Rockwell Automation 1606-XLS240UPSD User Manual

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLS240-UPSD

Index

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

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

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

4. Certication Marks

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

6. Output in Normal Mode

7. Output in Buer Mode

8. Battery Input

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

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

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

12. Check Wiring and Battery Quality Tests

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

14. Front Side User Elements ....................................13

15. Terminals and Wiring

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

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

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

..............................................................7

..........11

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

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

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

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

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

26.1. Battery Replacement Intervals

26.2. Parallel and Serial Use

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

26.4. Troubleshooting

................................. 24

.............. 19

....................... 23

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.

...... 22

Bulletin 1606 Switched Mode Power Supplies

Description

The 1606-XLS240-UPSD uninterruptible power supply (UPS) controller along with a standard 24V power supply and one 12V battery can bridge power failures or voltage uctuations. This unit can supply and bridge both a 24V load as well as a 12V load at the same time. The 12V is generated by a DC/DC converter from the 24V output. Therefore, systems that use 24V control circuits and require 12V for e.g. remote radio telemetry can be supplied with only one 1606-XLS240-UPSD DC-UPS controller.

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.

24V Power Supply

DC-UPS

Dual output

1606XLS240UPSD

12V Battery

24VDC

e.g.: PLC

12VDC

24V

Load

12V

Load

e.g.: radio

transmitter

DC-UPS, Dual Output

■ 24V DC-UPS With an Additional 12V Output for Various Applications

■ Only One 12V Battery Required

■ 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

Specication Quick Reference

Input voltage 24Vdc Nominal

22.5-30Vdc Input range

Output voltage (normal mode)

12V 12V output

Output voltage (buer mode)

Output current (normal mode)

Output current (buer mode)

Total output power

0.23V lower as input voltage

22.25V 12V

0 - 15A 0 - 5A

0 - 10A 10 – 15A for 5s 0 - 5A

360W 240W

Typ., 24V output

24V output at 10A 12V output at 5A

24V output 12V output

24V output 24V output 12V output

Normal mode

Buer mode Allowed batteries 3.9Ah to 40Ah VRLA lead acid Temperature range -25 to +70°C Operational Derating 6W/°C +50 to +70°C Dimensions 49x124x117mm WxHxD Buer time

typ. 6’30” 7Ah battery module

24V 7A, 12V 5A

typ. 54’ 26Ah module

24V 7A, 12V 5A

Catalog Numbers

DC-UPS 1606-XLS240-UPSD 24V and 12V output

Accessories

2 Rockwell Automation Publication 1606-RM017A-EN-P — February 2014

1606-XLSBATASSY1 1606-XLSBATBR1

1606-XLSBATASSY2 1606-XLSBARBR2

1606-XLB

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.

Battery module 12V 7Ah Mounting kit w/o battery

Battery module 12V 26Ah Mounting kit w/o battery

Panel/Wall mount bracket

It is assumed that the input power source can deliver a sufficient output current.

Certication Marks

IND. CONT. EQ.

UL 508

Marine RINA

UL 60950-1

GOST R

EMC, LVD

C-TICK

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 hazardous (pending), non-hazardous, ordinary or unclassified locations.

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-RM017A-EN-P — February 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. 140mA Internal current consumption for the DC-UPS

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,

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. Fig 5-3 shows the behavior when the 12V is not loaded. Power which is taken out from the 12V reduces the power on the 24V side.

20A

4812

20A

Output Voltage

20V

Overload

4 Rockwell Automation Publication 1606-RM017A-EN-P — February 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.

6. Output in Normal Mode

The total output power of 360W can be shifted dynamically between the two outputs.

24V Output:

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

input to output voltage drop.

Output voltage

Voltage drop between input and output

max. max.

0.3V

0.45V

At 10A output current, see Fig. 6-1 for typical values At 15A output current, see Fig. 6-1

for typical values

Ripple and noise voltage max. 20mVpp 20Hz to 20MHz, 50Ohm *) Output current nom. 0 – 15A Continuously allowed, lower if the 12V output is loaded.

min. 12.3A Output if 12V

output is loaded with 5A.

Short-circuit current min. 17.9A Load impedance 100mOhm, see Fig. 6-2 for typical values. The

12V output is o during an overload or short on the 24V.

max. 21A

Capacitive and inductive loads

No limitation

12V Output:

nom. DC 12V

Output voltage Output voltage tolerance

±2%

Ripple and noise voltage typ. 30mVpp 20Hz to 20MHz, 50Ohm *)

nom. 0 - 5A Continuously allowed, may be lower if the 24V output is loaded

more than 12.3A

Output current

Short-circuit current min.

Load impedance 100mOhm, see Fig. 7-5. for typical values. The 24V output is on during an overload or short on the 12V.

max. 5.5A

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 may 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

468 121416

Output Voltage

0 5 10 15 20

28V

25A

Output Current

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-RM017A-EN-P — February 2014 5

Bulletin 1606 Switched Mode Power Supplies

7. Output in Buer Mode

If the input voltage falls below the transfer threshold level, the DC-UPS starts buering without any interruption or voltage dips. The transfer threshold level is typically 80mV higher than the 24V output voltage in buer mode. Buering is possible even if the battery is not fully charged.

24V Output

Output voltage

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

22.45V ±1%, at no load,

22.25V ±1%, at 10A output current Ripple and noise voltage max. 20mVpp 20Hz to 20MHz, 50Ohm Output current nom. 0 - 10A Continuously allowed, 12V output not loaded.

10 - 15A *) 12V output not loaded.

min. 7.0A If 12V output is loaded with 5A.

Short-circuit current min. 17.9A Load impedance 100mOhm **); the 12V output is o during an

overload or short on the 24V.

max. 21A

12V Output

Output voltage

nom. DC 12V Output is stabilized and independent from battery voltage.

Output voltage tolerance

±2%

Ripple and noise voltage typ. 30mVpp 20Hz to 20MHz, 50Ohm ;

nom. 0 - 5A Continuously allowed, may be lower if the 24V output is loaded

more than 7.0A

Output current

Short-circuit current min. 4A Load impedance 100mOhm, see Fig. 7-5 for typical values.

Continuous constant; the 24V output is on during an overload or short on the 12V as long as the battery delivers current.

max. 5.5A

*) If the output current is in the range between 10A and 15A (Bonus Power) 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 at both outputs 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nition

Fig. 7-2 Transfer behavior, typ.

Buer mode

Output voltage

24V

28V

Input voltage

Transfer

threshold

6 Rockwell Automation Publication 1606-RM017A-EN-P — February 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

Fig. 7-4 24V 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

Fig. 7-5 12V Output voltage vs. output current in normal or buer mode, typ.

Output Voltage

Output Current

01 2 3

14V

45 6 A

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-RM017A-EN-P — February 2014 7

Bulletin 1606 Switched Mode Power Supplies

8. Battery Input

The DC-UPS requires one 12V VRLA battery to buer the 24V and 12V 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 Internal battery resistance max. 100mOhm See individual battery datasheets for this value 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

typ. 21A Buer mode, 240W output, 11.5V on the battery

terminal of the DC-UPS, see

Battery discharging current **)

Fig. 8-1 for other parameters typ. 0.3A Buer mode, 0A output current max. 50μ

At no input, buering had switched o, all LEDs are o

typ. 310mA 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 0% output load

typ. 9.0V At 100% output load

*) 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 at 24V output is 3h 20Min. for a 7Ah battery.

**) The current between the battery and the DC-UPS is more than twice the 24V 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 24 for additional 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 fall below a certain value.

Fig. 8-1 Battery discharging current vs. 24V output current, typ. (12V not loaded)

Fig. 8-2 Required input current vs. input voltage for battery charging (12V not loaded)

Battery Current

30A

2.5 7.5 10 5.21A515

Output Current

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

Input Voltage

24 25 26 28V

(

)

(

)

8 Rockwell Automation Publication 1606-RM017A-EN-P — February 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

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 24V output with the standard battery modules at 20°C.

Buer time with battery module 1606-XLSBATASSY1 min. 18’30’’ At 5A output current *)

min. 5’30’’ At 10A output current *) typ. 20’50’’ At 5A output current, see

Fig. 9-1 **)

typ. 6’30’’ At 10A output current, see Fig. 9-1 **)

Buer time with battery module 1606-XLSBATASSY2 min. 96’30’’ At 5A output current *)

min. 37’50” At 10A output current *) typ. 126’ At 5A output current, see Fig. 9-1 **) typ. 53’20” 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. 24V output current with the battery modules 1606-XLSBATASSY1 and 1606-XLSBATASSY2

Buer Current

515

10A

2010 25 30 35 45 5040 55 60 65 70 75 80 85

Buer Time (Minutes)

1606-XLSBATASSY2 typ.

1606-XLSBATASSY1 typ.

120 150 210 240

300

Min.

180 27090

1606-XLSBATASSY1 typ.

1606-XLSBATASSY2 typ.

The buer time is reduced if the 12V output is loaded. This can be calculated according to the following example:

Example:

24V, 5A and 12V, 4A load

Step1:

Convert the 12V current to a virtual 22.3V level:

Ratio: 12V/22.3V= 0.54 12V, 4A output converted to 22.3V level: 0.54*4A=2.15A

Step 2: Add the computed current to the actual 24V current:

2.15A+ 5A = 7.15A

Step 3: Determine the buer time by using the standard buer time curve

(

)

Fig. 9-1

7.15A load with 1606-XLSBATASSY2: Approx. 12 minutes buer time.

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 appropriable battery capacity. The magnitude of the reduction depends on the discharging cu rrent as well as on the type of battery. High current battery types can have up to 50% longer buer times co mpared to regular batteries when batteries will be 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

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-RM017A-EN-P — February 2014 9

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