Rockwell Automation 1606-XLSRED40 User Manual

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Reference Manual

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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

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-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

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:

2x10A2x5A

Input / Output Current

Input:

2x20A2x15A

0 0

140mV

160mV

24V,20A

I1I2=

U2U1= Voltage Drop

U1=

OUT

Output

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

Output Current

140mV

160mV

Voltage Drop

U1=

OUT

Not used or

power supply

with lower

voltage

24V,20A

Output

OUT

Variable

Load, 0-20A

Input 1

Input 2

Output

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.

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.

6.0

5.0

4.0

3.0

2.0

1.0 0

0510 30

Output Current

2515 20 35

24V,20A

e.g.

24.5V

24V,20A

e.g.

24.5V

I1I2=

input: 2x20A

(only one input is connected to input voltage)

(both inputs are connected to input voltages)

XLSRED40

Input 1

Input 2

U2U

L=osses

U1=

Output

I1+)(

Bulletin 1606 Switched Mode Power Supplies

Output

Variable

Load,

OUT

0-40A

OUT

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

Power Losses, typ.

3.5

3.0

2.5

2.0

24V,20A

XLSRED40

Input 1

1.5

1.0

0.5 0

Output Current

0 2.5 5 15

12.57.5 10 17.5

Input 2

Losses

U1=

OUT

-*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

OUT

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.

Bulletin 1606 Switched Mode Power Supplies

6. Terminals and Wiring

Input Output

Type Screw termination

IP20 Finger safe construction. Suitable for eld installation.

Screw termination IP20 Finger safe construction.

Suitable for eld installation. Solid wire 0.5-6mm2 0.5-16mm2 Stranded wire 0.5-4mm

0.5-10mm2 American Wire Gauge 20-10 AWG 22-8 AWG Max. wire diameter 2.8mm (including ferrule) 5.2mm (including ferrule) Wire stripping length 7mm / 0.275inch 12mm / 0.5inch Screwdriver 3.5mm slotted or Pozidrive No 2 3.5mm slotted or Pozidrive No 2 Recommended tightening torque 0.8Nm, 7lb.in 1.2Nm, 10.6lb.in

To connect the chassis to ground, use a ring-type terminal (ring cable lug) which is suitable for a M4 screw and connect it to the chassis ground terminal on top of the unit.

Instructions:

a) The external circuitry of all terminals must meet the safety requirements stipulated by IEC/EN/UL 60950-1: SELV. b) 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. c) Follow national installation codes and installation regulations! d) Ensure that all strands of a stranded wire enter the terminal connection! e) Screws of unused terminal compartments should be securely tightened. f) Ferrules are allowed. g) Do not connect or disconnect the wires from the terminals below -25°C (-13°F).

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 7

Bulletin 1606 Switched Mode Power Supplies

7. Functional Diagram

Fig. 7-1 Functional diagram

Input 1

control

Input 2

Chassis Ground

Output

8. Front Side and User Elements

Fig. 8-1 Front side

Output Terminals (screw terminals)

Chassis Ground Terminals

To be connected on the top side of the housing with a ring-type terminal (ring cable lug) which is suitable for a M4 screw. Connection of the chassis is optional and not required since the unit fulls the requirements according to protection class III.

Input Terminals for Input 1 (screw terminals)

Input Terminals for Input 2 (screw terminals)

Chassis Ground

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

8 Rockwell Automation Publication 1606-RM010A-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 on 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 20V/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

500V 1kV

Criterion A

Surge voltage on output lines

EN 61000-4-5 + -

+/-

Chassis ground

500V 1kV

Criterion A

Conducted disturbance EN 61000-4-6 0.15-80MHz 20V 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 limits for DC power ports according

EN 61000-6-3 fullled

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.

*) For information only, not mandatory for EN 61000-6-3. Provided, that power sources connected on the inputs fulll the requirements too.

Switching frequency

The internal auxiliary supply is generated with a boost converter. The switching frequency is typ. 16kHz.

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 9

Bulletin 1606 Switched Mode Power Supplies

10. Environment

Operational temperature

-40°C to +70°C (-40°F to 158°F) 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; 17.8-500Hz: 2g

2 hours / axis

IEC 60068-2-6

Shock 30g 6ms, 20g 11ms

3 bumps / direction, 18 bumps in total

IEC 60068-2-27

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,

see Fig. 10-2 Altitude de-rating 2.5A/1000m or 5°C/1000m > 2000m (6500ft), see Fig. 10-2 Over-voltage category not applicable The concept of the overvoltage category is

used for equipment energized directly from

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

use in paint shops.

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

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

Allowed Output Current

0 2000 4000

6000m

65A

Altitude

Allowed Output Current

-40 0 20 40

70°C

65A

60-25

Ambient Temperature

10 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.

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 Mosfet between input and output 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

Type test 60s 500Vac

Factory test 5s 500Vac

Field test 5s 500Vac

Cut-off current setting > 2mA

Chassis

In- / Output

Bulletin 1606 Switched Mode Power Supplies

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 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

Approval for use in hazardous locations Zone 2 Category 3G. Number of ATEX Certicate: EPS 11 ATEX 1 312 X The redundancy module must be built-in in an IP54 enclosure.

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-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.

Bulletin 1606 Switched Mode Power Supplies

15. Physical Dimensions and Weight

Weight 340g / 0.75lb 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 (127mm) 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, 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 13

Bulletin 1606 Switched Mode Power Supplies

16. Accessories

1606-XLC Wall mounting bracket This standard bracket is used to mount the 1606-XLSRED40 redundancy module on a wall, without a DIN rail.

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

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

14 Rockwell Automation Publication 1606-RM010A-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 load, including unlimited capacitive and inductive loads.

17.3. Lateral Installation Clearances

The minimum clearance recommendations are dened in section 2. Normally, the following installation clearance are recommended: 40mm on top, 20mm on the bottom, 5mm on the

left and right sides 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).

The clearance between the power supplies and the redundancy module can be reduced to zero under the following conditions:

0mm0mm

20A

Load

L1 L2 L3 PE

+ +

- -

Power Supply

24V,20A

DCOK

L1 L2 L3 PE

+ +

- -

Power Supply

24V,20A

DCOK

1606XLSRED40

Redundancy Module

Output

Input

+-+

- 1+1 redundancy application with maximum 20A output current.

- The power supplies are from the XLS family.

- The redundancy module is placed between the two power supplies.

- The output voltage is set to the same level on both power supplies.

Bulletin 1606 Switched Mode Power Supplies

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 15

Bulletin 1606 Switched Mode Power Supplies

17.4. 1+1 Redundancy up to 20A

1+1 Redundancy up to 20A requires two 20A power supplies and one 1606-XLSRED40 redundancy module.

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

Fig. 17-1 Wiring diagram, 1+1 Redundancy, 20A output current

Failure

Monitor

+-+

+ +

- -

DC-

24V,20A

Power Supply

L1 L2 L3 PE

I I I I I I

L1 L2 L3 PE

Input

1606XLSRED40

Redundancy Module

Output

+ +

- -

24V,20A

Power Supply

L1 L2 L3 PE

DCOK

20A

Load

17.5. N+1 Redundancy, Example with 60A

N+1 Redundancy up to 60A requires four 20A power supplies and two 1606-XLSRED40 redundancy modules.

+ +

24V,20A

Power Supply

L1 L2 L3 PE

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

Fig. 17-2 Wiring diagram, n+1 Redundancy, 60A output current

+-+

- -

DCOK

Input

1606XLSRED40

Redundancy Module

Output

+ +

- -

24V,20A

Power Supply

L1 L2 L3 PE

I I I

DCOK

+ +

- -

24V,20A

Power Supply

L1 L2 L3 PE

DCOK

+-+

Input

1606XLSRED40

Redundancy Module

Output

Input

Failure

Monitor

+ +

- -

DC-

24V,20A

Power Supply

L1 L2 L3 PE

I I II I I I I I

60A

Load

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

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

Bulletin 1606 Switched Mode Power Supplies

17.6. 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. The amount of reduction inuences the lifetime expectancy of the power supply. Therefore, two different derating curves for continuous operation can be found below:

Curve A1 Recommended output current. Curve A2 Max allowed output current (results in approximately half the lifetime expectancy of A1).

Fig. 17-3 Mounting Orientation A

(Standard orientation)

Redundancy

Module

INPUT

OUTPUT

Output Current

20 30 40 50

70°C

40A

Ambient Temperature

Fig. 17-4 Mounting Orientation B

(Upside down)

Redundancy

Module

INPUT

OUTPUT

Output Current

20 30 40 50

70°C

40A

Ambient Temperature

Fig. 17-5 Mounting Orientation C

(Table-top mounting)

Output Current

20 30 40 50

70°C

40A

Ambient Temperature

Fig. 17-6 Mounting Orientation D

(Horizontal cw)

Redundancy

Module

INPUT

OUTPUT

Output Current

20 30 40 50

70°C

40A

Ambient Temperature

Fig. 17-7 Mounting Orientation E

(Horizontal ccw)

Redundancy

Module

INPUT

OUTPUT

Output Current

20 30 40 50

70°C

40A

Ambient Temperature

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 17

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 Con ne ct representative, or visit http://www.rockwellautomation.com/support/

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 cator 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.

Documentation Feedback

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

literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf.

Publication 1606-RM010A-EN-P — February 2014

, available at http://

Rockwell Automation 1606-XLSRED40 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual