Rockwell Automation 1606-XLSPRED User Manual

Reference Manual

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLSPRED

Index

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

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

3. Input and Output Characteristics .......................4

4. Power Losses........................................................5

5. Lifetime Expectancy and MTBF...........................6

6. Terminals and Wiring..........................................7

7. Functional Diagram.............................................8

8. Front Side and User Elements.............................8

9. EMC......................................................................9

10. Environment ......................................................10

11. Protection Features ...........................................11

12. Safety Features..................................................11

13. Certications .................................................... 12

14. Physical Dimensions and Weight ..................... 13

15. Accessories ........................................................ 13

16. Application Notes............................................. 14

16.1. Recommendations for Redundancy .........14

16.2. Inductive and Capacitive Loads ................ 14

16.3. Example: 1+1 Redundancy .......................14

16.4. Example: N+1 Redundancy ....................... 15

16.5. Example: Battery Back-up ........................ 15

16.6. Mounting Orientations ............................16

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 dened, value or description will follow later.

DC 24V A gure displayed with the AC or DC before the value represents a nominal voltage with

24Vdc A gure with the unit (Vdc) at the end is a momentary gure without any additional

may A key word indicating exibility of choice with no implied preference

shall A key word indicating a mandatory requirement

should A key word indicating exibility of choice with a strongly preferred implementation

1+1 Redundancy Use of two identical power supplies in parallel to provide continued operation following most

N+1 Redundancy Use of three or more identical power

standard tolerances (usually ±15%) included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or at (10V)

tolerances included.

failures in a single power supply. The two power supply outputs should be isolated from each other by utilizing diodes or other switching arrangements.

ACDCACDCACDCACDCACDCAC

N+1

Redundancy

1+1

Redundancy

ACDCAC

E.g. two 2.5A power supplies are needed to achieve a 2.5A redundant system.

supplies in parallel to provide continued

IN 1

IN 2 IN 1

OUT

IN 2 IN 1

OUT

IN 2

IN 1

IN 2

OUT

operation following most failures in a single power supply. All power supply outputs should be isolated from each other

Load

by utilizing diodes or other switching arrangements. E.g.: To achieve a 10A redundant system, ve 2.5A power supplies are needed in a N+1 redundant system.

egaP egaP

Bulletin 1606 Switched Mode Power Supplies

Redundancy Module

Cost Effective Solution to Build Redundant Systems Dual Input with Single Output Two Diodes (Common Cathode) DC12-48V (120Vdc) ±25% Wide-range Input Full Power Between -40°C and +60°C Compact Design, Width only 45mm Quick-connect Spring-clamp Terminals Easy Wiring: Distribution Terminal for Negative Pole Included 3 Year Warranty

Description

The 1606-XLPRED is a simple redundancy module that you can use to build 1+1 and N+1 redundant systems. It is equipped with two input channels, which can be connected to power supplies with up to 5A output current and one output, capable of carrying nominal currents up to 10A. The module is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior.

Unique quick-connect spring-clamp terminals allow for a safe and fast installation and a large international approval package for a variety of applications makes this unit suitable for nearly every situation.

Specication Quick Reference

Input voltage

DC 12-48V

±25%

DC 12-120V

±25%

w/o restrictions

with restrictions Input voltage range

9-60Vdc 9-150Vdc

w/o restrictions

with restrictions Input current 2x 0-5A continuous 2x 0-8A for 5 seconds Output current 0-10A continuous 10-16A for 5 seconds

<16A at cont. overload/

short circuit Input to output

voltage drop

typ. 0.8V typ. 0.9V typ. 0.9V

input: 2x2.5A

input: 1x5A

input: 2x5A Power losses typ. 0W at no load typ. 4.0W input: 2x2.5A typ. 4.5W input: 1x5A typ. 9.0W input: 2x5A Temperature range -40°C to +70°C operational, Derating 0.25A/°C +60 to +70°C Dimensions 45x75x91mm WxHxD

Catalog Numbers

Redundancy 1606-XLPRED 12-48V (120V) Module Standard unit

Certications

IND. CONT. E

UL 508

UL 60950-1

ATEX

II 3G Ex nA IIC T4 Gc

Marine

EMC, LVD

UL Class 1 Div 2

C-Tick

Marine RINA

GOST R

2 Rockwell Automation Publication 1606-RM035A-EN-P — April 2014

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, 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, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM035A-EN-P — April 2014 3

Bulletin 1606 Switched Mode Power Supplies

3. Input and Output Characteristics

Number of inputs - 2 Number of outputs - 1 Input voltage nom. DC 12-48V

±25%

The input circuitry must meet the SELV requirements

stipulated by IEC/EN/UL 60950-1. Input voltage range - 9–60Vdc Input voltage with restrictions nom. DC 12-120V

±25%

See note 3 at the bottom of the table

Input voltage range with restrictions

- 9-150Vdc Restrictions apply, see note 3 at the bottom of the table.

at 2x2.5A, see Fig. 3-2Voltage drop, input to output typ. 0.8V typ. 0.9V at 1x5A, see Fig. 3-3 typ. 0.9V at 2x5A, see Fig. 3-2 Input current nom. 2x 0-5A continuous nom. 1x 0-10A continuous, see note 1 nom. 2x 5-8A for 5 seconds Peak input current max. 125A for maximal 10ms per input Output current nom. 10A continuous nom. 10-16A for 5 seconds max.

16A at continuous overload or short circuit, see note 2 Reverse current max. 0.6mA per input, -40°C to +60°C Reverse voltage max. 200Vdc voltage applied to the output, continuously allowed

Note 1: Each input can be loaded up to 10A. At currents above 10A, the other input should not be loaded. It is preferable to parallel the two

inputs in order to minimize the power loss in such cases.

Note 2: Ensure that the continuous output current does not exceed 16A. Check the short-circuit current of the power sources and if the

power source can deliver more than 16A together, use an appropriate fuse on the output.

Note 3: The redundancy module can be used with input voltages up to 150Vdc with the constraint, that it can be used only as a single input

module at voltages above 60Vdc. Both inputs need to be connected together as shown in Fig. 3-1. Ensure proper means to protect against touching this voltage.

Fig. 3-1 Restrictions for utilizing voltages between 60 and 150Vdc (See also Note 3)

(>60V)

Load

>60V

Power Supply

Diode Module

(>60V)

Load

>60V

Power Supply Diode Module

Diode Module

(>60V)

Power Supply

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

4 Rockwell Automation Publication 1606-RM035A-EN-P — April 2014

Fig. 3-2 Input to output voltage drop when both inputs draw current

(typical 1+1 redundant case, when the output voltages of the two units are equal or set into “parallel use” mode)

Voltage Drop, typ.

0A 2A 4A 8A

200mV

400mV

600mV

800mV

1000mV

Input, Output Current

0mV

Output:

2x2A2x1A

Input:

2x4A2x3A0A 2x5

A... 25°C B... 60°C

24V,5A

I1I2=

U2U1= Voltage Drop

U1=

OUT

Output

OUT

Variable

Load,

0-10A

1606-XLPRED

Input 1

Input 2

Output

Fig. 3-3 Input to output voltage drop when only one input draws current

Voltage Drop

U1=

OUT

Not used or

power supply

with lower

voltage

24V,10A

Output

OUT

Variable

Load,

0-10A

Input 1

Input 2

Output

1606-XLPRED

Voltage Drop, typ.

0A 2A 4A 8A

200mV

400mV

600mV

800mV

1000mV

Output Current

0mV

A... 25°C B... 60°C

4. Power Losses

DC 24V

Power losses typ.

4.0W input: 2x2.5A

typ.

4.5W

input: 1x5A

typ.

9.0W

input: 2x5A

Standby power losses typ. 0W at no output current

Fig. 4-1 Power losses

Power Losses, typ.

0A 2A 4A 8A

10W

Input, Output Current

Output:

2x2A2x1A

Input:

2x4A2x3A0A 2x5

A... 25°C

B... 60°C

A B

1606-XLS 240E

1606XLS120E

Bulletin 1606 Switched Mode Power Supplies

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

Rockwell Automation Publication 1606-RM035A-EN-P — April 2014 5

Bulletin 1606 Switched Mode Power Supplies

5. Lifetime Expectancy and MTBF

The redundancy module has two input channels which are completely independent from each other. Each control circuit, auxiliary voltage source, or other circuitry in the module is designed separately for each input. The dual input redundancy module can be considered as two single redundancy modules combined together in one housing. The only common point is the circuit trace that ties the two separate circuits together at the output.

The MTBF gures below are for the entire dual input module. If the MTBF number of only one path is needed, simply double the value from the table.

The redundancy module does not include electrolytic capacitors. Therefore, the lifetime expectancy is extremely high.

Input / output current conditions

Input: 2x5A

Output: 10A

Lifetime expectancy *) min. 25 years at 24V and 40°C min. 25 years at 24V and 25°C MTBF

**) SN 29500, IEC 61709 84 868 000h at 24V 40°C

125 266 000h at 24V 25°C MTBF **) MIL HDBK 217F 71 454 000h at 24Vand 40°C (Ground Benign GB40) 81 453 000h at 24Vand 25°C (Ground Benign GB25)

*) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life). **) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a

device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.

The MTBF gure is a statistical representation of the likelihood of a device to fail. A MTBF gure of e.g. 1 000 000h means that

statistically one unit will fail every 100 hours if 10 000 units are installed in the eld. However, it can not be determined if the failed unit has been running for 50 000h or only for 100h.

6 Rockwell Automation Publication 1606-RM035A-EN-P — April 2014

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.

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