Allen-Bradley 1606-XLBRED20 User manual

Dual Input Redundancy Module
- DC 12…28V, 20 A
Catalog Number 1606-XLBRED20
Reference Manual Original Instructions

2Rockwell Automation Publication 1606-RM111A-EN-P - July 2020
Dual Input Redundancy Module - DC 12…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-RM111A-EN-P - July 2020 3
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . . 8
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Using Only One Input Instead of Both Channels . . . . . . . . . . . . . . . . . . . 14
Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Use In a Tightly Sealed Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Example: Redundancy for Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Example: 1+1 Redundancy Up To 10 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example: 1+1 Redundancy Up To 20 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4Rockwell Automation Publication 1606-RM111A-EN-P - July 2020
Notes:

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 5
Terminology and
Abbreviations 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.
N+1 Redundancy
Use of three or more identical power supplies in parallel, which are allowed to be
connected in parallel for higher output currents, 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. For
example, to achieve a 40 A redundant system, five 10 A power supplies are needed in
an N+1 redundant system. Ensure that the power supplies are allowed to be connected
in parallel to increase the output power.
Figure 1 - 1+1 Redundancy Figure 2 - N+1 Redundancy
AC
DC
AC
DC
Load
+
-
IN 1
OUT
IN 2
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
IN 1
OUT
IN 2 IN 1
OUT
IN 2 IN 1
OUT
IN 2
Load
+
-

6Rockwell Automation Publication 1606-RM111A-EN-P - July 2020
Product Overview The 1606-XLBRED20 is a redundancy module, which can be used to build 1+1
and N+1 redundant systems. The 1606-XLBRED20 redundancy module has two
input channels, which can be connected to power supplies with up to 10 A
output current. The module has one output, which can carry nominal currents
up to 20 A.
The module is suitable for power supplies with constant current overload
behavior and any kind of “hiccup” overload behavior. The 1606-XLBRED20 is
well suited for use in a redundant system in which the power supply itself is
equipped with a DC-OK signal.
Another application for this redundancy module is to separate sensitive loads
from non-sensitive loads. This avoids the distortion of the power quality for
the sensitive loads, which can cause controller failures.
Product features:
• Cost-effective solution to build redundant systems
• Dual-input with single output
• Two diodes (common cathode)
• DC 12…28V ±25% wide-range input
• Full power from -40…+55 °C (-40…+131 °F)
• Width only 39 mm (1.54 in.)
• Large screw terminals
• Easy wiring: distribution terminal for negative pole included
Specifications
Catalog Number
Attributes Values Notes
Input voltage DC 12…28V ±25%
Input voltage range 9…35V DC —
Input current 2 x 0…10 A ambient < 55 °C (131 °F)
2 x 0…6.25 A ambient < +70 °C (158 °F)
Output current
0…20 A ambient < 55 °C (131 °F)
0…12.5 A ambient < +70 °C (158 °F)
26 A at cont. overload/ short circuit
Input to output voltage drop 0.46V typ input: 2 x 5 A
0.56V typ input: 2 x 10 A
Power losses
0 W at no load
4.6 W typ input: 2 x 5 A
11.2 W typ input: 2 x 10 A
Temperature range -40…+70 °C (-40…+158 °F) operational
Derating 0.5 A/1 °C (0.5 A/1.8 °F) 55…70 °C (131…158 °F)
Dimensions 39 x 124 x 124 mm
(1.54 x 4.88 x 4.88 in.) W x H x D
Weight 280 g (0.62 lb) —
Catalog Number Description
1606-XLBRED20 Redundancy module

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 7
Input and Output
Characteristics
In Figure 4, the power supplies can be either 1606-XLX120 or 1606-XLX240. The
redundancy module is 1606-XLBRED20.
Power Losses
Figure 5 - Power Losses at 25 °C (77 °F)
Attributes Values Notes
Number of inputs — 2 —
Number of outputs — 1 —
Input voltage Nom DC 12…28V ±25% —
Input voltage range — 9…35V DC —
Voltage drop, input to output Typ 0.46V at 2 x 5 A, see Figure 3
Typ 0.56V at 2 x 10 A, see Figure 3
Input current Nom 2 x 0…10 A continuous
Nom 2 x 10…16 A for 5 s
Peak input current Max 1000 A for 10 ms max per input
Output current
Nom 20 A continuous
Nom 20…32 A for 5 s
Max 26 A(1)
(1) Ensure that the continuous output current does not exceed 26 A. Check the short-circuit current of the power sources and if
the power source can deliver more than 26 A together, use an appropriate fuse on the output.
at continuous overload or short circuit
Reverse current Max 4 mA per input, -40…+70 °C (-40…+158 °F)
Reverse voltage Max 45V DC voltage applied to the output, continuously allowed
Figure 3 - Input to Output Voltage Drop Figure 4 - Test Setup For Voltage Drop Measurements
Voltage Drop, Typ
100 mV
200 mV
300 mV
400 mV
500 mV
600 mV
5 A 15 A 20 A10 A
Output:
2x5 A2x2.5 A
Input:
2x10 A2x7.5 A
0
0
Input, Output Current
A...25°C
B...60°C
AB
V
A
Power Supply
24V, 5 A or
24V, 10 A
+
-
V
A
I 1
I 2
U 1
U 2
I 1 I 2 = U 2 U 1 = Voltage Drop U 1 = U OUT -
Output
A
V
I OUT
U OUT
Variable
Load,
0…20 A
Redundancy Module
Input 1
Input 2
Output
Power Supply
24V, 5 A or
24V, 10 A
+
-
Attribute Values Notes
Power losses
— 0 W at no load (stand-by)
Typ 4.6 W at 24V and 2 x 5 A input current
Typ 11.2 W at 24V and 2 x 10 A input current
Power Losses, Typ
0
0510
2
4
6
8
10
12 W
20 A15
Output Current

8Rockwell Automation Publication 1606-RM111A-EN-P - July 2020
Lifetime Expectancy and
Mean Time Between Failure
The redundancy module has two input channels, which are completely
independent from each other. 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 in the following table are for
the entire dual-input module. If you need the MTBF number of only one path,
double the value from the table.
Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field wiring and
factory wiring.
Wiring rules:
• Use appropriate copper cables that are designed for minimum operating
temperatures of:
- 75 °C (167 °F) for ambient up to 55 °C (131 °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.
• Unused terminal compartments should be securely tightened.
• Ferrules are allowed.
Input / Output Current Conditions
N+1 Redundancy
Input: 2 x 10 A
Output: 20 A
1+1 Redundancy
Input: 2 x 5 A
Output: 10 A
Notes
Lifetime expectancy(1) Min 113,000 h 309,000 h at 24V and 40 °C (104 °F)
Min 320,000 h 874,000 h at 24V and 25 °C (77 °F)
MTBF(2) SN 29500, IEC 61709 — 7,837,000 h 20,310,000 h at 24V 40 °C (104 °F)
— 19,408,000 h 46,382,000 h at 24V 25 °C (77 °F)
MTBF (2) MIL HDBK 217F
— 1,774,000 h 1,817,000 h at 24V and 40 °C (104 °F) (Ground Fixed GF40)
— 2,709,000 h 2,782,000 h at 24V and 25 °C (77 °F) (Ground Fixed GF25)
— 3,675,000 h 3,707,000 h at 24V and 40 °C (104 °F) (Ground Benign GB40)
— 5,620,000 h 5,674,000 h at 24V and 25 °C (77 °F) (Ground Benign GB25)
(1) The Lifetime expectancy values that are shown in the table indicate the minimum operating hours (service life) and are 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 h). Any number that exceeds this value is a calculated theoretical lifetime, which can be used to compare devices.
(2) Mean Time Between Failure (MTBF) 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 h 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 h or only for 100 h.
Attributes Values and Descriptions
Type screw terminals
Solid wire 6 mm2max
Stranded wire 4 mm2max
American Wire Gauge AWG20…10
Wire diameter max 2.8 mm (0.110 in.) (including ferrules)
Wire stripping length 7 mm (0.28 in.)
Screwdriver 3.5 mm (0.138 in.) slotted or cross-head No 2
Recommended tightening torque 1 N•m, 9 lb•in

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 9
Functional Diagram Figure 6 - Functional Diagram
Front Side and User
Elements
+
-
+
-
+
Input 1
Input 2
Output
-
Surge
Protection
Surge
Protection
Surge
Protection
+
Figure 7 - Front Side User Elements
1 Input terminals for input 1 and input 2
2Outputterminals
Two identical (+) poles
1
2

10 Rockwell Automation Publication 1606-RM111A-EN-P - July 2020
Electromagnetic
Compatibility
The redundancy module is suitable for applications in industrial, residential,
commercial, and light industrial environments without any restrictions.
The following table shows electromagnetic compatibility (EMC) immunity
according to generic standards EN 61000-6-1 and EN 61000-6-2.
The following table shows EMC emission according to generic standards
EN 61000-6-3 and EN 61000-6-4. The redundancy module incorporates only
diodes and no RF-generating circuits and does not contribute to EMC
emissions.
Attributes Standards Values Criteria(1)
Electrostatic discharge EN 61000-4-2
Contact discharge
on indirect coupling plane 8 kV Criterion A
Air discharge 15 kV Criterion A
Electromagnetic RF field EN 61000-4-3 80 MHz…2.7 GHz 20V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines 2 kV Criterion A
Output lines 2 kV Criterion A
Surge voltage on input lines EN 61000-4-5 + -500V Criterion A
+/- earthed DIN rail 1 kV Criterion A
Surge voltage on output lines EN 61000-4-5 + -500V Criterion A
+/- earthed DIN rail 1 kV Criterion A
Conducted disturbance on input lines EN 61000-4-6 0.15…80 MHz 20V Criterion A
Conducted disturbance on output lines EN 61000-4-6 0.15…80 MHz 20V Criterion A
Power-frequency magnetic field(2) EN 61000-4-8 50 Hz 30 A/m Criterion A
(1) Criteria A: Redundancy module shows normal operation behavior within the defined limits.
(2) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic fields,
for example hall elements and electrodynamic microphones.
Attributes Standards Notes
Conducted emission input lines IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 limits for DC power ports according to EN 61000-6-3 fulfilled(1) (2)
Conducted emission output lines IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 limits for DC power ports according to EN 61000-6-3 fulfilled(1) (2)
Radiated emission EN 55011, EN 55022 Class B(2)
This device complies with FCC Part 15 rules.
Operation is subjected to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any
interference received, including interference that may cause undesired operation.
(1) For information only, not mandatory for EN 61000-6-3.
(2) if power sources that are connected on the inputs fulfill the requirements too.