Rockwell Automation Allen-Bradley 1606-XLERED20Y Bedienungsanleitung

Dual Redundancy Module with

Load Sharing - 24…28V, 20 A

Catalog Number 1606-XLERED20Y

Reference Manual Original Instructions

2Rockwell Automation Publication 1606-RM107A-EN-P - July 2020

Dual Redundancy Module with Load Sharing - 24…28V, 20 A Reference Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize

themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to

be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be

impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use

or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for

actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software

described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is

prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may

lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or

economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may

be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach

dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc

Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements

for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 1606-RM107A-EN-P - July 2020 3

Table of Contents

Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lifetime Expectancy and Meant Time Between Failure . . . . . . . . . . . . . . 9

Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Redundancy OK Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Load Share OK Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Automated Load Sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Approximate Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

JulySide Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Using Only One Input Instead of Both Channels . . . . . . . . . . . . . . . . . . . 19

Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Applications that Allow Reduced Side Clearances . . . . . . . . . . . . . . . . . . 20

1+1 Redundancy Up to 10 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4Rockwell Automation Publication 1606-RM107A-EN-P - July 2020

Notes:

Rockwell Automation Publication 1606-RM107A-EN-P - July 2020 5

Terminology and

Abbreviations

Figure 1 - 1 + 1 Redundancy

Product Overview

The redundancy uses MOSFETs instead of diodes for the decoupling of the two

input channels. This redundancy design reduces the heat generation and the

voltage drop between input and output. The redundancy module does not

require an additional auxiliary voltage.

Due to the low power losses, the unit is slender and only requires 32 mm

(1.26 in.) width on the DIN rail. Large connection terminals allow for a safe and

fast installation. The large international approval package makes this unit

suitable for nearly every application.

Terms Descriptions

DC 24V A value that is displayed with the AC or DC before the value represents a nominal

voltage with standard tolerances (usually ±15%) included. For example: DC 12V

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

24V DC A value with the unit (V DC) at the end is a momentary value without any additional

tolerances included.

nom Indicates a nominal value.

typ Indicates a typical value.

— (alone in table cell) A single dash alone in a table cell indicates that there is no information to be included

in that cell.

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. For

example, two 10 A power supplies are needed to achieve a 10 A redundant system.

Load

IN 1

OUT

IN 2

Figure 2 - 1606-XLERED20Y

Dual Redundancy Module The 1606-XLERED20Y is a redundancy module

for building redundant power supply systems.

It is equipped with two input channels and one

output. MOSFET technology is used to

decouple the two inputs.

The device is equipped with an automated load

sharing feature, which can compensate a small

voltage imbalance between the power supplies

connected to the inputs to achieve an even

current share. It also monitors the function of

the redundancy circuitry and provides a signal

if there is a failure or a high output current,

which could prevent redundancy if one power

supply fails. If this feature is not required, the

1606-XLERED20 is available.

6Rockwell Automation Publication 1606-RM107A-EN-P - July 2020

Product features include:

• Design for 1+1 redundancy with automated load sharing

• Dual-input with single output

• Redundancy OK Signal, which reports the loss of redundancy

• 160% (32.5 A) peak load capability

• Reverse input polarity protection

• Full power at temperatures -40…+70 °C (-40…+158 °F)

• Width only 32 mm (1.26 in.)

• Rugged metal housing

• Easy wiring, with distribution terminal for negative pole

Specifications

Catalog Numbers

Attributes Values Notes

Input voltage DC 24…28V ±25%

Input voltage range 18…35V DC —

Input current 2 x 0…12 A ambient < 45 °C (113 °F)

2 x 0…10 A ambient < 70 °C (158 °F)

Output current

0…24 A ambient < 45 °C (113 °F)

0…20 A ambient < 70 °C (158 °F)

26 A max in overload(1) or short circuit mode

(1) Currents at voltages below 6V.

Input to output voltage drop 0.1…0.5V(2)

(2) Depending on load share function.

input: 2 x 5 A

0.2…0.5V(2) input: 2 x 10 A

Power losses

1.7 W at no load

2.6…4.7 W(2) input: 2 x 5 A

5.6…8.7 W(2) input: 2 x 10 A

Temperature range -40…+70 °C

(-40…+158 °F) operational

Dimensions 32 x 124 x 117 mm

(1.26 x 4.88 x 4.61 in.) W x H x D

Weight 310 g (0.69 lb) —

Catalog Numbers Descriptions

1606-XLERED20Y Redundancy module

1606-XLA-S37 Side mount bracket

Rockwell Automation Publication 1606-RM107A-EN-P - July 2020 7

Input and Output

Characteristics

Attributes Values Notes

Number of inputs — 2 —

Number of outputs — 1 —

Input voltage Nom DC 24…28V ±25% —

Input voltage range — 18…35V DC —

Voltage drop, input to output

Typ 0.1…0.5V at 2 x 5 A, load share dependent on function, see Figure 3

Typ 0.2…0.5V at 2 x 10 A, load share dependent on function, see Figure 3

Typ 0.24…0.5V at 2 x 12 A, load share dependent on function, see Figure 3

Input current

Nom 2 x 0…12 A continuous, ambient temperature < 45 °C (113 °F)

Nom 2 x 0…10 A continuous, ambient temperature < 70 °C (158 °F)

Nom 2 x 17 A(1) for 5 s max

Max 2 x 700 A for 1 ms max

Output current

Nom 24 A continuous, ambient temperature < 45 °C (113 °F)

Nom 20 A continuous, ambient temperature < 70 °C (158 °F)

Nom 32.5 A for 5 s max

Max 26 A in overload /short-circuit (voltage < 6V). Ensure that the sum of

input currents does not exceed this value.

Reverse current Max 1 mA at 24V, per input, -40…+70 °C (-40…+158°F)

Reverse voltage Max 40V DC voltage applied to the output, continuously allowed

Output capacitance Typ 320 μF —

(1) The average value (R.M.S. value) of the output current must not exceed the values of the continuous output current.

Figure 3 - Input to Output Voltage Drop Figure 4 - Test Setup for Voltage Drop Measurements

Voltage Drop, typ

0 mV

5 A 15 A

100 mV

200 mV

300 mV

400 mV

500 mV

20 A10 A

Output:

2 x 5 A2 x 2.5 A

Input:

2 x 10 A2 x 7.5 A

600 mV

25 A

2 x 12.5 A

Input / Output Current

Depending on

Load Share

Regulation 25 °C

60 °C

Power

Supply

24V, 12 A

= Voltage Drop

OUT

Output

OUT

Variable

Load,

0...24 A

1606-XLERED20Y

Input 1

Input 2

Output

Power

Supply

24V, 12 A

8Rockwell Automation Publication 1606-RM107A-EN-P - July 2020

Power Losses

Lifetime Expectancy and

Meant Time Between

Failure

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 in one housing. The only common point is the circuit trace

that ties the two separate circuits together at the output.

The mean time between failure (MTBF) values below are for the entire dual-

input module. If the MTBF number of only one path is needed, double the

value from the table.

Attributes Values Notes

Power losses Typ 2.6…4.7 W at 2 x 5 A, 25 °C (77 °F) ambient temperature

Typ 5.6…8.7 W at 2 x 10 A, 25 °C (77 °F) ambient temperature

Standby power losses Typ 1.7 W at no output current

Figure 5 - Power Losses Figure 6 - Test Setup for Power Loss Measurements

Power Losses, typ

5 A 15 A

2 W

4 W

6 W

8 W

10 W

20 A10 A

Output:

2 x 5 A2 x 2.5 A

Input:

2 x 10 A2 x 7.5 A

12 W

25 A

2 x 12.5 A

Input / Output Current

Depending on

Load Share

Regulation

25 °C

60 °C

25/

60 °C

Output

Power

Supply

24V, 12 A

OUT

L=osses

OUT

+)(*

OUT

Variable

Load,

0...24 A

1606-XLERED20Y

Input 1

Input 2

Output

Power

Supply

24V, 12 A

Attributes

Values Based on Input and Output

Current Conditions Notes

Input: 2 x 5 A

Output: 10 A

Input: 2 x 10 A

Output: 20 A

Lifetime expectancy(1) 372,000 hr 182,000 hr at 24V and 40 °C (104 °F)

1,053,000 hr 516,000 hr at 24V and 25 °C (77 °F)

MTBF(2) SN 29500, IEC 61709 2,306,000 hr 1,954,000 hr at 24V and 40 °C (104 °F)

3,913,000 hr 3,359,000 hr at 24V and 25 °C (77 °F)

MTBF(2) MIL HDBK 217F

964,000 hr 858,000 hr Ground Fixed GF40: 24V, and 40 °C (104 °F)

1,379,000 hr 1,226,000 hr Ground Fixed GF25: 24V, and 25 °C (77 °F)

278,000 hr 243,000 hr Ground Benign GB40: 24V, and 40 °C (104 °F)

381,000 hr 330,000 hr Ground Benign GB25: 24V, and 25 °C (77 °F)

(1) The lifetime expectancy that is 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 specified in operational hours and is calculated according to the

manufacturer specification of the capacitor. The manufacturer of the electrolytic capacitors only states a maximum life of up to 15 years

(131,400 hr). Any number exceeding this value is a calculated theoretical lifetime, which can be used to compare devices.

(2) Mean time between failure 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 value is a statistical

representation of the likelihood of a device to fail. An MTBF value of for example 1,000,000 hr means that statistically one unit fails every 100

hours if 10,000 units are installed in the field. However, it cannot be determined if the failed unit has been running for 50,000 hr or only for

100 hr.

Rockwell Automation Publication 1606-RM107A-EN-P - July 2020 9

Terminals and Wiring

When wiring, be aware of the following:

• Use appropriate copper cables that are designed for minimum

operating temperatures of:

- 60 °C (140 °F) for ambient up to 45 °C (113 °F)

- 75 °C (167 °F) for ambient up to 60 °C (140 °F)

- 90 °C (194 °F) for ambient up to 70 °C (158 °F)

• Follow national installation codes and installation regulations.

• Ensure that all strands of a stranded wire enter the terminal

connection.

• Securely tighten screws of unused terminal compartments.

• Ferrules are allowed.

Functional Diagram

Input and Output Attributes Values Signals

Type Screw termination

IP20 fingersafe construction.

Suitable for field installation. Push-in terminals

Solid wire 6 mm2max 1.5 mm2max

Stranded wire 4 mm2max 1.5 mm2max

American Wire Gauge 20…10 AWG AWG 24…16

Wire diameter max 2.8 mm (0.11 in.)

(including ferrule) 1.6 mm (0.06 in.) max

(including ferrules)

Wire stripping length 7 mm (0.28 in.) 7 mm (0.28 in.)

Screwdriver 3.5 mm (0.14 in.) slotted or

Pozidriv No 2 not required

Recommended tightening torque 0.8 N•m (7 lb•in) not applicable

Figure 7 - Functional Diagram

Input 1

Control

Input 2

Redundancy OK

Contact

Redundancy

Chassis

Ground

Output

Load Share

Load Share OK

Contact

Load Share

Controller

5 A

10 A Output current

alarm threshold

20 A

Input 2Input 1

Output current <

Redundancy OK

Controller

Redundancy OK

Input

Voltages

Monitor Output Current

Monitor

10 Rockwell Automation Publication 1606-RM107A-EN-P - July 2020

Front Side and User

Elements

Redundancy OK Relay

Contact

This feature reports the loss of redundancy by opening the relay contact (pin 23

and 24).

Figure 8 - Front Side User Elements

1 Input Terminals for Input 1 (screw terminals)

2 Input Terminals for Input 2 (screw terminals)

3 Output Current < INStatus Indicator The LED is in a solid on state when the

output current is smaller than the output current alarm threshold. See Output

Current Alarm Threshold Selector (user element 6).

4 Redundancy OK Status Indicator The LED is in a solid on state when no errors

are detected. Errors include:

• One or both input voltages are out of range (below 22V or above 30V).

• Output current is higher than the adjusted value of the output current

threshold setting.

• Internal anomaly is detected.

5 Load Share Status Indicators The three LEDs indicate the status of the load

sharing between the two power supplies. See Automated Load Sharing on

page 11 for detailed description.

6 Output Current Alarm Threshold Selector If the output current increases, for

example due to additional loads, and exceeds the nominal current of one power

supply unit, redundancy is no longer guaranteed. To avoid the loss in

redundancy, the output current is monitored and is reported through LEDs and

relay contacts when exceeding the predefined value.

• Set the selector to 5 A in combination with two 5 A power supplies (1+1 red.)

• Set the selector to 10 A in combination with two 10 A power supplies (1+1 red.)

• Set the selector to 20 A for n+1 redundant systems. With this setting, the

redundancy module cannot check redundancy.

Exceeding the current by less than 2 seconds is ignored.

7OutputTerminals(screw terminals)

8 Chassis-Ground Terminal Connection of the chassis is optional and not

required since the unit fulfills the requirements according to protection class III.

9 Relay Contact Redundancy OK (push-in terminals) The relay contact is closed

when no redundancy errors are detected. The relay contact is also synchronized

with the Redundancy OK LED. See Redundancy OK Relay Contact on page 10 for

contact ratings.

10 Relay Contact Load Share OK (push-in terminals) The relay contact is closed

when the output voltage of the two power supplies is sufficiently adjusted.

Deviations less than 2 s are ignored. See Automated Load Sharing on page 11 for

detailed description. See Load Share OK Relay Contact on page 11 for contact

ratings.

Attributes Values Notes

Contact ratings Max 60V DC 0.3 A, 30V DC 1 A, 30V AC 0.5 A resistive load

Min 1 mA at 5V DC permissible load min

Isolation voltage See Dielectric Strength on page 14.

Contact is closed When no errors are detected.

Contact is open

When:

One or both input voltages are below 22V DC or above 30V DC.

The output current is higher than the adjusted value of the output current threshold setting.

An internal anomaly of the redundancy module is detected (decoupling measures and several

internal test routines).

Input voltage errors less than 2 s are ignored.

Overcurrent errors (less than 150% of the adjusted value) less than 4 s are ignored.

Overcurrent errors (above 150% of the adjusted value) less than 30 ms are ignored.

Internal errors less than 10 s are ignored.

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