Rockwell Automation Allen-Bradley 1606-XLSCAP24-6 Bedienungsanleitung

Capacitor-based DC Uninterruptible Power Supplies

Catalog Numbers 1606-XLSCAP24-6, -XLSCAP24-12

Reference Manual

Original Instructions

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-RM054A-EN-P - September 2016 3

Table of Contents

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page.

To order paper copies of technical documentation, contact your local

Allen-Bradley distributor or Rockwell Automation sales representative.

Topic Page Topic Page

Additional Resources 3 Ready and Buffer Relay Contact 15

Terminology and Abbreviations 4 Inhibit Input 16

Product Overview 5 PC-mode 16

Front Side and User Elements 6 Efficiency and Power Loss 17

Accessories 7 Lifetime Expectancy and Mean Time Between

Failure 17

Protection Features 7 Functional Diagram 19

Safety Features 8 EMC 20

Installation Notes 8 Application Notes 21

Terminals and Wiring 10 Troubleshooting 26

Input 11 Specifications 26

Output 12 Environment 27

Charging 14 Standards Compliance and Certifications 28

Buffer Time 14 Approximate Dimensions and Weight 29

Resource Description

Switched Mode Power Supply Technical Data, publication

1606-TD002 Provides specifications and approximate dimensions

for full line of switched mode power supplies.

Industrial Automation Wiring and Grounding Guidelines,

publication 1770-4.1 Provides general guidelines forinstalling a Rockwell

Automation industrial system.

Product Certifications website, http://

www.rockwellautomation.com/global/certification/

overview.page

Provides declarations of conformity, certificates, and

other certification details.

4Rockwell Automation Publication 1606-RM054A-EN-P - September 2016

Capacitor-based DC UPS Power Supplies

Terminology and

Abbreviations Term Definition

Normal mode Describes a condition where the capacitor is charged,

the input voltage is in range, and the output is loaded

within the allowed limits.

Buffer mode Describes a condition where the input voltage is below

the transfer threshold level, the unit is running on

capacitor (buffering) and the output is loaded within

the allowed limits.

Charging mode Describes a condition where the capacitor is being

charged, the input voltage is in range and the output is

loaded within the allowed limits.

Inhibit mode Describes a condition where buffering is disabled on

purpose (service actions)

AC 24V A figure displayed with the AC or DC before the value

represents a nominal voltage with standard tolerances

included. For example, DC 12V describes a 12V battery

disregarding whether it is full (13.7V) or flat (10V)

24V AC A figure with the unit (V AC) at the end is a momentary

figure without any additional tolerances included.

DC-UPS Direct Current- Uninterruptible Power Supplies

ELDC Electrochemical Double Layer Capacitors

EMC Electromagnetic Compatibility

VRLA Valve-regulated Lead-acid

PELV Protected Extra-low Voltage

SELV Separated Extra-low Voltage

Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 5

Capacitor-based DC UPS Power Supplies

Product Overview Bulletin 1606 DC- Uninterruptible Power Supplies (DC-UPSs) use

electrochemical double-layer capacitors (EDLC), commonly known as

ultracapacitors or supercapacitors, that are installed inside. They can bridge

power failures or voltage fluctuation and supply voltage to the DC 24V bus for

a certain period, which allows for a controlled shut-down of the system.

Expensive downtimes, long restart cycles, and loss of data can be avoided.

The power supply provides sufficient voltages, the DC-UPS stores energy in

the capacitors. If there is a mains voltage fault, this energy is released to the DC

bus in a regulated process.

The DC-UPSs require no maintenance and have a similar lifetime expectancy

as standard power supplies. No regular replacement of the capacitors is

necessary as is required for battery-based DC-UPS systems. The wide

temperature range makes the unit suitable for many applications.

Two versions of the DC-UPSs are available and differ by the size of the

installed capacitor.

• Built-in capacitors as energy source, EDLC

• Wide temperature range: -40…+60 °C (-40…+140 °F)

• Typically >10 years operational lifetime expectancy

•RegulatedoutputvoltageinBuffermode

• No ventilated cabinets required, no generation of hydrogen as valve-

regulated lead-acid (VRLA) batteries do

• Active balancing for longest life and buffer times

• Short charging time, unit is rapidly back in Ready mode

• Output is decoupled from the input to separate load

• Circuits into buffered and non-buffered sections

• Supports PC-mode function

• One year warranty

6Rockwell Automation Publication 1606-RM054A-EN-P - September 2016

Capacitor-based DC UPS Power Supplies

Front Side and User Elements

Figure 1 - Front Side of DC-UPS A. Input Terminals (quick-connect spring-clamp terminal)

B. Output Terminals (quick-connect spring-clamp terminal)

Minus-pole has the same reference as the minus-pole of the input terminals

C. Signal Connector (plug connector)

• Ready: contact is closed when status indicator shows ready

• Buffering: contact is closed during buffering

• Inhibit: a voltage applied on this input signal disables buffering (during

service)

• PC-mode: To activate the PC-mode connect the two pins of the signal

connector together (See PC-mode on page 16)

D. Status Indicator (green) Figure 2

• Ready: capacitors are fully charged, no failures detected.

• Charging: capacitors are being charged

• Buffering: capacitors are being discharged

Figure 2 - Updating pattern for the green

status indicator

E. Diagnosis status indicator (yellow) Figure 3

Helps troubleshooting and indicates the following:

• Current Overload: output voltage below 20V DC due to a too high

output current, ready contact is open

• High Temperature: signals capacitor temperature is too high(>65 ºC),

charging and buffering is still possible, ready contact is open

• Buffer Time Expired: buffering stopped due to discharged capacitors -

Inhibit Active: buffering is blocked by the inhibit signal

Figure 3 - Updating Pattern for the Yellow

Diagnosis Status Indicator:

F. Warning status indicator (red) Figure 4

• Check Input Voltage: Indicates a too low or too high input voltage. The

input voltage must be between 23V DC and 30V DC to turn-on the

output and to start charging of the capacitors.

• PC-mode activated indicates, that the PC-mode (See PC-mode on

page 16) is activated.

Figure 4 - Updating pattern for the Red

Warning Status Indicator: G. Chassis Ground (screw)

Use a M4 ring-type terminal to connect the housing to ground, when required

Ready

0Charging

0Buering

Current

Overload

High

Temperature

Buer time

expired

Inhibit

active

Check input

voltage

0PC-Mode

activated

Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 7

Capacitor-based DC UPS Power Supplies

Accessories Wall Mounting Bracket

This bracket is used to mount the DC-UPS on to a flat surface without using a

DIN rail.

Protection Features

With Cat. No. 1606-XLSCAP24-6 With Cat. No. 1606-XLSCAP24-12

Cat. No. 1606-XLC

Feature Description

Output protection Electronically protected against overload, no-load and Short Circuits(1)

Output Overvoltage protection in

buffer mode typ 32V DC

max 35V DC

In case of an internal DC-UPS Anomaly, a redundant circuit

limits the Maximum output voltage. The output shuts down

and automatically attempts to restart.

Degree of protection IP 20 EN/IEC 60529 For use in a controlled environment according

to CSA 22.2 No 107.1-01.

Penetration protection > 3.5 mm screws, small parts

Over-temperature protection included Output shuts down with automatic restart

Input Overvoltage protection - Max. 35V DC, no harm or Anomaly of the unit

Internal input fuse Included Non-user replaceable The tripping of this fuse is caused by

an internal Anomaly. In such cases, send unit to the factory

for inspection.

Internal capacitor fuse Included Non-user replaceableThe tripping of this fuse is caused by

an internal Anomaly. In such cases, send unit to the factory

for inspection.

Overcharging of capacitors Included The capacitors are permanently monitored. In case of a too

high charging voltage, the charger will be switched off with

redundant protection measures.

Balancing of capacitors Included An active balancing circuit Confirms uniform capacitor

voltages. If necessary, the charging current will be reduced

to a safe value.

Failing of one or more capacitors in

the capacitor-string Included Ready contact open, moving light pattern on the three

Status Indicators

Temperature of capacitors Included Indicated by the diagnosis Status Indicator, ready contact

open

Internal errors (broken wires, …) Included Charging is stopped, ready contact open, moving light

pattern on the three Status Indicators

(1) In case of a protection event, audible noise may occur.

8Rockwell Automation Publication 1606-RM054A-EN-P - September 2016

Capacitor-based DC UPS Power Supplies

Safety Features

Installation Notes • The DC-UPS can only be installed and put into operation by qualified

personnel.

• The input must be powered from a Separated Extra-low Voltage (SELV)

or Protected Extra-low Voltage (PELV) power source.

• The DC-UPS does not contain serviceable parts. The tripping of an

internal fuse is caused by an internal anomaly. 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 power terminals are on the top

of the unit.

• The DC-UPS is designed for convection cooling and does not require

an external fan. Do not obstruct airflow and do not cover ventilation

grid (cable conduits) by more than 15%.

• Keep the following installation clearances: 40 mm (1.57 in.) on top,

20 mm (0.79 in.) on the bottom, 5 mm (0.20 in.) on the left and right

sides are recommended when the DC-UPS is loaded permanently with

more than 50% of the rated power. Increase this clearance to 15 mm

(0.59 in.) in case the adjacent device is a heat source, such as a power

supply.

Figure 5 - Typical Wiring Diagram

Attribute Value

Output voltage SELV IEC/EN 60950-1, The input must be powered from a SELV power source.

PELV IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41, The input must be

powered from a PELV power source.

Class of protection III PE (Protective Earth) connection not required

Isolation

resistance > 5 MOhm

> 800 kOhm

> 5 MOhm

Power port to signal port

Power port to housing

Signal port to housing

Dielectric strength 500V AC

500V AC

Power port to signal port

Power port / signal port to housing

Touch current

(leakage current) The leakage current which is produced by the DC-UPS itself depends on the input voltage ripple

and need to be investigated in the final application. For a smooth DCinput voltage, the produced

leakage current is less than 100 µA.

buffered branches

non-buffered branches

L N PE

+ +

- -

Power

Supply

24V Output

DC-UPS

OUT

Ready

Buffering

Inhibit

PC-Mode

Input

Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 9

Capacitor-based DC UPS Power Supplies

The EDLC (storage capacitors) contains Acetonitrile and

Tetraethylammonium-tetrafluoroborate. These components are declared as

non-dangerous goods regarding shipment.

Hazardous Location Information

The DC-UPS 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 are

evaluated according to EN 60079-0 and EN 60079-15.

SHOCK HAZARD: Turn power off before working on the power supply.

Avoid inadvertent repowering.

• 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 hazardous energy can be present inside. Info

for service personnel: Before opening the unit, wait at least 45

minutes after disconnecting the unit from input power so that the

remaining capacitor charge has been fully discharged.

• Use caution so that foreign objects cannot enter the housing.

• Do not use in wet locations or in areas where moisture or

condensation can be expected.

BURN HAZARD: Do not touch components during power-on, and

immediately after power-off. Hot surfaces can cause burns.

WARNING: Explosion Hazard. Substitution of components can impair

suitability for this environment. Do not disconnect the unit or change unit

settings 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 that

has a minimum protection of IP54 and fulfills the requirements of the

EN 60079-15.

10 Rockwell Automation Publication 1606-RM054A-EN-P - September 2016

Capacitor-based DC UPS Power Supplies

Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field and factory

wiring.

• Use appropriate copper cables that are designed for minimum operating

temperatures of:

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

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

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

• Follow national installation codes and installation regulations

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

connection

• Unused terminal compartments should be securely tightened or closed

• Ferrules are allowed

Figure 6 - Connecting a Wire

Attribute Input and Output Signals

Type Bi-stable quick-connect spring-clamp terminals Pluggable spring-clamp terminals

Solid wire, max 6 mm max1.5 mm

Stranded wire, max 4 mm max1.5 mm

American wire gauge AWG 20-10 AWG 24-14

Wire diameter, max 2.8mm (including ferrules) 1.5 mm (including ferrules)

Wire stripping length 10mm (0.4 in.) 8 mm (0.3 in.)

Screwdriver - 2.5 mm slotted

Insert the wire

Close the lever

To disconnect wire:

reverse the procedure

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