Rockwell Automation 1606-XLSRED User Manual

Reference Manual

N+1

Redundancy

1+1

Redundancy

ACDCACDCACDCACDCACDCAC

DC

IN 1

OUT

IN 2 IN 1

OUT

IN 2 IN 1

OUT

IN 2

Load

+

-

ACDCAC

DC

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

Q.

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)

AC

DC

(>60V)

+

-

Load

>60V

+

-

Power Supply

Power Supply

Diode Module

+

-

+

+

-

-

AC

DC

(>60V)

+

-

AC

DC

(>60V)

+

-

Load

>60V

+

-

Power Supply Diode Module

+

-

+

+

-

-

Diode Module

+

-

+

+

-

-

AC

DC

(>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

A

A

(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

I

1

A

+

V

U

1

-

+

-

Input 1

I

2

A

V

U

2

Input 2

U2U

1

= Voltage Drop

A

B

Input, Output Current

5A 15A 20A10A

2x5A2x2.5A

24V,10A

.

.

.

A

°

5

2

C

B

.

.

.

°

0

6

C

2x10A2x7.5A

24V,10A

I1I

2

=

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

Voltage Drop, typ.

1000mV

800mV

600mV

400mV

200mV

0mV

A

B

.

A

.

2

5

.

°

C

B

.

0

6

.

.

°

C

Output Current

5A 15A 20

10A0

24V,20A

+

-

Not used or

power supply

with lower

voltage

1606-XLSRED/XLERED

I

1

A

Input 1

V

U

1

Input 2

Bulletin 1606 Switched Mode Power Supplies

Output

Variable

Load,

I

OUT

0-20A

A

V

U

OUT

Output

U

1

=

U

OUT

-

Output

Variable

Load,

I

OUT

0-20A

A

Output

Voltage Drop

V

U

OUT

U

1

=

U

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

20

16

12

8

4

0

0 5 10 20

Output Current

15

25

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.

Bulletin 1606 Switched Mode Power Supplies

6. Terminals and Wiring

Input and output

Type Bi-stable, quick-connect spring clamp terminals.

IP20 Finger safe construction.
Suitable for eld- and factory installation.

Shipped in open position.
Solid wire 0.5-6mm2
Stranded wire 0.5-4mm

2

American Wire Gauge 20-10 AWG
Max. wire diameter 2.8mm (including ferrule)
Wire stripping length 10mm / 0.4inch
Pull-out force 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E)

Fig. 6-1 Connecting a wire

1. Insert the wire 2. Snap the lever

Instructions:

a) Use appropriate copper cables that are designed for

minimum operating temperatures of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C and
90°C for ambient up to 70°C minimum.

b) Follow national installation codes and installation

regulations!

c) Ensure that all strands of a stranded wire enter the

terminal connection!
d) Ferrules are allowed.
e) Do not connect or disconnect the wires from the

terminals below -25°C (-13°F).

To disconnect wire: reverse this procedure.

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 7

Bulletin 1606 Switched Mode Power Supplies

7. Functional Diagram

Fig. 7-1 Functional diagram

+

-

+

-

+

-

Input 1

Input 2

Output

Chassis
Ground

8. Front Side and User Elements

Fig. 8-1 Front side

A

Output terminals

B

Chassis ground terminal

Connection of the chassis to ground is optional and not required since the unit
fulls the requirements according to protection class III.

C

Input terminals for input 1

D

Input terminals for input 2

A

B

C

D

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

8 Rockwell Automation Publication 1606-RM009A-EN-P — February 2014

Bulletin 1606 Switched Mode Power Supplies

9. EMC

The redundancy module is suitable for applications in industrial environment as well as in residential, commercial and
light industry environment without any restrictions. A detailed EMC report is available upon request.

EMC Immunity

According generic standards: EN 61000-6-1 and EN 61000-6-2

Electrostatic discharge EN 61000-4-2 Contact discharge

Air discharge

8kV
15kV

Criterion A

Criterion A
Electromagnetic RF eld EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines

Output lines

2kV
2kV

Criterion A

Criterion A
Surge voltage on input lines EN 61000-4-5 + -

+/-

Chassis ground

200V
1kV

Criterion A

Criterion A

Surge voltage on output
lines

EN 61000-4-5 + -

+/-

Chassis ground

200V
1kV

Criterion A

Criterion A

Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Power-frequency magnetic

eld *)

EN 61000-4-8 50Hz 30A/m Criterion A

Criteria:
A: Redundancy module shows normal operation behavior within the dened limits.
Notes:
*) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic elds, e.g. hall

elements, electrodynamic microphones, etc.

EMC Emission

According generic standards: EN 61000-6-3 and EN 61000-6-4
Conducted emission IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, input lines *)
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, output lines *)
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.

*) Provided, that power sources connected on the inputs fulll the class B requirements as well.

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 9

Bulletin 1606 Switched Mode Power Supplies

10. Environment

Operational temperature
Output de-rating 0.5A/°C 60-70°C (140°F to 158°F), see
Storage temperature -40 to +85°C (-40°F to 185°F) for storage and transportation
Humidity **) 5 to 95% r.H. IEC 60068-2-30
Vibration sinusoidal 2-17.8Hz: ±1.6mm

Shock 30g 6ms, 20g 11ms

Altitude 0 to 2000m (0 to 6 560ft) without any restrictions
2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature,

Altitude de-rating 1.25A/1000m or 5°C/1000m > 2000m (6500ft), see Fig. 10-2
Over-voltage category not applicable The concept of the overvoltage category is

Degree of pollution 2 IEC 62103, EN 50178, not conductive
LABS compatibility The unit does not release any silicone or other LABS-critical substances and is suitable for

*) Operational temperature is the same as the ambient temperature and is dened as the air temperature 2cm below the unit.
**) Do not energize while condensation is present

Fig. 10-1 Output current vs. ambient temp. Fig. 10-2 Output current vs. altitude

Allowed Output Current

30A

25

a

t

o

20

15

10

5

0

Ambient Temperature

-40 0 20 40

*) -40°C to +70°C (-40°F to 158°F) Reduce output power above +60°C

IEC 60068-2-6

17.8-500Hz: g
2 hours / axis

IEC 60068-2-27
3 bumps / direction
18 bumps in total

see Fig. 10-2

used for equipment energized directly from

the low voltage mains (IEC 60664-1 §4.3.3.2.1).

use in paint shops.

Allowed Output Current

v

l

r

e

o

a

d

s

/

h

o

r

c

t

r

c

u

i

t

i

n

o

r

m

l

a

o

m

d

e

25

20

15

10

5

0

70°C

30A

60-25

o

v

l

e

r

o

d

a

/

s

h

o

c

t

r

n

o

r

m

l

a

o

m

d

e

.

A

.

T

a

.

b

m

<

6

°

0

B

.

a

T

.

.

C

.

a

T

.

.

C

b

m

<

5

°

0

C

b

m

<

4

°

C

0

0 2000 4000

i

c

r

u

t

i

A

C

B

Altitude

6000m

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

10 Rockwell Automation Publication 1606-RM009A-EN-P — February 2014

Bulletin 1606 Switched Mode Power Supplies

11. Protection Features

Output over-current protection not included
Reverse input polarity protection included unit does not start when input voltage is reversed
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.6mm e.g. screws, small parts
Over-temperature protection not included
Input transient protection not included
Output transient protection included see EMC section
Internal input fuse not included

12. Safety Features

Input / output separation no galvanic separation 200V epitaxial diode between input and output
Safety level of output voltage The output voltage is regarded to be SELV (EN 60950-1) or PELV (EN 60204-1, EN

50178, IEC 60364-4-41) if the input voltage fullls the requirements for a SELV

source or PELV source.
Class of protection III PE (Protective Earth) or chassis connection not required
PE resistance < 0.1Ohm between housing and chassis-ground terminal

13. Dielectric Strength

The input and output voltages have the same reference, are oating and have no ohmic connection to ground.
Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the eld using the
appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect input/output
terminals together before conducting the test.
When testing, set the cut-off current settings to the value in the table below.

Fig. 13-1 Dielectric strength

A

Type test 60s 500Vac

Factory test 5s 500Vac

Field test 5s 500Vac

Cut-off current setting > 2mA

A

Chassis

In- / Output

-

+

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 11

Bulletin 1606 Switched Mode Power Supplies

14. Certications

EC Declaration of
Conformity

Complies with

- CE EMC directive,

- CE Low-voltage directive

UL 508

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

GOST R

C-TICK

C-tick compliance is for products intended for sale and use within
the Australian market. See below for the link to the C-tick
Declarations of Conformity.

Marine GL GL (Germanischer Lloyd) classied for marine and offshore

applications. Environmental category: C, EMC2. See below for link
to Certicate.

Marine Rina

RINA (Registro Italiano Navale) certied. See below for the link to
Certicate.

The CE mark indicates conformance with the

- ATEX directive 94/9/EC (Equipment and protection systems
intended for use in potentially explosive atmospheres)

CSA Certied under File Number 2400020; CERTIFIED for use
in the U.S.A. (ISA 12.12.01) and Canada (C22.2 No. 213)
Hazardous Location Class I Div. 2 - Groups A, B, C, D

CSA 22.2 No 107,1-01

RECOGNIZED UNDER FILE NUMBER E244404 for use in the U.S.A.
(ISA 12.12.01) and Canada (C22.2 No 213)
Hazardous Location Class I Div. 2 - Groups A, B, C, D

ISA 12.12.01, CSA
C22.2 No. 213

ATEX

II 3G Ex nA IIC T4 Gc
EPS 11 ATEX 1 312 X

II 3G Ex nA IIC T4 Gc

GOST R certication is applicable for products intended for sale
and use within Russia. See below for link to Certicate.

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

12 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.

Bulletin 1606 Switched Mode Power Supplies

15. Physical Dimensions and Weight

Weight 290g / 0.64lb
DIN Rail Use 35mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.

The DIN rail height must be added to the unit depth (102mm) to calculate the total required
installation depth.

Installation clearances See section 2.

Fig. 15-1 Front view Fig. 15-2 Side view

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 13

Bulletin 1606 Switched Mode Power Supplies

16. Accessories

1606-XLB Wall mounting bracket
This standard bracket is used to mount the redundancy module onto a at surface without a DIN rail.

Fig. 16-1 1606-XLB Wall mounting bracket Fig. 16-2 Assembled wall mounting bracket

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

14 Rockwell Automation Publication 1606-RM009A-EN-P — February 2014

17. Application Notes

17.1. Recommendations for Redundancy

Recommendations for the conguration of redundant power systems:

• Use separate input fuses for each power supply.

• Use three-phase power supplies to gain functional safety if one phase fails.

• When single-phase power supplies are utilized connect them to different phases or mains circuits if possible.

• Set the power supply in “Parallel-Use” mode if this feature is available

• It is desirable to set the output voltages of all power supplies to the same value.

17.2. Inductive and Capacitive Loads

The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads.

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

1+1 Redundancy up to 10A requires two 10A power supplies and one 1606-XLSRED redundancy module.

Fig. 17-1 Wiring diagram, 1+1 Redundancy, 10A output current

L N PE

+ +

- -

1606­XLS240EA

Power
Supply

Adj

Overload

DCok

24V,10A

Failure

Monitor

10A

Load

optional

I I

L
N

PE

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

24V,10A

1606­XLSRED

Redundancy
Module

+

-

OUT

+

-

IN 1

+

-

IN 2

Note: Use separate mains systems for each power supply whenever possible.

1606­XLS240EA

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-RM009A-EN-P — February 2014 15

Bulletin 1606 Switched Mode Power Supplies

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

N+1 Redundancy up to 30A requires four 10A power supplies and two 1606-XLSRED redundancy modules.

Fig. 17-2 Wiring diagram, n+1 Redundancy, 30A output current

optional

I I

L
N

PE

I

1606­XLSRED

Redundancy

Module

+

-

OUT

+

-

IN 1

+

-

IN 2

1606­XLSRED

Redundancy
Module

+

-

OUT

+

-

IN 1

+

-

IN 2

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

24V,10A

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

24V,10A

L N PE

+ +

- -

1606­XLS240EA

Power

Supply

Adj

Overload

DCok

24V,10A

Failure

Monitor

30A

Load

L N PE

+ +

- -

Power
Supply

Adj

Overload

DCok

24V,10A

I

Note: Use separate mains systems for each power supply whenever possible.

17.5. Example: Battery Back-up

A battery back-up with 10A requires one 10A power supply and one 1606-XLSRED redundancy module.

Please note:
Set output voltage of power supply to 26.5Vdc minimum to ensure that the load current is delivered from the power
supply and not from charger (battery). Use a fuse between battery and 1606-XLSRED.

Fig. 17-3 Wiring diagram, 10A Battery back-up

optional

L
N

PE

24V Battery

I

Battery
Charger

+

-

Failure

Monitor

10A

Load

L N PE

+ +

- -

1606­XLS240EA

Power
Supply

Adj

Overload

DCok

24V,10A

1606­XLSRED

Redundancy
Module

+

-

OUT

+

-

IN 1

+

-

IN 2

1606­XLS240EA

1606­XLS240EA

1606­XLS240EA

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

16 Rockwell Automation Publication 1606-RM009A-EN-P — February 2014

Bulletin 1606 Switched Mode Power Supplies

17.6. Example: Redundancy for Controls

The example shows a cost effective solution to get redundant power for a PLC or controller system.
In many cases, two power supplies are used; one for the demanding loads and another one for the controls and

sensitive loads. The power supply for the demanding loads can be used as a redundant source to supply the controls.

Traditional approach:

LoadPS1

PLC

PS2

Load

PLC

PS1

PS2

XLS

RED

Improved approach:

Fig. 17-4 Wiring diagram, redundancy for sensitive loads

Sensitive

Load

e.g.

Controller

optional

L N PE

+ +

- -

Power

Supply

Adj

Overload

DCok

24V,
5A

I I I

L1
L2

PE

L3

I

N

Heavy
Loads

e.g. Motors

L1 L2 L3 PE

+ +

- -

1606-XLS480EA

Power
Supply

Adj

Overload

DCok

24V,20A

1606­XLSRED

Redundancy
Module

+

-

OUT

+

-

IN 1

+

-

IN 2

Failure

Monitor

Note: Use separate mains systems for each power supply whenever possible.

1606­XLS120E

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 17

Bulletin 1606 Switched Mode Power Supplies

17.7. Example: Decoupling of Branches

Buffer energy supplied from a DC-UPS or buffer module is not wasted in “power branches.”

Please note:
Set output voltage of the power supply to a level that the buffer unit or DC-UPS will not start unexpected. Take the
voltage drop of the 1606-XLSRED into account.

Fig. 17-5 Wiring diagram, decoupling of buffered branches

Buffered

Load

e.g.

Controller

optional

I I I

L1
L2

PE

L3

Load

e.g. Motor

Buffer

Module

+

-

Failure

Monitor

1606­XLSRED

Redundancy
Module

+

-

OUT

+

-

IN 1

+

-

IN 2

L1 L2 L3 PE

+ +

- -

1606-XLS480EA

Power
Supply

Adj

Overload

DCok

24V,20A

Note: Use separate mains systems for each power supply whenever it is possible

17.8. Use in a Tightly Sealed Enclosure

When the redundancy module is installed in a tightly sealed enclosure, the temperature inside the enclosure will be
higher than outside. The inside temperature denes the ambient temperature for the redundancy module.

Results from such an installation:
Power supply is placed in the middle of the box, no other heat producer is inside the box.
Enclosure: Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm

Load: 24V, 16A; (=80%) load is placed outside the box
Input: 24Vdc
Temperature inside enclosure: 57.8°C (in the middle of the right side of the power supply with a distance of 2cm)
Temperature outside enclosure: 24.6°C
Temperature rise: 33.2K

18 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.

Bulletin 1606 Switched Mode Power Supplies

17.9. Mounting Orientations

Mounting orientations other than input terminals on the bottom and output on the top require a reduction in
continuous output power or a limitation in the maximum allowed ambient temperature.

Fig. 17-6

Mounting
Orientation A

(Standard
orientation)

Fig. 17-7

Mounting
Orientation B

(Upside down)

INPUT

Redundancy

Module

OUTPUT

INPUT

OUTPUT

Module

Redundancy

Fig. 17-8

Mounting
Orientation C

(Table-top
mounting)

Fig. 17-9

Mounting
Orientation D

(Horizontal cw)

OUTPUT

Module

Redundancy

INPUT

Fig. 17-10

Mounting
Orientation E

(Horizontal ccw)

INPUT

Module

Redundancy

OUTPUT

Output Current

20A

16
12

8
4
0

Ambient Temperature

10 20 30 40

Output Current

20A

16
12

8
4
0

Ambient Temperature

10 20 30 40

Output Current

20A

16
12

8
4
0

Ambient Temperature

10 20 30 40

Output Current

20A

16
12

8
4
0

Ambient Temperature

10 20 30 40

Output Current

20A

16
12

8
4
0

Ambient Temperature

10 20 30 40

50

50

50

50

50

60°C

60°C

60°C

60°C

60°C

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 19

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
TechC on ne ct
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 Worldw ide L ocat or 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 Suppor t 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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improve this document, complete this form, publication RA-DU002

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Publication 1606-RM009A-EN-P — February 2014 Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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