Rockwell Automation 1606-XLSRED40 User Manual

Reference Manual

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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. Lateral Installation Clearances ............15

17.4. 1+1 Redundancy up to 20A...................... 16

17.5. N+1 Redundancy, Example with 60A ......16

17.6. Mounting Orientations ............................17

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-XLSRED40

Index

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, respec tively: flexibility of choice with no implied preference, a mandatory requirement, flexibility of

choice

• 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

Q.

Description

The 1606-XLSRED40 is a redundancy module which 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 20A output
current and one output, which can carry nominal
currents up to 40A. The module is suitable for power
supplies with constant current overload behavior as well
as any kind of “Hiccup” overload behavior.

The novelty of this redundancy module is the utilization
of mosfets instead of diodes for the decoupling of the
two input channels. This reduces the heat generation
and the voltage drop between input and output. The
redundancy module does not require an additional
auxiliary voltage and is self-sufcient even in case of a
short circuit across the output.

Due to the low power losses, the unit is very slender and
only requires 36mm width on the DIN rail. Large
connection terminals allow for a safe and fast
installation with a large international approval package.
This unit is suitable for nearly every application.

Catalog Numbers

Redundancy 1606-XLSRED40 12-28V Standard unit
Module

Accessory

1606-XLC Wall/panel mount
bracket

Mosfet Redundancy Module

For N+1 and 1+1 Redundant Systems
Dual Input with Single Output
Suitable for all Power Supplies
Only 72mV Voltage Drop at 20A Output Current
Only 2.15W Loss at 20A and 6.3W at 40A Output Current
160% (65A) Peak Load Capability
Reverse Input Polarity Protection
Full Power Between -40°C and +70°C
Width only 36mm
Rugged Metal Housing
Easy Wiring:
Distribution Terminal for Negative Pole Included
3 Year Warranty

Specication Quick Reference

Input voltage DC 12-28V ±30%
Input voltage
range
Input current 2x 0-20A continuous
2x 20-32.5A for 5 seconds
Output current 0-40A continuous
40-65A for 5 seconds

Input to output
voltage drop

Power losses typ. 700mW at no load
typ. 2.15W input: 2x10A
typ. 2.65W input: 1x20A
typ. 6.3W input: 2x20A
Temperature range -40°C to +70°C operational,

Dimensions

*) plus 4mm in depth for the screw terminal

Certication Marks

IND. CONT. E

UL 508

IECEx

II 3G Ex nA IIC T4 Gc

8.4-36.4Vdc

65A at cont. overload

typ. 72mV
typ. 112mV
typ. 140mV

36x124x127mm

UL 60950-1

ATEX

Marine

or short circuit
input: 2x10A

input: 1x20A
input: 2x20A

no de-rating req.

*)

WxHxD

Class I Div 2

EMC, LVD

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time, unless noted otherwise.

2 Rockwell Automation Publication 1606-RM010A-EN-P — February 2014

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 redundancy module 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.

• 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 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 (refer to section 17.6).

• 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 the side clearance to 15mm in case the adjacent device is a heat
source (e.g. another power supply). See section 17.3 for further information in combination with poser supplies.

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, 40A output current, 26°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM010A-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 12-28V ±30% The input circuitry must meet the SELV requirements

stipulated by IEC/EN/UL 60950-1.
Input voltage range - 8.4-36.4Vdc
Voltage drop, input to output typ. 140mV at 2x20A, see Fig. 3-1
typ. 72mV at 2x10A, see Fig. 3-1
typ. 112mV at 1x20A, see Fig. 3-2
Input current nom. 2x 0-20A continuous
nom. 2x 20-32.5A for 5 seconds
max 2x 32.5A at continuous overload or short circuit
Peak input current max. 1000A for max. 1ms per input
Output current nom. 40A continuous
nom. 40-65A for 5 seconds
max.

65A at continuous overload or short circuit
Reverse current max. 1mA at 24V, per input, -40°C to +70°C
Reverse voltage max. 40Vdc voltage applied to the output, continuously allowed
Output capacitance typ. 320μF

Note: Ensure that the continuous output current does not exceed 65A. Check the short-circuit current of the power sources and if the

power source can deliver more than 65A together, use an appropriate fuse on the output.

Fig. 3-1 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)

Voltage Drop, typ

0mV

10A 30A

20mV

40mV

60mV

80mV

100mV

120mV

40A20A

Output:

A

.

.

.

2

5

°

C

B

.

.

.

6

0

°

C

2x10A2x5A

Input / Output Current

Input:

2x20A2x15A

0
0

140mV

160mV

AB

V

A

24V,20A

+

-

24V,20A

+

-

V

A

I

1

I

2

U

1

U

2

I1I2=

U2U1= Voltage Drop

U1=

U

OUT

-

Output

A

V

I

OUT

U

OUT

Variable

Load,
0-40A

Input 1

Input 2

Output

Fig. 3-2 Input to output voltage drop when only one input draws current

Voltage Drop, typ.

0mV

5A 15A

20mV

40mV

60mV

80mV

100mV

120mV

20A10A

A

.

.

.

2

5

°

C

B

.

.

.

6

0

°

C

Output Current

0

140mV

160mV

AB

Voltage Drop

U1=

U

OUT

-

Not used or

power supply

with lower

voltage

V

A

24V,20A

+

-

I

1

U

1

Output

A

V

I

OUT

U

OUT

Variable

Load,
0-20A

Input 1

Input 2

Output

XLSRED40

XLSRED40

4 Rockwell Automation Publication 1606-RM010A-EN-P — February 2014

All parameters are specified at 24V, 40A output current, 26°C ambient and after a 5 minutes run-in time, unless noted otherwise.

A

A

4. Power Losses

Power losses typ.
typ.
typ.

DC 24V

2.15W input: 2x10A

6.3W

2.6W input: 1x20A,

Standby power losses typ. 0.35W at no output current,

typ. 0.7W at no output current,

Fig. 4-1 Power losses when both inputs draw equal current

Power Losses, typ.

7W

6.0

5.0

4.0

3.0

2.0

1.0
0

0510 30

.

A

5

2

.

.

°

C

B

.

0

6

.

.

°

C

B

A

Output Current

2515 20 35

40

24V,20A

+

e.g.

24.5V

-

24V,20A

+

e.g.

24.5V

-

I1I2=

input: 2x20A

(only one input is connected to input voltage)

(only one input is connected to input voltage)

(both inputs are connected to input voltages)

XLSRED40

I

1

A

Input 1

V

U

1

I

2

A

Input 2

V

U

2

U2U

1

L=osses

U1=

Output

I1+)(

*

Bulletin 1606 Switched Mode Power Supplies

Output

Variable

Load,

I

OUT

0-40A

A

V

U

OUT

U

OUT

-

U

2

I

2

I

*

OUT

*

Fig. 4-2 Power losses when only one input is used

Power Losses, typ.

4W

3.5

A

3.0

B

2.5

2.0

24V,20A

+

.

.

5

2

.

°

C

.

0

6

.

.

°

C

AB

-

XLSRED40

1

I

A

Input 1

V

U

1

1.5

1.0

0.5
0

Output Current

0 2.5 5 15

12.57.5 10 17.5

20

Input 2

Losses

U1=

U

OUT

-*I

1

I

OUT

*

Note: As soon as voltage is applied on input 2, an additional 0.35W will be consumed. It is not relevant whether this channel contributes

to the output current or not.

Output

Output

I

OUT

A

U

OUT

V

Variable

Load,
0-20A

All parameters are specified at 24V, 40A output current, 26°C ambient and after a 5 minutes run-in time, unless noted otherwise.

Rockwell Automation Publication 1606-RM010A-EN-P — February 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 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.

Input / output current
conditions

Input: 2x10A

Output: 20A

Input: 2x20A

Output: 40A

Lifetime expectancy

*)

649 000h

*)

246 000h

*)

at 24V and 40°C

1 835 000h

*)

696 000h

*)

at 24V and 25°C

MTBF

**)

SN 29500, IEC 61709 3 386 000h 2 706 000h at 24V 40°C
5 667 000h 4 686 000h at 24V 25°C
MTBF

**)

MIL HDBK 217F 116 000h 97 000h Ground Fixed GF40 (24V and 40°C)
155 000h 128 000h Ground Fixed GF25 (24V and 25°C)
612 000h 522 000h Ground Benign GB40 (24V and 40°C)
813 000h 687 000h Ground Benign GB25 (24V and 25°C)

*) The Lifetime expectancy shown in the table indicates the minimum 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 and is calculated according to the
capacitor’s manufacturer specication. The manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years
(131 400h). Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices.

**) 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-RM010A-EN-P — February 2014

All parameters are specified at 24V, 40A output current, 26°C ambient and after a 5 minutes run-in time, unless noted otherwise.