Rockwell Automation 1606-XLSBUFFER48 User Manual

Reference Manual

1. Description .............................................................. 1

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

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

4. Certication Marks .............,..................................... 1

5. Standby Mode ........................................................4

6. Charging Mode ..................................................... 4

7. Buer Mode ............................................................ 5

8. Functional Diagram ............................................. 6

9. Front Side and User Elements ........................ 6

10. Operating Diagram ............................................. 7

11. Active and Ready Signal, Inhibit Input .......... 7

12. Terminals and Wiring .................................... 8

13. Reliability .......................................................... 8

14. EMC ...................................................................... 9

15. Environment ................................................... 9

16. Protection Features .................................. 10

17. Safety ................................................................ 10

18. Certications

.................................................. 10

19. Physical Dimensions and Weight ......... 11

20. Wiring Diagrams ........................................ 12

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLSBUFFER48

Index

Installation Notes

Mounting Orientation—The power terminal shall be located on top of the unit.

Cooling—Convection cooled, no forced air cooling required. Do not obstruct air flow!

Recommended Installation Clearances—40mm on top of unit; 20mm on bottom of unit; 0mm (or 15mm if adjacent device is a heat source) on

the left and right sides of the unit.

Intended Use—This buffer unit is designed for use in panel board installations or other in-building applications where a suitable mechanical
enclosure is provided to fulfil local requirements.

Service Parts—This unit does not contain any service part. Should damage or malfunction occur during installation, turn power off immediately and
return unit to the manufacturer for inspection.

Bulletin 1606 Switched Mode Power Supplies

Buer Unit

■

Buering with electrolytic capacitors instead
of lead batteries

■

Buering of 48V loads

■

Minimum hold-up time 0.1s at 20A and 0.2s at 10A

■

Longer hold-up time at lower loads

■

Clear status indication by status LED and signaling
terminals

■

Quick-connect spring-clamp terminals

■

3 year warranty

1. Description

2. Specication Quick Reference

Rated voltage DC 48V
Voltage range 48-56V
Output voltage 45V or

V

IN

–2V

Buer mode
select with jumper

Output current 0 to 20A

Hold-up time

min 0.1s 45V, 20A
typ 0.15s 45V, 20A
min 13.4s 45V, 0.1A
typ 21s

45V, 0.1A

Charging current

max 500mA

Charging time

typ 21s

Input current typ 40mA standby mode
Power dissipation typ 1.9W standby mode
Temperature range

-25°C to +70°C operational

Dimensions 64x124x102mm WxHxD

The buer unit is a supplementary device for regulated
DC48V power supplies. It buers load currents during
typical mains faults and load peaks.

Working principle

In times when the power
supply provides sucient
voltages, the buer unit
stores energy in integrated electrolytic capacitors. In case of
mains voltage fault, this energy is released again in a
regulated process.

Bridges mains faults
without interruption

Statistic show that 80% of
all mains fault lasts less
than 0.2s. These mains
faults are completely bridged by the buer unit. This
increases the reliability of the system as a whole.

Extended hold-up time

Once mains power fails or
is switched o, the buer
unit will continue to
provide the load current
for a dened period of time. Process data can be saved and
processes can be terminated before the DC power switches
o. Controlled restarts are subsequently possible.

Easy to handle, expandable and maintanance-free

The buer unit does not require
any control wiring. It can be
added parallel to the load circuit
at any given point. Buer units
can be switched in parallel to
increase the output ampacity or the hold-up time.

DC

Charge

Discharge

Buffer

AC

DC

Buffer Unit

AC

DC

Buffer Unit

DC

Buffer

Unit(s)

Power

Supply

Load

AC

+

-

3. Catalog Numbers

4. Certication Marks

Buer Unit

1606-XLSBUFFER48

48V, 20A, 200ms

Accessory 1606-XLB Wall mounting

bracket

UL 508

UL 60950-1

EMC, LVD

C-Tick

GOST R

2 Rockwell Automation Publication 1606-RM027A-EN-P — April 2014

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

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 equipment 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. 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, 0mm 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, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM027A-EN-P — April 2014 3

Bulletin 1606 Switched Mode Power Supplies

5. Standby Mode

Input voltage

nom. DC 48V

Voltage range

nom. 48-56Vdc

Input current

typ. 40mA

Power dissipation typ. 1.9W
Status lamp always on
Active signal high ohmic

Ready signal

low ohmic

6. Charging Mode

Charging current

min. 0.3A Charging mode
max. 0.5A Charging mode

Charging time

min. 22s / 17s

Initial charge

1)

/ Re-charging

2)

max. 32s / 25s

Initial charge

1)

/ Re-charging

2)

Status lamp ashes 1.25Hz

Active signal high ohmic

Ready signal

high ohmic

1) Initial charging is the rst charge after voltage is applied to the buer unit.

2) Re-charging is the charging of the internal capacitors after voltage interruptions of less than 2 minutes.

Fig. 6-1 Re-charging time, 48V

Charge

20

0 5 10 30s

Charging Time

40

80

60

100%

15 20 25

m

a

x

m

i

n

4 Rockwell Automation Publication 1606-RM027A-EN-P — April 2014

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

7. Buer Mode

Rated output current nom. 20A
Current limitation min. 20A Electronically limited

Output voltage typ. 45V Jumper in position “45V xed”

typ.

2V below input
voltage

Jumper in position “Vin –2V”

Ripple and noise voltage max.

max. 400mVpp 10A, 20 Hz to 20 MHz, 50Ohm
max. 600mVpp 20A, 20Hz to 20MHz, 50Ohm
may increase below -10°C

250mVpp 5A, 20Hz to 20MHz, 50Ohm

Hold-up time min. 0.1s 45V, 20A
typ. 0.15s 45V, 20A
min. 13.4s 45V, 0.1A
typ. 21s 45V, 0.1A

To increase buer current or extend hold-up time, any given number of buer
units can be installed in parallel.

Activation threshold typ. 45V Jumper in position “45V xed”

Buering starts if terminal voltage falls below 22.5V.

typ. Vin –2V Jumper in position “Vin –2V”

Buering starts if the terminal voltage decreases by
more than 2V. Buering ends when terminal voltage
increases by more than 2V.
Voltage changes slower than 1.1V/s will be ignored
unless the voltage is above 45V. Below 45V
buering starts immediately.

Status lamp

ashes 10Hz

Active signal low ohmic

Ready signal

high ohmic

Fig. 7-1 Hold-up time

0,01 A

0,10 A

1,00 A

10,00 A

100,00 A

0,1 s 1,0 s 10,0 s 100,0 s

Buffe r

Curr ent

typ. ( 45,0 V )

typ. ( 56,0 V )

min . ( 4 5 V )

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM027A-EN-P — April 2014 5

Bulletin 1606 Switched Mode Power Supplies

8. Functional Diagram

Fig. 8-1 Functional diagram

Buffer Capacitor

Charger &

Inrush Limiter

Buffer

Capacitor

Buffer Capacitor

Discharger

Status
lamp

7 Active

6 +

Ready Monitor

+

-

Active Monitor

+

-

Optokoppler

Optokoppler

8 Ready

9 Inhibit

Optokoppler

Buffer

Capacitor

Shut-Down

Input / Output

Voltage Monitor

Back-up

Level

Selector

Reverse-

Polarity

Protection

-

-

+

+

Safety and

Over-

Voltage

Protection

Chassis
Ground

9. Front Side and User Elements

Fig. 9-1 Front side

A. I/O Power Port

Quick-connect spring-clamp
terminals,

+ Positive terminal

- Negative terminal
Chassis Ground

to bond the housing

B. Status lamp
OFF: Buer is discharged, or

terminal voltage is below 22V

ON: Unit is fully charged
Flashes 1,25Hz:

Unit is in charging mode

Flashes 10Hz:

Unit is in discharging mode

C. Signal Port

Plug Connector

6 common + pole
7 Active : unit is buering
8

Ready: unit is on stand-by

9

Inhibit : initiates buer

discharging and inhibits
recharging of capacitors

D. Back-up threshold jumper
1-2: Variable mode

Unit switches to buer mode when input
voltage decreases by 1V within 1.1V/s or
the input voltage falls below 45V.

2-3: Fixed mode, (factory setting)
Unit switches to buer mode as soon as the
voltage falls below 45V

Missing jumper = 45V xed

Set the unit to xed mode:

-

when using other power supplies
than the 1606-XLS series

-

with back-feeding loads

-

when the buer unit is placed close to
the load

-

whenever in doubt

Set the unit to variable mode:

-

for 48V applications

-

when the buer unit is placed close to
the power supply

A

B

C

D

6 Rockwell Automation Publication 1606-RM027A-EN-P — April 2014

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

10. Operating Diagram

Fig. 10-1 Operating diagram

Fig. 10-2 Signals schematic

Ready

t

Acti ve

t

Optocoupler high ohmic

Optocoupler high ohmic

Optocoupler low ohmic

Optocoupler

low ohmic

V

Mains

t

V

Buffer

Capacitor

t

V

out

t

Charging Mode

LED

t

Buffer Mode

Hold-up Time Power Supply

Standby

Mode

10Hz1.25Hz

8 Ready

7 Active

6 +

5,1V

3mA

9 Inhibit

11. Active and Ready Signals, Inhibit Input

Active signal (Pin 7)

low ohmic while buer capacitors are discharging
Signal voltage max. 60Vdc
Signal current max. 6mA
Voltage drop across opto-coupler typ 1.2V / 3.3V at 1mA / 5mA, while opto-coupler is low ohmic
Leakage current max. 50μA while opto-coupler is high ohmic
Isolation nom. 500Vac signal port to power port

Ready signal (Pin 8)

low ohmic when buer is fully charged
Signal voltage max. 60Vdc
Signal current max. 6mA
Voltage drop across opto-coupler typ 1.2V / 3.3V at 1mA / 5mA, while opto-coupler is low ohmic
Leakage current max. 50μA while opto-coupler is high ohmic
Isolation nom. 500Vac signal port to power port

Inhibit input (Pin 9)

“High” input signal initiates unit shutdown and buer discharge
Signal voltage max. 60Vdc
Signal current max. 4mA current limited
Shut-down threshold min. 6Vdc unit is in shut-down mode above this threshold level.
max. 10Vdc
Isolation nom. 500Vac signal port to power port

Wiring diagrams can be found in section 20.

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM027A-EN-P — April 2014 7

Bulletin 1606 Switched Mode Power Supplies

12. Terminals and Wiring

Power terminal

Type Bi-stable, quick-connect spring clamp terminals. IP20 Finger-safe construction.

Suitable for eld- and factory installation. Shipped in open position.

Solid wire 0.5-6mm

2

Stranded wire 0.5-4mm

2

AWG 20-10AWG
Ferrules Allowed, but not required
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)
Wire stripping length 10mm / 0.4inch

Fig. 12-1 Connecting a wire

Instructions:

a) Use appropriate copper cables designed

for an operating temperature of 60°C.
b) Follow national installation codes and regulations.
c) Ensure that all strands of a stranded wire are fully

inserted in the terminal connection.
d) Up to two stranded wires with the same cross-

section are permitted in one connection point.

1. Insert the wire 2. Snap the lever

To disconnect wire : reverse above procedure.

Signal terminal

Type Plug connector with screw terminal mechanism.

Finger-touch-proof terminal with captive screws for 3.5mm slotted screwdriver.

Solid / stranded wire

0.2-2.5mm

2

AWG 22-14AWG
Ferrules

up to 1.5 mm

2

wire gauge
Wire stripping length 6mm / 0.24inch
Tightening torque 0.4Nm, 3.5lb.in

13. Reliability

Lifetime expectancy min. 41 000h 40°C, stand-by mode

min. 116 000h 25°C, stand-by mode

MTBF SN 29500, IEC 61709 2 348 000h 40°C, stand-by mode

4 231 000h 25°C, stand-by mode

MTBF MIL HDBK 217F 405 000h 40°C, stand-by mode, ground benign GB40

636 000h 25°C, stand-by mode, ground benign GB25

The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the
lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specied in operational hours.
Lifetime expectancy is calculated according to the capacitor’s manufacturer specication.

MTBF means Mean Time Between Failures, which is calculated according to statistics of device failures, and

indicates reliability of a device. It is the statistical representation of the likelihood of failure of a given device, and
does not necessarily represent the life of a product.

8 Rockwell Automation Publication 1606-RM027A-EN-P — April 2014

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

14. EMC

The unit is suitable for applications in industrial environnent as well as in residential, commercial and light industry
environments without any restriction. The CE Mark is in conformance with EMC guidelines 89/336/EEC and 93/68/EEC and
the low-voltage directive (LVD) 73/23/EWG.

A detailed EMC Report is available on request

EMC Immunity

EN 61000-6-1 EN 61000-6-2

Generic standards

Electrostatic discharge 1) EN 61000-4-2 Contact discharge

Air discharge

8kV
15kV

Criterion A

Criterion A
Electromagnetic RF eld EN 61000-4-3 80MHz-1GHz 10V/m Criterion A
Fast transients (Burst) EN

61000-4-4

2kV Criterion A

Surge voltage EN 61000-4-5 + -

+ / -

housing

500V
500V

Criterion A

Criterion A
Conducted disturbance EN 61000-4-6 0,15-80MHz 10V Criterion A

1) Grounded on the DIN rail

EMC Emission

EN 61000-6-3 and EN 61000-6-4 Generic standards
Conducted emission EN 55022 Class B
Radiated emission EN 55011, EN 55022 Class B
This device complies with FCC Part 15 rules.

Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.

15. Environment

Operational temperature -25°C to +70°C full power
Storage temperature -40 to +

85°C

storage and transportation

Humidity 5 to 95% r.H.

no condensation allowed
Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g IEC 60068-2-6
Vibration random 0.5m

2(s3

)

IEC 60068-2-64
Shock 30g 6ms, 20g 11ms IEC 60068-2-27
Altitude 0 to 6000m All approvals apply only up to 2000m
Over-voltage category III EN 50178

II EN 50178 above 2000m altitude

Degree of pollution 2 EN 50178, not conductive

The ambient temperature is dened 2cm below the unit.

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM027A-EN-P — April 2014 9

Bulletin 1606 Switched Mode Power Supplies

16. Protection Features

Buer protection Electronically protected against overload, no-load and short-circuits

Output over-voltage protection

in buer mode

typ. 58Vdc
max. 60Vdc

In case of an internal defect, a redundant circuitry
limits the maximum output voltage. The output shuts

down and makes automatic restart attempts.
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm e.g. screws, small parts
Reverse polarity protection yes max. –35Vdc
Input over-voltages protection yes max. 35Vdc, no harm or defect to the unit
Internal fuse not included

17. Safety

Output voltage SELV IEC/EN 60950-1

PELV EN 60204-1, EN 50178, IEC 60364-4-41
Class of protection II
Isolation resistance > 5MOhm Power port to housing, 500Vdc
PE resistance < 0.1Ohm between housing and chassis ground terminal
Dielectric strength 500Vac Power port to signal port

500Vac Power port / signal port to housing

18. Certications

UL 508

IND. CONT. EQ.

18WM

LISTED E56639 for use in the U.S.A. (UL 508) and
Canada (C22.2 No. 14-95)
Industrial Control Equipment

UL 60950-1

RECOGNIZED E168663 for use in the U.S.A. (UL 60950-1) and
Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3

EN 60950-1, EN 61204-3

Complies with CE EMC and CE Low Voltage Directives

GOST R GOST R certication is applicable for products intended for sale

and use within Russia. See below for link to the Certicate.

C-TICK C-Tick compliance is for products intended for sale and use within

the Australian market. See below for link to the C-Tick Declarations
of Conformity.

Product certification information (including Certificates and declarations of Conformity) can be found at www.ab.com/certifications.

10 Rockwell Automation Publication 1606-RM027A-EN-P — April 2014

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Bulletin 1606 Switched Mode Power Supplies

19. Physical Dimensions and Weight

Width 64mm / 2.51’’
Height 124mm / 4.88’’
Depth 102mm / 4.02’’ plus depth of DIN rail and depth of signal connector
Weight 740g / 1.63lb
DIN Rail Use DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm

Fig. 19-1 Side view Fig. 19-2 Front view

Signal
Connector

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM027A-EN-P — April 2014 11

Bulletin 1606 Switched Mode Power Supplies

20. Wiring Diagrams

Fig. 20-1 General wiring diagram Fig. 20-2 Signals supplied from an external voltage

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

optional

L
N

PE

+ +

- -

XLS
Buffer Unit

Back-up
Threshold

Status

6 +

7 Active

8 Ready

9 Inhibit

Load

+

-

Inhibit

Active

Relay, lamp or signal

Ready

Relay, lamp or signal

+

+ +

- -

XLS
Buffer Unit

Back-up

Threshold

Status

6 +

7 Active

8 Ready

9 Inhibit

Inhibit

Active

Relay, lamp or signal

Ready

Relay, lamp or signal

Fig. 20-3 Paralleling of buer units Fig. 20-4 Decoupling of buered branches

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

optional

L

N

PE

+ +

- -

XLS
Buffer Unit

Back-up

Threshold

Status

6 +

7 Active

8 Ready

9 Inhibit

Load

+

-

+ +

- -

XLS
Buffer Unit

Back-up

Threshold

Status

6 +

7 Active

8 Ready

9 Inhibit

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

optional

L
N

PE

+ +

- -

XLS
Buffer Unit

Back-up

Threshold

Status

6 +

7 Active

8 Ready

9 Inhibit

Un-

buffered

Load

+

-

XLSRED

Decoupling
Module

+

-

OUT

+

-

IN 1

+

-

IN 2

Buffered

Load

+

-

12 Rockwell Automation Publication 1606-RM027A-EN-P — April 2014

All parameters are specified at 24V, 20A, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support
notes, sample code and links to software service packs, and a MySupport feature that you can customize to
make the best use of these tools. You can also visit our Knowledgebase at http://

www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums,

software updates, and to sign up for product notification updates.

, you can find technical manuals, technical and application

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
Tech Co nn ec t
representative, or visit http://www.rockwellautomation.com/support/

SM

support programs. For more information, contact your local distributor or Rockwell Automation

.

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in
this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Wor ldwi de Lo cato r at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local

Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from
the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these
procedures.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

distributor to complete the return process.

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Your comments will help us serve your documentation needs better. If you have any suggestions on how to
improve this document, complete this form, publication RA-DU002

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Publication 1606-RM027A-EN-P — April 2014

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