Rockwell Automation Allen-Bradley 1606-XLSRED40 Bedienungsanleitung

Reference Manual

egaPegaP

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

Bulletin 1606 Switched Mode Power Supplies

CatalogNumber: 1606-XLSRED40

Index

•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

• 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.

Terminology and Abbreviations

N+1

Redundancy

1+1

Redundancy

IN 1

OUT

IN 2 IN 1

OUT

IN 2 IN 1

OUT

IN 2

Load

IN 1

OUT

IN 2

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

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

Bulletin 1606 Switched Mode Power Supplies

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

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.

Specication Quick Reference

Input voltage DC 12-28V ±30%

Input voltage

range

8.4-36.4Vdc

Input current 2x 0-20A continuous

2x 20-32.5A for 5 seconds

Output current 0-40A continuous

40-65A for 5 seconds

65A at cont. overload

or short circuit

Input to output

voltage drop

typ. 72mV

typ. 112mV

typ. 140mV

input: 2x10A

input: 1x20A

input: 2x20A

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,

no de-rating req.

Dimensions 36x124x127mm

WxHxD

*) plus 4mm in depth for the screw terminal

Catalog Numbers

Redundancy 1606-XLSRED40 12-28V Standard unit

Module

Accessory

1606-XLC Wall/panel mount

bracket

Certication Marks

IND. CONT. E

UL 508

UL 60950-1

Class I Div 2

IECEx

ATEX

II 3G Ex nA IIC T4 Gc

Marine

EMC, LVD

Mosfet Redundancy Module

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

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.

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.

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.

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

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

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...25°C

B...60°C

2x10A2x5A

Input / Output Current

Input:

2x20A2x15A

140mV

160mV

24V,20A

= Voltage Drop

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

A...25°C

B...60°C

Output Current

140mV

160mV

Voltage Drop

OUT

Not used or

power supply

with lower

voltage

24V,20A

Output

OUT

Variable

Load,

0-20A

Input 1

Input 2

Output

XLSRED40

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

4. Power Losses

DC 24V

Power losses typ. 2.15W input: 2x10A

typ.

6.3W input: 2x20A

typ.

2.6W input: 1x20A,

(only one input is connected to input voltage)

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

(only one input is connected to input voltage)

typ. 0.7W at no output current,

(both inputs are connected to input voltages)

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

Output

24V,20A

e.g.

24.5V

OUT

L=osses

OUT

+)(*

OUT

24V,20A

e.g.

24.5V

Variable

Load,

0-40A

XLSRED40

Input 1

Input 2

Output

Power Losses, typ.

0510 30

1.0

2.0

4.0

5.0

2515 20 35

Output Current

3.0

A...25°C

B...60°C

6.0

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

Power Losses, typ.

0 2.5 5 15

0.5

1.0

2.0

2.5

12.57.5 10 17.5

Output Current

1.5

3.0

3.5

A...25°C

B...60°C

Losses

OUT

Output

24V,20A

OUT

XLSRED40

Input 1

Input 2

Output

Variable

Load,

0-20A

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.

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

6Rockwell Automation Publication 1606-RM010A-EN-P — February 2014

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.

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

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 0.5-6mm20.5-16mm2

Stranded wire 0.5-4mm20.5-10mm2

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.

8Rockwell Automation Publication 1606-RM010A-EN-P — February 2014

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

AOutput Terminals (screw terminals)

BChassis 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.

CInput Terminals for Input 1 (screw terminals)

DInput 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.

Rockwell Automation Publication 1606-RM010A-EN-P — February 2014 9

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

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

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.

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

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

normalmode

Altitude

overload/shortcircuit

A...Tamb<70°C

B...Tamb<60°C

C...Tamb<50°C

ABC

Allowed Output Current

-40 0 20 40 70°C

65A

60-25

normalmode

atoverload/shortcircuit

Ambient Temperature

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