Rockwell Automation 1606-XLSRED User Manual

Reference Manual

N+1

Redundancy

1+1

Redundancy

ACDCACDCACDCACDCACDCAC

IN 1

OUT

IN 2 IN 1

OUT

IN 2 IN 1

OUT

IN 2

Load

ACDCAC

Load

IN 1

OUT

IN 2

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLSRED

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. Dielectric Strength ............................................11

14. Certications .....................................................12

15. Physical Dimensions and Weight ..................... 13

16. Accessories ........................................................ 14

17. Application Notes............................................. 15

17.1. Recommendations for Redundancy ......... 15

17.2. Inductive and Capacitive Loads ................ 15

17.3. Example: 1+1 Redundancy up to 10A ......15

17.4. Example: N+1 Redundancy up to 30A .....16

17.5. Example: Battery Back-up ........................16

17.6. Example: Redundancy for Controls .........17

17.7. Example: Decoupling of Branches ........... 18

17.8. Use in a Tightly Sealed Enclosure ............18

17.9. Mounting Orientations ............................19

egaP egaP

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 (usually ±15%) included. E.g.: DC

12V describes a 12V battery whether it is full (13.7V) or flat (10V)

• 24Vdc—A figure with the unit (Vdc) at the end is a momentary figure with no additional tolerance included.

• may, shall, should—Three key words indicating, respectively: flexibility of choice with no implied preference, a mandatory requirement, flexibility of

choice with a strongly preferred implementation.

•1+1 Redundancy—Use of two identical power supplies in parallel to provide continued operation following most failures in a single power supply. The two power supply outputs should be isolated from each other by using diodes or other switching arrangements. E.g. two 10A power supplies are needed to achieve a 10A redundant system.

• N+1 Redundancy—Use of three or more identical power supplies in parallel to provide continued operation following most failures in a single power supply. All power supply outputs should be isolated from each other by using diodes or other switching arrangements. E.g. to achieve a 40A redundant system, five 10A power supplies are required in a N+1 redundant system.

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 (120V) ±25% Wide-range Input Full Power Between -40°C and +60°C Width only 32mm Rugged Metal Housing Quick-connect Spring-clamp Terminals Easy Wiring:

Distribution Terminal for Negative Pole Included 3 Year Warranty

Description

The 1606-XLSRED is a redundancy module that can be used 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 10A output current and one output, able to carry nominal currents up to 20A. The module is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior.

The 1606-XLSRED is the perfect solution to use in a redundant system, if the power supply itself is equipped with a DC-OK signal. In addition to the 1606-XLSRED is the 1606-XLERED which includes monitoring circuitry. LEDS and relay contacts signal when one of the two DC-input voltages is out of range due to a non-functioning power supply.

Another interesting application for the redundancy module is to separate sensitive loads from non-sensitive loads. This avoids the distortion of the power quality for the sensitive loads which can cause controller failures.

Unique quick-connect spring-clamp terminals allow 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 0-10A continuous 2x 0-16A for 5 seconds Output current 0-20A continuous 20-32A for 5 seconds

25A at cont. overload/

short circuit Input to output

voltage drop

typ. 0.78V typ. 0.85V typ. 0.85V

input: 2x5A

input: 1x10A

input: 2x10A Power losses typ. 0W at no load typ. 7.8W input: 2x5A typ. 8.5W input: 1x10A typ. 17W input: 2x10A Temperature range -40°C to +70°C operational, Derating 0.5A/°C +60 to +70°C Dimensions 32x124x102mm WxHxD

Catalog Numbers

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

Accessory 1606-XLB Wall/panel mount bracket

Certication Marks

IND. CONT. E

UL 508

UL 60950-1

Class I Div 2

IECEx

ATEX

II 3G Ex nA IIC T4 Gc

Marine

EMC, LVD

Marine RINA

GOST R

C-Tick

2 Rockwell Automation Publication 1606-RM009A-EN-P - February 2014

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

Bulletin 1606 Switched Mode Power Supplies

1. Intended Use

• This redundancy module is designed for installation in an enclosure and is intended for general use such as in industrial control, office,

communication and instrumentation equipment.

• This redundancy module can be used with any type of power supply as long as the maximum ratings are not exceeded. It is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior.

• 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 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 occurs 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 input terminals are located on top and the output terminals on the bottom of the unit. For other

mounting orientations, see derating requirements in the present 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 unless power has been switched off or the area is known to be non-hazardous.

A suitable enclosure must be provided for the end product which has a minimum protection of IP54 and meets the requirements of the EN 60079-15:2010.

Notes for use in hazardous location areas:

• The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations and for use in Group II Category 3 (Zone 2) environments and is

evaluated according to EN 60079-0:2009 and EN 60079-15:2010.

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-RM009A-EN-P — February 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 below table.

Input voltage range with restrictions

- 9-150Vdc Restrictions apply, see Note 3 below table.

at 2x5A, see Fig. 3-2Voltage drop, input to output typ. 0.78V typ. 0.85V at 1x10A, see Fig. 3-3 typ. 0.85V at 2x10A, see Fig. 3-2 Input current nom. 2x 0-10A continuous nom. 1x 0-20A continuous, see note 1 nom. 2x 10-16A for 5 seconds Peak input current max. 150A for maximal 10ms per input Output current nom. 20A continuous nom. 20-32A for 5 seconds max.

25A at continuous overload or short circuit, see note 2 Reverse current max. 2mA 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 20A. 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 25A. Check the short-circuit current of the power sources and if the

power source can deliver more than 25A 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-RM009A-EN-P — February 2014

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

Voltage Drop, typ.

1000mV

800mV

600mV

400mV

200mV

0mV

Output:

Input:

0 0

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

1606-XLSRED/XLERED

Input 1

Input 2

U2U

= Voltage Drop

Input, Output Current

5A 15A 20A10A

2x5A2x2.5A

24V,10A

2x10A2x7.5A

24V,10A

I1I

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

Voltage Drop, typ.

1000mV

800mV

600mV

400mV

200mV

0mV

Output Current

5A 15A 20

10A0

24V,20A

Not used or

power supply

with lower

voltage

1606-XLSRED/XLERED

Input 1

Input 2

Bulletin 1606 Switched Mode Power Supplies

Output

Variable

Load,

OUT

0-20A

OUT

Output

OUT

Output

Variable

Load,

OUT

0-20A

Output

Voltage Drop

OUT

4. Power Losses

Power losses typ. typ. typ.

DC 24V

7.8W input: 2x5A

8.5W

17.0W

Standby power losses typ. 0W at no output current

Fig. 4-1 Power losses

Power Losses, typ.

24W

0 5 10 20

Output Current

input: 1x10A input: 2x10A

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-RM009A-EN-P — February 2014 5

Bulletin 1606 Switched Mode Power Supplies

5. Life 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 are 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 have electrolytic capacitors included. Therefore, the lifetime expectancy is extremely high.

Input / output current conditions

Input: 2x10A

Output: 20A

Input: 2x5A

Output: 10A

Lifetime expectancy *) min. 25 years 25 years at 24V and 40°C min. 25 years 25 years at 24V and 25°C MTBF **) SN 29500, IEC 61709 46 500 000h 55 700 000h at 24V 40°C 70 000 000h 84 000 000h at 24V 25°C MTBF **) MIL HDBK 217F 36 200 000h 43 500 000h at 24Vand 40°C (Ground Benign GB40) 41 100 000h 49 300 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-RM009A-EN-P — February 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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