Rockwell Automation 1606-XLS240-UPS User Manual

Reference Manual

1. Description

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

2. Specication Quick Reference

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

3. Catalog Numbers

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

4. Certication Marks

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

5. Input .............................................................................4

6. Output in Normal Mode .......................................5

7. Output in Buer Mode ..........................................6

8. Battery Input .............................................................7

9. Buer Time ................................................................8

10. Eciency and Power Losses ..............................10

11. Functional Diagram .............................................10

12. Check Wiring and Battery Quality Tests .......10

13. Relay Contacts and Inhibit Input ....................12

14. Front Side User Elements ..................................14

15. Terminals and Wiring ........................................15

16. Reliability ...........................................................15

17. EMC ........................................................................ 16

18. Environment ....................................................... 17

19. Protection Features .......................................... 17

20. Safety .................................................................... 18

21. Certications ................................................. 18

22.

Environmental Compliance ........................... 19

23. Physical Dimensions and Weight ................. 19

24. Installation Notes ............................................. 20

25. Accessories ........................................................... 21

26. Application Notes .............................................. 22

26.1. Battery Replacement Intervals .......... 22

26.2. Parallel and Serial Use ......................... 23

26.3. Using the Inhibit Input ........................ 24

26.4. Troubleshooting ................................... 24

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLS240-UPS

Index

Terminology and Abbreviations

•DC-UPS—Uninterruptible power supply with DC Input.

•Normal mode—Describes a condition in which 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 in the process of charging, the input voltage is in range and the output is loaded within the allowed limits.

• Inhibit mode—Describes a condition where buffering is intentionally disabled by using the inhibit input of the DC UPS (e.g. to perform service actions or to save battery capacity).

•Buffer time—This term is equivalent to “hold-up time.”

• T.b.d.—To be defined, value or description will follow later.

Bulletin 1606 Switched Mode Power Supplies

DC-UPS Control Unit

■

Requires Only One 12V Battery for a 24V Output

■

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

■

Selectable Buer Time Limiter

■

3 Year Warranty

1. Description

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

as input voltage

Normal mode

22.25V Buer mode, 10A Allowed batteries 3.9Ah to 40Ah VRLA lead acid Temperature range -25 to +70°C Operational

Derating 0.43A/°C

+60°C to +70°C

normal mode Dimensions 49x124x117mm WxHxD Buer time (at 10A) typ. 6’45” 7Ah battery module

typ. 55’ 26Ah batt. module

This uninterruptible power supply (UPS) controller 1606-XLS240-UPS is an addition to standard 24V power supplies to bridge power failures or voltage uctuations. Expensive downtimes, long restart cycles and loss of data can be avoided.

The DC-UPS includes 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-UPS 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.

The 1606-XLS240-UPS requires one external 12V battery for which two preassembled battery modules are available: a lightweight 7Ah battery that can be mounted on the DIN rail and a 26Ah module that can be panel-mounted for longer buer times.

In addition to the 1606-XLS240-UPS, the 1606-XLS240-UPSC UPS includes the same controller with an integrated 5Ah battery.

Typical setup of a DC-UPS system with the 1606-XLS240-UPS:

24V Power Supply

12V

Battery

24V

DC-UPS

24V

Load

AC DC

e.g.: PLC

3. Catalog Numbers

4. Certication Marks

DC-UPS

1606-XLS240-UPS

Standard controller

Accessories 1606-XLSBATASSY1 Battery module 12V 7Ah

1606-XLSBATBR1 Mounting kit w/o battery

IND. CONT. E

UL 508

UL 60950-1

Class I Div 2

1606-XLSBATASSY2 Battery module 12V 26Ah 1606-XLSBATBR2

Mounting kit w/o battery

1606-XLB

Panel/Wall mount bracket

EMC, LVD

Marine

GOST R

C-Tick

Marine RINA

2 Rockwell Automation Publication 1606-RM036A-EN-P — April 2014

All parameters are specified at 24V, 10A output load 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

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 non-hazardous, ordinary or unclassified locations.

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.

• 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.

All parameters are specified at 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-RM036A-EN-P — April 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

typ. 1.1A Current consumption for battery charging in constant

current mode at 24V input See

Fig. 8-2 ***)

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 plus the current required to charge the battery during the charging

process and the current which is needed 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 owing into the battery in the process of charging. The battery current

is indicated 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: Buer 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)

Electronic 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 limit ation 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-RM036A-EN-P — April 2014

All parameters are specified at 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

nom. DC 24V The output voltage follows the input voltage reduced by

the input to output voltage drop.

Output voltage in normal mode

max. 0.3V At 10A output current, see Fig. 6-1 for typical values Voltage drop between input and

output

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 Continuously 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

*) This gure shows the ripple and noise voltage which is generated by the DC-UPS. The ripple and noise voltage

might be higher if the supplying source has a higher ripple and noise voltage.

Fig. 6-2 Output voltage vs. output current in

normal mode at 24V input, typ.

Fig. 6-1 Input to output voltage drop, 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

4 6 8 121416

Output Voltage

05101520

28V

25A

Output Current

All parameters are specified at 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-RM036A-EN-P — April 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 the battery is not fully charged.

nom. DC 24V Output voltage is stabilized and independent from

battery voltage

Output voltage in buer mode

22.45V ±1%, at no load,

22.25V ±1%, at 10A output current

typ. 80mV higher than the output voltage in buer mode Transfer threshold for buering

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cient to maintain the 24V, buering stops after another 5s. Buering is possible again 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 Fig. 7-2 Transfer behavior, typ.

Buer mode

Output voltage

24V

28V

Input voltage

Transfer

threshold

Fig. 7-4 Output voltage vs. output current

in buer mode, typ.

Fig. 7-3 Available output current in

buer mode

Output Voltage

A B C

Continuously available Available for 5s then auto switching to curve

Buering will stop after 5s.

5101520

25V

Output Current

A B

Buering will stop after 5s.

Output Current

05 Sec.

15A

10A

Time

BonusPower

6 Rockwell Automation Publication 1606-RM036A-EN-P — April 2014

All parameters are specified at 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

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.

9.0 – 15.0V Continuously allowed, except deep discharge protection

Battery voltage range max. 35Vdc Absolute maximum voltage with no damage to the unit

typ. 7.4V Above this voltage level battery charging is possible.

Allowed battery sizes min. 3.9Ah max. 40Ah

max. 100mOhm See individual battery datasheets for this value. Internal battery resistance

Battery charging method CC-CV Constant current, constant voltage mode Battery charging current (CC-mode) nom. 1.5A Independent from battery size,

max. 1.7A Corresponding 24V input current see Fig. 8-2

End-of-charge-voltage (CV-mode) 13.4-13.9V Adjustable, see section 14. Battery charging time typ. 5h *) For a 7Ah battery typ. 17h *) For a 26Ah 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. 50 μA 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)

typ. 10.5V At 0A output current

Deep discharge protection ***) typ. 9.0V 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. A typical gure for a buer current of 10A is 3h 20 min (200 min) for a 7Ah 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 25 for further 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.

Fig. 8-2 Required input current vs. input

voltage for battery charging

Battery Current

30A

2.5 7.5 10 15A12.55

Voltage on battery terminal of the DC-UPS:

10.5V

11V

12V

A B C

Input Current

0.5

1.0

0.25

0.75

1.25

1.5A

24 25 26 28V

(

)

(

)

All parameters are specified at 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-RM036A-EN-P — April 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 battery module 1606-XLSBATASSY1 min. 19’12’’ At 5A output current *)

min. 5’42’’ At 10A output current *) typ. 21’30’’ At 5A output current, see Fig. 9-1 **) typ. 6’45’’ At 10A output current, see

Fig. 9-1 **)

Buer time with battery module 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 **)

*) 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 the battery modules 1606-XLSBATASSY1 and 1606-XLSBATASSY2

Buer Current

515

10A

2010 25 30 35 45 550405 60 65 70 75 80 85

Buer Time (Minutes)

-X

6-XL

SBA

120 150 210 240

300

Min.

180 27090

606

-X

SBA

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 1 hour.

High discharging currents do not necessarily mean high power losses as the appropriable 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 which was taken out of the battery needs to be “replenished.”

For this reason, the buer time cannot be calculated using the Ah capacity value. The equation “l x t = capacity” in Ah generally leads to incorrect results when the discharging current is higher than C20 (discharging current for 20h). Study the battery datasheet and determine the expected buer time by using the example on the next page.

1606-XLSBAT1 typ.

8 Rockwell Automation Publication 1606-RM036A-EN-P — April 2014

All parameters are specified at 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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