Allen-Bradley 1606-XLS960BUFFER User manual

Buffer Module - 24V, 40 A,
160 ms
Catalog Number 1606-XLS960BUFFER
Reference Manual Original Instructions

2Rockwell Automation Publication 1606-RM105A-EN-P - July 2020
Buffer Module - 24V, 40 A, 160 ms 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-RM105A-EN-P - July 2020 3
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bridge Mains Faults without Interruption . . . . . . . . . . . . . . . . . . . . . . 7
Extend Hold-up Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Easily Add and Expand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Select the Backup Threshold Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fixed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Variable Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Buffer Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Charging Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Active Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ready Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . 12
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mounting Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wall Mounting Bracket 1606-XLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Side Mounting Bracket 1606-XLA-S76 . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4Rockwell Automation Publication 1606-RM105A-EN-P - July 2020
Table of Contents
Notes:

Rockwell Automation Publication 1606-RM105A-EN-P - July 2020 5
Terminology and
Abbreviations
Product Overview The 1606-XLS960 buffer module is a supplementary device for regulated DC
24V power supplies, which can be used for various purposes:
• Deliver DC-power to bridge failures of the DC voltage supply system.
• Extend the hold-up time after loss of the AC power.
• Deliver extra short-term peak current above the current rating of the
power supply.
The buffer module uses service-free electrolytic capacitors for storing the
energy, which allows usage even at ambient temperatures up to +70 °C (158 °F).
The buffer module does not require any control wiring. It can be added in
parallel to the load circuit at any given point.
Buffer modules can be connected in parallel to increase the output ampacity or
the hold-up time.
Product features:
• Buffering with electrolytic capacitors instead of lead acid batteries
• Buffering of 24V loads
• Minimum hold-up time 0.16 seconds at 40 A, longer hold-up time at
lower loads
• Clear status indication by LED status indicator and signaling terminals
• Extra large screw terminals
Terminology Descriptions
Power supply mode
Describes a condition where the supply voltage is in the rated supply voltage range and the
supplying power supply can deliver enough current for the buffer module and the load. This
mode can also be called “Normal mode”.
Buffer mode
Describes a condition where the input voltage is below the transfer threshold level, the unit
is running on capacitors (buffering), and the output is loaded within the allowed limits. The
mode can also be called “Capacitor mode”.
Inhibit mode Describes a condition where buffering is disabled on purpose (for example: for service
actions).
DC 24V
A value that is 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 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 there is no information to be included in that
cell.

6Rockwell Automation Publication 1606-RM105A-EN-P - July 2020
Specifications
Catalog Numbers
Attributes Values Notes
Supply voltage DC 24V -20%/+25% 19.2…30V DC
Required voltage to charge capacitors 23V DC —
Threshold voltage for buffer mode 22.5V / VIN-1V Selectable
Buffer voltage 22.5V / VIN-1V Selectable
Buffer current 40 A —
Charging time 34 s typ —
Current consumption 80 mA typ Stand-by mode
600 mA max During charging
Power dissipation 1.9 W Stand-by mode
Buffer time
160 ms min At 22.5V, 40 A
320 ms min At 22.5V, 20 A
250 ms typ At 22.5V, 40 A
500 ms typ At 22.5V, 20 A
62 s typ At 22.5V, 0.1 A
Temperature range -25…+70 °C (-13 °F…158 °F) operational
Dimensions 64 x 124 x 142 mm
(2.52 x 4.88 x 5.59 in.) W x H x D
Weight 1040 g (2.3 lb) —
Catalog Numbers Descriptions
1606-XLS960BUFFER Buffer module
1606-XLC Panel/wall-mount bracket
1606-XLA-S76 Side-mount bracket

Rockwell Automation Publication 1606-RM105A-EN-P - July 2020 7
Functional Description This section describes how the buffer module works in general and some
specific uses.
Working Principle
When the power supply provides sufficient
voltage, the buffer module stores energy in the
integrated electrolytic capacitors. If there is a
voltage dip or loss, this energy is released to the
DC bus in a regulated process.
Bridge Mains Faults without Interruption
Statistics show that 80% of all mains faults last less
than 0.2 seconds. The buffer module bridges any
mains faults of this length. This increases the
reliability of the system as a whole.
Extend Hold-up Time
Once mains power fails or is switched off, the
buffer unit continues to provide the load current
for a defined period. Process data can be saved and
processes can be terminated before the DC power
switches off. Controlled restarts are then possible.
Easily Add and Expand
The buffer module does not require any control
wiring. It can be added parallel to the load circuit
at any given point. Buffer modules can be
connected in parallel to increase the output
ampacity or the hold-up time.
Figure 1 - Typical Wiring Diagram Figure 2 - Transfer Behavior
PE
L
+
-
N
Power
Supply
+ -
Load
+ -
Buer
Module
optional
Buer
Mode
Supply
Voltage
Power
Supply
Output
t
t
Transfer Threshold
Power
Supply
Mode
Power
Supply
Mode
DC
Charge
Discharge
Storage
AC
DC
Buer Module
AC
DC
Buer Module
DC
Buer
Module
Power
Supply Load
AC
+
-

8Rockwell Automation Publication 1606-RM105A-EN-P - July 2020
Electrical Ratings
Attributes Values Notes
Supply voltage Nom DC 24V -20%/+25% —
Supply voltage range(1) Nom 19.2…30V DC —
Normal operating voltage range(2) Typ 23…30V DC —
Transfer voltage for switching into
buffer mode
Typ 22.5V DC Back-up threshold jumper set to “22.5V fixed”
Typ VIN – 1V Back-up threshold jumper set to “VIN – 1V”
—— SeealsoSelect the Backup Threshold Voltage on page 9.
Transfer voltage for switching from
buffer mode into power supply mode
Typ 22.5V DC Back-up threshold jumper set to “22.5V fixed”
Typ VBUFFER + 1V Back-up threshold jumper set to “VIN – 1V”
—— SeealsoSelect the Backup Threshold Voltage on page 9.
Buffer voltage Typ Same as the transfer voltage for switching into buffer mode.
Ripple and noise voltage
- in buffer mode
- in power supply mode Max 200 mVpp Generated by the buffer module. Defined at 20 Hz to 20 MHz, 50 Ω.
The the power supply defines the ripple and noise voltage.
Current consumption
Typ 80 mA When capacitor is fully charged
Min 400 mA During charging of the capacitors
Max 600 mA During charging of the capacitors
Power dissipation Typ 1.9 W When capacitor is fully charged
Buffer current Min 40 A —
Buffer current overload behavior — Electronically limited, buffering stops and capacitor gets discharged below 17V. See Figure 4.
Allowed voltage between supply
voltage and chassis ground Max 60V DC or 42.4V AC Continuous, IEC 62477-1
Capacitive and inductive loads — No limitation —
(1) Supply Voltage Range: At voltages within the input voltage range, control functions such as LEDs, monitoring features, and relay contacts, are
functioning normally. Within the input voltage range, the unit can either be in power supply mode or in buffer mode.
(2) Normal Operating Voltage Range: The normal operating voltage range describes the supply voltage, which supports the full functionality of the
buffer module (including charging) but without entering the buffer mode.
Figure 3 - Selection of an Appropriate Power Supply Figure 4 - Output Characteristic in Buffer Mode,
22.5V Fixed Mode, typ
Internal
current
consumption
Current
consumption
for charging
Load
Current
Power
Supply
Current
Buer Voltage
0
400
4
8
12
28V
16
20
64 A248 16 32 48 56
Output Current
24 22.5V
Buering stops
below 17V

Rockwell Automation Publication 1606-RM105A-EN-P - July 2020 9
Select the Backup
Threshold Voltage
The functionality of the buffer is determined by what mode the buffer is in,
either Fixed mode or Variable mode. You can set the mode using the backup
jumper selector. The factory default setting is Fixed mode. If the buffer has no
jumper, it is also in Fixed mode.
Fixed Mode
The buffer module is in Fixed mode when the jumper is in position “2-3” or
position “22.5V fixed”.
If the supply output voltage falls below 22.5V, buffering starts and the supply
voltage is kept at this level.
Fixed mode is recommended in the following situations:
• when power supplies other than bulletin 1606-XL S power supplies are
used
• with back-feeding loads
• when the buffer module is placed close to the load
•wheneverindoubt
Variable Mode
The buffer module is in Variable mode when the jumper in position “1-2” or
position “VIN – 1V”.
Buffering starts if the supply voltage decreases by more than 1V. Buffering
ends when supply voltage increases by more than 1V.
Voltage changes slower than 0.54 V/s are ignored if the voltage is above 22.5V.
Below 22.5V buffering starts immediately.
Variable mode is recommended in the following situations:
• 22.5V is too low for the application
• when the buffer module is placed close to the power supply

10 Rockwell Automation Publication 1606-RM105A-EN-P - July 2020
Buffer Time The buffer time (sometimes also called autonomy time) is the maximum
period for which the capacitor can maintain the required output current. The
buffer time mainly depends on the output current in buffer mode.
To increase the buffer time, any given number of buffer modules can be
connected in parallel.
Charging Time The internal capacitors are charging when the LED status indicator is flashing
with a slow frequency (1.25 Hz).
Figure 7 - Charging Time, Recharging
Attribute Values Notes
Buffer time
Min 160 ms At 22.5V, 40 A
Min 320 ms At 22.5V, 20 A
Typ 250 ms At 22.5V, 40 A
Typ 500 ms At 22.5V, 20 A
Typ 62 s At 22.5V, 0.1 A
Figure 5 - Buffer Time, typ Figure 6 - Buffer Time for Small Buffer
Currents, typ
Buer Current, typ.
0
0 0.3 3 s
10
30
20
40 A
0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.4
Buer Time
Buer Current, typ.
0
318s
0.5
1.5
1.0
2.0 A
6912 15
Buer Time
Attribute Values Notes
Charging time
Min 29 s Initial charging(1)
(1) Initial charging is the first charge after voltage is applied to the
buffer module.
Max 50 s
Initial charging(1)
Min 24 s
Recharging(2)
(2) Recharging is the charging of the internal capacitors after
voltage interruptions shorter than 2 minutes.
Max 40 s
Recharging*2)
Charge
20
0 5 10 45 s
Charging Time
40
80
60
100%
15 20 25 30 35 40
max. min.typ.