications

................................................... 14

19. Physical Dimensions and Weight ..................... 15

20. Accessories ........................................................ 16

21. Application Notes ............................................. 17

21.1. Peak Current Capability ...........................17

21.2. Back-feeding Loads ..................................17

21.3. Inductive and Capacitive Loads ................ 17

21.4. External Input Protection .........................18

21.5. Requirements for the Supplying Source .. 18

21.6. Parallel Use to Increase Output Power ....18

21.7. Parallel Use for Redundancy ....................18

21.8. Series Operation ....................................... 19

21.9.Charging Batteries ...............................19

21.10. Use in a Tightly Sealed Enclosure ............ 19

21.11. Mounting Orientations ............................ 20

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLDC92D

Index

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.

• DC 24V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances included.

E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)

• 24Vdc—A figure with the unit (Vdc) at the end is a momentary figure without any additional tolerance included.

Bulletin 1606 Switched Mode Power Supplies

Description

The 1606-XLDC92D DC/DC converter is installable on a
DIN rail and provides a 92-120W output power range
in a very compact housing.
This DC/DC converter is allowed to run with a battery
or similar source. It may also be used to refresh and
stabilize the 24Vdc on the end of long cable runs.
This unit includes all the essential basic functions,
with a powerboost of 20% incorporated. This extra
power can even be used continuously, up to +45°C.

DC/DC Converter

24V DC-Input
Isolated 24Vdc Output
NEC Class 2 Output
Efciency up to 90.5%
Width only 32mm
Full Power Between -25°C and +60°C
Soft-start Function Included
Minimal Inrush Current Surge
Reverse Input Polarity Protection
3 Year Warranty

Specication Quick Reference

Output voltage DC 24V
Adjustment range not adjustable
Output current 3.8A NEC Class 2
Output power 92W
Output ripple < 50mVpp 20Hz to 20MHz
Input voltage DC 24V
Input voltage range 14.4 to 32.4Vdc full specied
Input current typ. 4.25A at 24Vdc input
Input inrush current typ. 1.2A peak
Efciency 90.5% at 24Vdc input
Losses 9.7W at 24Vdc input
Temperature range -25°C to +70°C operational
Derating 0W/°C +60 to +70°C
Hold-up time typ. 7ms at 24Vdc input
Dimensions 32x124x102mm WxHxD

Catalog Numbers

DC/DC Converter 1606-XLDC92D Standard unit

Accessory 1606-XLB Wall mount bracket

Certications

C-Tick

ATEX

Ind. Cont. Eq.

UL 508, NEC Class 2

IECEx

II 3G Ex nA IIC T4 Gc

All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2 Rockwell Automation Publication 1606-RM023A-EN-P — January 2014

Class I Div 2

Class I Div 2

Marine RINA

Marine

UL 60950-1
UL 61010-1

EMC, LVD

Gost R

Bulletin 1606 Switched Mode Power Supplies

1. Intended Use

• 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.

• This device is designed for use in hazardous (pending), non-hazardous, ordinary or unclassified locations.

2. Installation Requirements

• This device may only be installed and put into operation by qualified personnel.

• This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.

• If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.

• Mount the unit on a DIN rail so that the terminals are located on the bottom of the unit. For other mounting orientations, refer to derating

requirements in this document.

• This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid
(e.g. cable conduits) by more than 30%!

• Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the
device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat
source (e.g. another power supply).

SHOCK HAZARD: Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input

block for earth connection and not one of the screws on the housing.

- Turn power off before working on the device. Protect against inadvertent re-powering

- Make sure that the wiring is correct by following all local and national codes

- Do not modify or repair the unit

- Do not open the unit as high voltages are present inside

- Use caution to prevent any foreign objects from entering the housing

- Do not use in wet locations or in areas where moisture or condensation can be expected

- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.

WARNING: EXPLOSION HAZARDS!

Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment or S/P jumper unless
power has been switched off or the area is known to be non-hazardous.

Notes for use in hazardous location areas:

• The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations

All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM023A-EN-P — January 2014 3

Bulletin 1606 Switched Mode Power Supplies

3. Input Voltage

Input voltage nom. DC 24V
Input voltage range 14.4-32.4Vdc full specied
max. 36.0Vdc absolute maximum continuous input voltage with no

damage to the DC/DC converter

Allowed voltage between input
and earth

max. 60Vdc or

42.2Vac

in case the output voltage is not grounded.

Allowed input ripple voltage

max. 5Vpp 47Hz-40kHz, the momentary input voltage must always

be within the specied limits.
Turn-on voltage typ. 17.5Vdc steady-state value, see Fig. 3-1
Shut-down voltage typ. 14.0Vdc steady-state value, see Fig. 3-1
typ. 35.0Vdc steady-state value, see Fig. 3-1
Input current typ. 4.25A at 24Vdc input and output 24V, 3.8A, see Fig. 3-3
Start-up delay typ. 290ms see Fig. 3-2
Rise time typ. 520ms 0mF, 24V, resistive load 3.8A, see Fig. 3-2
typ. 610ms 3.8mF, 24V, resistive load 3.8A, see Fig. 3-2
Turn-on overshoot max. 500mV see Fig. 3-1
Input capacitance typ. 3 000μF external capacitors on the input voltage bus are allowed

without any limitations.

Fig. 3-1 Input voltage range

Turn-on

17.

5Vdc

V

IN

P

OUT

Shut-down

4Vdc

0Vdc

4Vdc

32.

14.

14.

Rated input range

35.

0Vdc

Fig. 3-2 Turn-on behavior, denitions Fig. 3-3 Input current vs. output load

Start-up

delay

Rise

Time

Ov

4A

ershoot

- 5%

Output
Voltage

Input
Voltage

1

1.5 2

3

0

1

3

5

6A

Output Current

2.5

3.5

0.5

Input Current, typ

I

n

p

u

t

:

1

8

V

d

c

2

4

I

n

pu

t

:

2

4

Vdc

4 Rockwell Automation Publication 1606-RM023A-EN-P — January 2014

All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

4. Soft-start and Input Inrush Current Surge

Inrush current limitation

An active inrush limitation circuit (inrush limiting resistor which is bypassed by a relay contact) limits the input inrush
current after turn-on of the input voltage.

The charging current into EMI suppression capacitors is disregarded in the rst microseconds after switch-on.

Inrush current max. 1.6A

peak

-25°C to +70°C, input: 24Vdc

typ. 1.2A

peak

-25°C to +70°C, input: 24Vdc

Inrush energy typ. negligible -25°C to +70°C, input: 24Vdc

Fig. 4-1 Input inrush current, typical behavior

Input Current

Input Voltage

Output Voltage

Input: 24Vdc
Output: 24V, 3.8A, constant current load
Ambient: 25°C

Upper curve: Input current 2A / DIV
Middle curve: Input voltage 20V / DIV
Lower curve: Output voltage 20V / DIV
Time basis: 100ms / DIV

Soft-start function:

After the DC/DC converter is turned on, the internal output current rises slowly to its nominal value. This method
charges the output capacitors (internal and external capacitors) slowly and avoids high input currents during turn-on.
High input currents can produce a high voltage drop on the input wiring (especially with long and thin cables) which
reduces the terminal voltage on the DC/DC converter. If the terminal voltage is below the shut-down voltage, the
DC/DC converter will turn-off and will make a new start-up attempt. This effect is avoided with the integrated soft­start function. Please note, that this function increases the rise time of the output voltage by a small amount.

Fig. 4-2 Soft-start behavior

Input Current

Input: 24Vdc
Output: 24V, 3.8A, constant current load
Ambient: 25°C

No additional external output capacitors

Upper curve: Input current 2A / DIV
Lower curve: Output voltage 10V / DIV
Time basis: 20ms / DIV

Output Voltage

All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM023A-EN-P — January 2014 5

Bulletin 1606 Switched Mode Power Supplies

5. Output

Output voltage nom. 24V
Adjustment range min. - not adjustable
Factory setting 24.1V ±0.2%, at full load, cold unit
Line regulation max. 25mV Input voltage variations between 18 to 32.4Vdc
Load regulation max. 100mV static value, 0A 3.8A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output current nom. 3.8A see Fig. 5-1
Output power nom. 92W
Short-circuit current min. 3A continuous current, short circuit impedance 200mOhm
max. 6A continuous current, short circuit impedance 200mOhm
Output capacitance typ. 2 200μF

Fig. 5-1 Output voltage vs. output current,

typ.

Fig. 5-2 Current limitation vs. input voltage,

(23V constant voltage load), typ.

Output Voltage

0

024

4

8

12

28V

16

20

24

6

A

315

Output Current

Output Current

3.8

14 18 22

3.9

4.0

4.1

4.3A

4.2

Input Voltage

3.7
610242 26283032Vd

c

Peak current capability (up to several milliseconds)

The DC/DC converter can deliver a peak current, which is higher than the specied 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 DC/DC converter. During this event, the capacitors will
be discharged and causes a voltage dip on the output. Detailed curves can be found in section 22.1.

Peak current voltage dips typ. from 24V to 16V at 7.6A for 50ms, resistive load
typ. from 24V to 12.5V at 15.2A for 2ms, resistive load
typ. from 24V to 8.5V at 15.2A for 5ms, resistive load

6 Rockwell Automation Publication 1606-RM023A-EN-P — January 2014

All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

6. Hold-up Time

The input side of the DC/DC converter is equipped with a bulk capacitor which keeps the output voltage alive for a
certain period of time when the input voltage dips or is removed. The bulk capacitor can be discharged by loading the
DC/DC converter on the output side or through a load which is parallel to the input. There is no protection in the
DC/DC converter which prevents current from owing back to the input terminals. If prevention is needed, an external
diode should be used.

Hold-up Time typ. 13.8ms input 24Vdc, output: 24Vdc, 1.9A, see Fig. 6-1
typ. 7ms input 24Vdc, output: 24Vdc, 3.8A, see Fig. 6-1

Fig. 6-1 Hold-up time vs. input voltage

0

2

4

6

8

12ms

18 20 22 24 28Vdc

Input Voltage

Hold-up Time

(a) 24V, 1.9A, typ.
(b) 24V, 1.9A, min.
(c) 24V, 3.8A, typ.
(d) 24V, 3.8A, min.

10

26

(

a

)

(

b

)

(

c

)

(

d

)

Fig. 6-2 Shut-down test setup Fig. 6-3 Shut-down behavior, denitions

Load

+

-

DC/DC

Converter

DC

Source

+

-

Input

Output

+

-

S1

- 5%

Hold-up Time

Output
Voltage

Intput
Voltage

S1 opens

Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on at this time.

All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM023A-EN-P — January 2014 7