Allen-Bradley DC-UPS User manual

Reference Manual Original Instructions
DC-UPS - 24V, 20 A, 480 W
Catalog Number 1606-XLS480-UPS

2Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W 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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 3
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Batteries and Battery Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Buffer Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ready and Buffering Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replace Battery Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lifetime Expectancy and MTBF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Dieletric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Certifications and Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . 26
Approximate Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
Table of Contents
Notes:

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 5
DC-UPS - 24V, 20 A, 480 W Reference Manual
Terminology and
Abbreviations
All values in this document are typical values under the following conditions
unless otherwise noted: 230V AC 50 Hz input voltage, 24V 2.5 A output load,
25 °C (77 °F) ambient temperature, and after a 5 minutes run-in time.
Product Overview The 1606-XLS480-UPS uninterruptible power supply
controller (DC-UPS) is used in addition with a 24V
power supply and batteries to bridge power failures
or voltage fluctuations. This configuration can help
prevent expensive downtimes, long restart cycles,
and loss of data.
A unique feature is the constant voltage in battery
mode, which will not change as the batteries
discharge. The buffer voltage in battery mode can be
set to four different output values. Another feature is
the utilization of two independent battery chargers
for the two 12V-batteries in series. This feature
makes matching batteries unnecessary and allows for precise battery
charging, testing, and optimized usage of the battery capacity to achieve the
longest battery service life.
The 1606-XLS480-UPS includes many battery diagnostic functions that deliver
a reliable operation of the entire system. Furthermore, a temperature that is
controlled charging extends the life of the batteries. It also includes a
selectable buffer time limiter and ready, buffering, and replace battery
contacts. For safety and maintenance, an inhibit input signal is included which
helps prevent a battery backup.100…240V wide-range input
• No Change in Output Voltage in Battery Mode
• Selectable Output Voltages in Battery Mode
• 1-Battery-Concept Each 12V Battery is Charged and Monitored
Separately for Longest Battery Life
• Precise Battery Charging by Using a Temperature Sensor
• Battery Size Selector for Small or Large Batteries
• 50% Bonus Power, 30 A for up to 4 s
• High Breaking Capacity for Branch Protectors
•SmartBatteryDiagnosticsand Monitoring Functions
Terms Descriptions
PE The abbreviation for Protective Earth. PE has the same meaning as the symbol.
The symbol for Protective Earth.
Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”.
AC 230V 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 whether it is full (13.7V) or flat (10V).
230V AC A value with the unit (V AC) at the end is a momentary value without any additional tolerances included.
50 Hz versus 60 Hz As long as not otherwise stated, AC 100V and AC 230V parameters are valid at 50 Hz mains frequency. AC 120V parameters are valid for 60 Hz mains
frequency.
Nom Indicates a nominal value.
Typ Indicates a typical value.
— (alone in table cell) A dash alone in a table cell indicates that there is no information to be included in that cell.

6Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
Specifications
Catalog Numbers
Installation Instructions
Observe the following installation instructions:
• This device may only be installed and put into operation by qualified
personnel.
• This device 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.
• Turn power off and disconnect the battery fuse before working on the
device.
• Install the device in an enclosure providing protection against electrical,
mechanical, and fire hazards.
Attributes Values Notes
Input voltage DC 18…30V ±25% DC 24V, nominal
Output voltage nom same as input voltage in power supply mode
22.5V, 24V, 25V, 26V (selectable) in battery mode
Output current
25 A continuous
30 A for 4 s in power supply mode
20 A continuous
30 A for 4 s in battery mode
Allowed battery sizes 3.9…150 Ah 2 batteries in series, each 12V
Buffer Time
6 min 45 s at 20 A. 7 Ah
16 min 47 s at 20 A, 12 Ah
2 h 49 min
at 20 A. 65 Ah
6 h 20 min
at 20 A, 140 Ah
Temperature range -40…+70 °C (-40…+158 °F) operational
Derating 0.5 A/°C 60 …70°C
Size (W x H x D) 46 x 124 x 127 mm
(1.81 x 4.88 x 5 in.) Without DIN rail
Weight 700 g (1.54 lb) —
Catalog Number Description
1606-XLS480-UPS DC UPS
1606-XLSBATASSY3 Battery module 24V, 7 Ah
1606-XLSBATASSY4 Battery module 24V, 12 Ah
1606-XLC Wall/panel-mount bracket
1606-XLA-S44 Side-mount bracket
WARNING: Risk of electrical shock, fire, personal injury, or death.
• Turn power off before working on the device and protect against inadvertent
repowering.
• Do not open, modify, or repair the device.
• Use caution to eliminate any foreign objects from entering into 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 surface
may cause burns.

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 7
DC-UPS - 24V, 20 A, 480 W Reference Manual
• Install the device onto a DIN rail according to EN 60715 with the input
terminals on the top of the unit.
• The input can be powered from a regulated power supply or a similar DC
source. The voltage between the input and ground must not exceed
60V DC continuously. The ripple voltage in the low frequency range
between 50 Hz and 10 kHz must be negligible when used in marine
applications.
• The input must be powered from a PELV or SELV source or an “Isolated
Secondary Circuit” to maintain a SELV or PELV output.
• Use an appropriately sized 24V power supply, which can deliver the
additional internal current consumption, required to charge the battery.
• Use only VRLA lead acid batteries with a capacity between 3.9 Ah and 150
Ah.
• Check for correct input and battery polarity. The device will not operate
when the voltage is reversed.
• Make sure that the wiring is correct by following all local and national
codes. Use appropriate copper cables that are designed for a minimum
operating temperature of 60 °C for ambient temperatures up to +45 °C, 75
°C for ambient temperatures up to +60 °C and 90 °C for ambient
temperatures up to +70 °C. Confirm that all strands of a stranded wire
enter the terminal connection.
• Do not use wires smaller than 4 mm2(AWG 12) and not longer than
2 x 1.5 m between the battery and the DC-UPS controller. Longer or
smaller gauge wires can change performance of the system.
• Use a 35 A fuse (ATOF® 287 035 from Little fuse or an UL Listed fuse with
the same characteristics) in the battery circuit. The battery fuse protects
the wires between the battery and the DC-UPS and shall be located close
to the battery.
• The device is designed for pollution degree 2 areas in controlled
environments. No condensation or frost is allowed.
• The device is designed as “Class of Protection III” equipment according
to IEC 61140.
• The enclosure of the device provides a degree of protection of IP20.
• A disconnecting means shall be provided for the input and the battery
input of the device.
• The device is designed for convection cooling and does not require an
external fan. Do not obstruct airflow and do not cover ventilation grid.
• Keep the following minimum installation clearances: 40 mm on top, 20
mm on the bottom, 5 mm left and right side. Increase the 5 mm to 15mm
in case the adjacent device is a heat source. When the device is
permanently loaded with less than 50%, the 5 15 mm can be reduced to
zero.
• The device is designed for altitudes up to 6000 m (19,685 ft). See
additional requirements in the product data sheet for use above 2000 m
(6560 ft).
• The maximum surrounding air temperature is +70 °C (+158 °F). The
operational temperature is the same as the ambient or surrounding air
temperature and is defined 2 cm below the device.
• The device is designed to operate in areas between 5% and 95% relative
humidity.
• The device is designed, tested, and approved for branch circuits up to 28
A without additional protection device.
• Use a 25 A melting fuse with a melting I2t of 400A2s – 1500A2s or a 25 A
circuit breaker with tripping characteristic B, C, D, or K on the input of
the DC-UPS if the current of the power supply is higher than 28 A.

8Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
• Use a 4 A fuse (ATOF® 287 004 from Little fuse or an UL Listed fuse with
same characteristics) between the connection point of the two 12V
batteries and the “Center Tap” connection point of the DC-UPS. An
equivalent protection is included on the original battery modules. The
center tap connection is not mandatory but enables an individual
charging and monitoring of the two batteries.
• Optionally, a PT1000 temperature sensor can be connected to terminals
point 11 and 12 to measure the battery temperature. This adjusts the
charging voltage according to the battery temperature, which extends
the battery life. This sensor is already installed in the original battery
modules.
Installation Instructions for Hazardous Location Areas
• The device 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.
• Hazardous Location Classification: ATEX: EPS 15 ATEX 1 025 X, II 3G EX
EC nC IIC T4 Gc
Figure 1 - Typical Wiring Diagram
WARNING: Explosion Hazards
• Substitution of components may impair suitability for this environment.
• Do not disconnect the device 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, which has a
minimum protection of IP54 and, fulfills the requirements of the EN 60079-
24V Power
Supply
+
-
Input
+
-
+
-
24V Battery
Module
+
Buffered
Load
+
-
Non-
buffered
Load
+
-
24V
buffered
branches
24 V
Non-bufferd
branches
Temp.
Sensor
Output
Battery -
Bat1
12V
Bat2
12V
Center Tap
Temp. Sensor
DC-UPS
AC
DC
Output
Input
NLPE
+
+
optional

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 9
DC-UPS - 24V, 20 A, 480 W Reference Manual
Input/Output The output is connected to the input through a back-fed protection (MOSFET).
In power supply mode, the output voltage follows the input voltage decreased
by a small voltage loss. In battery mode, the output voltage is a constant
voltage, which can be preselected in one of four voltages.
Input Voltage Range: At voltages within the input voltage range, control
functions such as light-emitting diode (LEDs), monitoring features, relay
contacts, etc. are functioning normally. Within the input voltage range, the
unit can either be in power supply mode or in battery mode.
Normal Operating Voltage Ranges (four ranges): The normal operating
voltage range describes the input voltage, which supports the full functionality
of the DC-UPS (including charging) but without entering the battery mode. It
requires a minimum of 1V higher than the buffer voltage settings and a
maximum voltage of not more than 30V DC.
Buffering and Buffer Voltage: Buffering will start immediately without
interruption after the input voltage falls below the lower end of the normal
operating voltage range. Buffering is possible even if the batteries are not fully
charged. Buffering cannot be started without having previously entered the
normal operating voltage range. The buffer voltage is the output voltage that is
determined by “the buffer voltage setting” and will not change as the batteries
discharge. The buffer voltage is pre-selectable in one of four voltages.
Figure 2 - Definition of “power supply mode” and “Battery mode”
Battery
Mode
Output
Voltage
Input
Voltage
t
t
Transfer Threshold
Power
Supply
Mode
Power
Supply
Mode

10 Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
Figure 3 - Input Voltage Ranges
Figure 4 - Buffer Voltage Settings on the Front
Temporarily
allowed -
No Charging,
no Buffering
D: 26V
C: 25V
B: 24V
A: 22.5V
27V
26V
25V
23.5
V
30V30V30V30V30V
18V
35V
Buffer Voltage Settings
Four Ranges:
26V25V24V22.5V
Normal
Operating
Voltage
(4 Ranges)
Buffer
Voltage
Rated Input Voltage Range
Battery Mode
0V
DCBA
Range A
Range B
Range C
Range D

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 11
DC-UPS - 24V, 20 A, 480 W Reference Manual
Input voltage Nom DC 24V -±25%
Input voltage range
Nom 18…30V DC Control functions such as light-emitting diode (LEDs), monitoring features, relay contacts, etc. are working. The unit can either be in power supply mode
or in battery mode. See Figure 3 on page 10.
Max 30…35V DC Temporarily allowed, no damage to the DC-UPS. The red error light-emitting diode (LED) reports “Input Voltage”, charging and buffering are not possible.
See Figure 3 on page 10.
Max 35V DC Absolute max voltage with no damage to the unit.
Normal operating input voltage ranges
Ranges, where the unit does not switch to battery mode. See Figure 3 on page 10. Please note: The lower end must be
at least 1V higher than buffer voltages settings.
Typ. 23.5…30V DC Range A for a 22.5V buffer voltage setting
Typ 25…30V DC Range B for a 24V buffer voltage setting
Typ 26…30V DC Range C for a 25V buffer voltage setting
Typ 27…30V DC Range D for a 26V buffer voltage setting
Important: The lower end must be at least 1V higher than buffer voltages settings.
Transfer voltage for switching into battery mode
Typ 23.5V DC Range A, 22.5V buffer voltage
Typ 25V DC Range B, 24V buffer voltage
Typ 26V DC Range C, 25V buffer voltage
Typ 27V DC Range D, 26V buffer voltage
Output voltage
in power supply mode Typ 0.12V less than input
voltage at 20 A
The output voltage is always slightly lower than the input voltage,
independent of the value of the input voltage. See Figure 5 and Figure 6 on
page 12
in battery mode
Nom 22.5V DC±3%
The buffer voltage is the output voltage in battery mode, selectable in four
steps via rotary switch on the front of the unit and will not change as the
batteries discharge. See Figure 3 on page 10.
Nom 24.0V DC±3%
Nom 25.0V DC±3%
Nom 26.0V DC±3%
Ripple and noise voltage in power supply mode not applicable better as the supplying power supply (filter included)
in battery mode Max 120mVpp 20 Hz to 20 MHz, 50 Ohm
Requirements for the power supply on the input
- Use an appropriately sized 24V power supply, which can deliver the additional required internal current
consumption of the DC-UPS and the required current for charging the batteries. See also Figure 7 on
page 12
- Use power supplies that do not deliver more than 28 A continuous output current 1).
Input Current internal consumption
Typ 80 mA When batteries are fully charged
Max 2.1 A / 4.0 A For <10 Ah / >10 Ah settings; during battery charging,
no temperature sensor installed
Max 2.3 A / 4.3 A For <10 Ah / >10 Ah settings; during battery charging,
temperature sensor is installed
total input current Max Sum of the output (load) current and the internal current consumption
Output Current
in power supply mode Nom 25 A Continuously allowed
Nom 30 A For max 5 s
in battery mode
Nom 20 A at 22.5V, 18 A at 26V Continuously allowed see Figure 8 on page 12 (interpolate linearly between
22.5V and 26V)
Nom 30 A at 22.5V, 26 A at 26V For typ 4 s (BonusPower (1)) see Figure 7 on page 12 (interpolate linearly
between 22.5V and 26V)
Typ 80 A For typ. 25 ms, output voltage stays above 20V, (dynamic peak current), see
Figure 10 on page 12.

12 Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
Overload behavior in power supply mode not limited (2)
in battery mode HiccupPLUS Mode (3)
Output short circuit
current
in power supply mode not limited (2)
in battery mode Typ 31 A for 2 s 50 m Ohm impedance, repetitive pulses, see Figure 9 on page 12.
Return current Typ -200 µA Leakage current to the input of the DC-UPS in battery mode
Allowed voltage between input and earth (chassis) Max 60V DCor 42.4V AC continuous, IEC 62103
Capacitive and inductive loads No limitation
(1) BonusPower: The DC-UPS is designed to support loads with a higher short-term power requirement without damage or shutdown. In battery mode, the short-term duration is hardware that
is controlled by an output power manager. At 150% output current, it is typically 4 s and longer for lower currents. Once the BonusPower time is exceeded, the maximum output current is
automatically reduced to the nominal output current or the DC-UPS goes into the HiccupPLUS mode.
(2) Use a 25 A melting fuse with a melting I2t of 400A2s – 1500A2s or a 25 A circuit breaker with tripping characteristic B, C, D, or K on the input of the DC-UPS if the current of the power supply
is higher than 28 A.
The DC-UPS has no current limiting feature included in power supply mode. The current is limited by the supplying power supply or the fuse/ circuit breaker, which must be installed when
the power supply has a continuous output current capability of more than 28 A.
(3) HiccupPLUS Mode: In battery mode, the DC-UPS can deliver 50% more output current for up to 4 s before it reduces the output current automatically to the nominal output current. If the
current requirement is continuously higher than the nominal current, the current regulation of the DC-UPS reduces the output voltage. As soon as the output voltage falls below 18V, the
output switches off and makes a restart attempt every 17 s. This cycle is repeated as long as the overload exists.
Figure 5 - Input to Output Voltage Loss Figure 6 - Input to Output Voltage Loss Measurement Setup
Input to Output Voltage Loss, typ.
0mV
10A
30mV
60mV
90mV
120mV
25A20A
Output Current
0
150mV
AB
A... 25°C
B... 60°C
5A 15A
180mV
V
Power
Supply +
-
UIN
Voltage Loss U IN=UOUT-
A
V
IOUTUOUT Variable
Load,
0-25A
UPS
Input Output
Figure 7 - Select an appropriate power supply, which can deliver the
additional current for charging and internal consumption the DC-UPS Figure 8 - Battery mode: Output voltage vs. output current, typical
Figure 9 - Battery mode: HiccupPLUS behavior during a short-circuit
on output, typical Figure 10 - Battery mode: Dynamic peak current behavior, typical
Internal
current
consumption
Current
consumption
for battery
charging
Output
Current
Input
Current
Output Voltage
0
020
4
8
12
28V
16
20
32A
124 816 24 28
Output Current
continuous
Hiccup
mode
for 4s
24
26V
22.5V
Output Current
0
31A
17s 17s
17s 2s 2s
2s
t
Short -
circuit Normal
load
Normal
load
Output Voltage (dynamic behavior, < 25ms)
0
0
4
8
12
28V
16
20
100A40
20 60 80
10 30 50 70 90
26V
22.5V
24
Output Current

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 13
DC-UPS - 24V, 20 A, 480 W Reference Manual
Batteries and Battery
Charging
The battery is not included in the DC-UPS. Use one 24V battery modules (see
24V, 12AH Battery Module - 1606-XLSBATASSY3 on page 30 and 1606-
XLSBATASSY4 on page 30). In addition to the battery module, the 1606-
XLS480-UPS is also designed to be compatible with a large variety of different
VRLA (Valve Regulated Lead Acid) or SLA (Sealed Lead Acid) batteries from
various suppliers.
The battery is one of the most important parts of a DC-UPS system, which
must be carefully selected while also paying close attention to storage,
charging and environmental conditions. Select the proper size (capacity)
according to the required buffer time (see Buffer Time on page 15) and the
lifetime requirements (see Battery Replacement Intervals on page 31).
Batteries are service parts and must be replaced periodically or when the
internal battery tests of the DC-UPS report a random failure. Information
regarding the DC-UPS battery tests and the replacement requirements can be
found in Battery Replacement Intervals on page 31
The wiring from the battery to the DC-UPS must follow the Installation
Instructions on page 6. The current from the battery to the DC-UPS can be
higher than the load current due to the buffer voltage transformation, which
restores the battery voltage to a constant buffer voltage.
The 1606-XLS480-UPS has a battery size selector included that allows an
optimal use of small and large battery sizes.
It is not recommended to connect multiple batteries or battery modules in
parallel. Choose larger sized battery instead.
Charging
The 1606-XLS480-UPS comprises a constant current / constant voltage (CC-
CV) charging method.
When the center-tap connection is installed, both 12V batteries are charged
individually with their own charger. The center-tap connection is optional and
if not installed, both batteries are charged with one common charging voltage.
The 1606-XLS480-UPS automatically recognizes if the center-tap connection is
present or not.
When charging is approximately 85% completed, the individual green “Ready”
light-emitting diode (LED) for the specific battery stops updating and is on
solid.
During charging, the DC-UPS consumes additional current from the input.
The supplying power supply must be able to deliver the additional required
internal current consumption (including the charging current) specified as
input current in the table in Input/Output on page 9.
When the temperature sensor is installed, the end-of-charge-voltage is
temperature that is compensated. The 1606-XLS480-UPS automatically
recognizes if a temperature sensor is connected or not. In case no temperature

14 Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
sensor is installed, the end-of-charge-voltage is fixed to a value that
corresponds to a battery temperature of 40 °C.
Use a PT1000 temperature sensor or battery modules, which have this sensor
already included. A list of suitable PT1000 temperature sensors from different
vendors can be provided.
Setting of battery size selector small battery < 10
Ah large battery > 10 Ah
Allowed battery sizes Nom 3.9 Ah…10 Ah(1)
(1) Batteries smaller than 6Ah are only recommended when the load current is below 10 A.
10 Ah… 150 Ah
Battery voltage Nom 24V 24V 2x 12V batteries in series
Battery charging current Typ 1.5 A 3 A In constant current mode
End-of-charge-voltage
Typ 2 x13.25V 2 x13.25V center-tap connected, no
temperature sensor connected
Typ 26.5V 26.5V center-tap not connected, no
temperature sensor connected
Typ 2x 13.1 …14.2V(2)
(2) The end-of-charge voltage depends on the battery temperature. At 20 °C the end-of-charge voltage is set to 13.6V (rsp. 27.2V)
and changes with -18mV/°C for 12V batteries and -36mV/°C for 24V batteries but not higher than 14.2V rsp. 28.4V.
2x 13.1 …14.2V center-tap connected, temperature
sensor connected
Typ 26.2V…28.4V 26.2V…28.4V center-tap not connected,
temperature sensor connected
Temperature range for which
the charging process is
enabled (3)
(3) Corresponds to the temperature readings of the external temperature sensor of the battery and is not the surrounding air
temperature of the DC-UPS. Frequent charging below +5 °C (41 °F) reduced the lifetime of the battery and should be avoided.
Low temperatures increase the battery impedance and also change the battery characteristics. This could result in a false
“replace battery” signal or an unexpected interruption of a buffer event, especially with small batteries. To avoid this, the
temperature range for charging is limited at low temperatures depending on the battery size. If the end application requires
temperatures below +5 °C, it is recommended to use batteries >10 Ah.
Nom -10…+50°C -40… +50°C
Deep-discharge protection
Typ 10.5V / 9.0V 10.5V / 9.0V
At 0 A / 20 A buffer current, center-
tap connected, Buffering stops as
soon as one battery falls below this
value.
Typ 21V / 18V 21V / 18V At 0 A / 20 A buffer current, center-
tap not connected
Required min battery voltage
to allow charging(4)
(4) Below this voltage level, charging does not start and the DC-UPS reports “check wiring”.
Min 2 x 7V 2 x 7V center-tap connected
Min 14V 14V center-tap not connected
Battery charging time(5)
(5) The listed charging time applies for a complete discharged battery until the DC-UPS indicated “Ready” with the green status
LED. In practice, the charging time can be much shorter, since the battery is not completely discharged. An extended
charging time is likely caused by a defective or old battery.
Max 4 h 40 mins — for a 7 Ah battery
Max 8 h 4 h for a 12 Ah battery
Max 44 h 22 h for a 65 Ah battery
Max 94 h 47 h for a 140 Ah battery
Battery discharge current Typ 170 mA 170 mA in battery mode at no output
current

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DC-UPS - 24V, 20 A, 480 W Reference Manual
Buffer Time The buffer time (sometimes also called autonomy time) is the maximum time
for which the battery can maintain the required output current. The buffer
time mainly depends on the capacity and quality of the battery and the output
current in battery mode.
The following times are typical values for a new product and the aging effect
during operation is not included.
Figure 11 - Buffer Time Definition
IMPORTANT • The following buffer times apply for a battery temperature from
20...30°C and a buffer voltage setting of 22.5V. At higher voltages, the
buffer time is correspondingly shorter. Furthermore, with a wire length
of 2x1m (equal 1 m cord length) and a cross section of 4 mm2(or AWG 12)
between the battery module and the DC-UPS.
• Due to long-term aging effects of batteries consider a buffer time
reduction of 30…50% over time.
• The shown buffer times only apply for Rockwell Automation battery
modules or from Rockwell Automation recommended batteries.
• The buffer time is defined for a fully charged battery. The buffer time
can be 10…20% shorter for buffer events, which start immediately after
the “Ready” signal becomes active.
Buffer Time
Battery
Size 7 Ah 12 Ah 26 Ah Notes
Typ 1 d: 17 h: 40 m: 0 s 2d: 22 h: 50 m: 0 s 6d: 19 h: 53 m: 20s At 22.5V, 0 A
Typ 17 h: 13 m: 20s 1d: 6 h: 41 m: 40s 2d: 20 h: 03 m: 20s At 22.5V, 0.2 A
Typ 5 h: 16 m: 40s 9 h: 51 m: 40s 21 h: 43 m: 20s At 22.5V, 1 A
Typ 2 h: 32 m: 0 s 5 h: 17 m: 59 s 11 h: 27 m: 30s At 22.5V, 2 A
Typ 46 m: 30s 2 h: 2 m: 55 s 4 h: 26 m: 40s At 22.5V, 5 A
Typ 19 m: 11 s 46 m: 2 s 2 h: 10 m: 0 s At 22.5V, 10 A
Typ 10 m: 35 s 27 m: 34 s 1 h: 17 m: 40s At 22.5V, 15 A
Typ 06 m: 45 s 16 m: 47 s 55 m: 00s At 22.5V, 20 A
Typ 4 s 4 s 4 s At 22.5V, 30 A
Battery
Charge
100%
80-90%
"Ready" signal threshold
t
t
Battery
Mode
Buffer Time

16 Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
Figure 12 - Buffer Time Curves for Battery Modules
Figure 13 - Buffer Time Curves for Battery Modules
Buffer Time
10A
12A
14A
16A
18A
20A
6A
8A
4A
2A
0A
Buffer Current
20 3010060705040 9080
Minutes
B
1,5 35281076
Hours
49
Batteries:
A... 7Ah - 1606-XLSBATASSY3
B... 12Ah - 1606-XLSBATASSY4
A
A
B
10A
12A
14A
16A
18A
20A
6A
8A
4A
2A
0A
Buffer Current
2310675410119814151312 18 191716 20 hours
Buffer Time
A
Batteries:
A... 7Ah
B... 12Ah
C... 26Ah
D... 65Ah
E... 100Ah
F... 140Ah
B
C
D
E
F

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DC-UPS - 24V, 20 A, 480 W Reference Manual
Ready and Buffering Relay
Contact
The DC-UPS is equipped with two independent relay contacts for remote
monitoring and controlling of the unit.
Ready Contact
Contact is closed when both batteries are charged more than typical 85%, no
wiring failure is detected, input voltage is sufficient and inhibit signal is not
active.
Buffering Contact
Contact is closed when unit is in battery mode.
Replace Battery Relay
Contact
The contact is closed when one of the battery quality tests of at least one
battery reports a negative result. To reset the “replace battery” signal, cycle the
input power. The battery that has failed is indicated by the green LED that is
off. The battery should be replaced as soon as possible.
Inhibit Input The inhibit input disables buffering. In power
supply mode, a static signal is required. In battery
mode, a pulse with a minimum length of 250 ms is
required to stop buffering.See Using the Inhibit
Input on page 36 for details.
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 Min permissible load
Isolation Voltage See Dielectric Strength
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 Min permissible load
Isolation Voltage See Dielectric Strength
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 Min permissible load
Isolation Voltage See Dielectric Strength
Signal voltage Max 35V DC
Signal current Max 6 mA current limited
Inhibit threshold Min 6V DC buffering is disabled
above the threshold level
Max 10V DC
Isolation voltage Dielectric Strength on page 26
7 +
5.1V
3 mA
Inhibit
8-

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DC-UPS - 24V, 20 A, 480 W Reference Manual
Efficiency and Power
Losses
Lifetime Expectancy and
MTBF
Efficiency Typ 99% Power supply mode, 20 A output current, batteries fully
charged
Power Losses
Typ 1.9 W Power supply mode, 0 A output current, batteries fully
charged
Typ 4.8 W Power supply mode, 0 A output current, during charging
batteries < 10 Ah
Typ 6.8 W Power supply mode, 0 A output current, during charging
batteries > 10 Ah
Typ 4.6 W Power supply mode, 20 A output current, batteries fully
charged
Typ 4.2 W Battery mode, 0 A output current
Typ 7.6 W Battery mode, 10 A output current
Typ 21.3 W Battery mode, 20 A output current
Calculated lifetime expectancy(1)
(1) The calculated 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 specified in
operational hours and is calculated according to the capacitor’s manufacturer specification. The manufacturer of the
electrolytic capacitors only guarantees a maximum life of up to 15 years (131 400 h). Any number exceeding this value is a
calculated theoretical lifetime which can be used to compare devices.
440,000 h Power supply mode, 10 A and 40 °C
1, 244,000 h Power supply mode, 10 A and 25 °C
122,000 h Power supply mode, 20 A and 40 °C
345,000 h Power supply mode, 20 A and 25 °C
MTBF (2)
(2) MTBF represents 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 figure is a statistical representation of the likelihood of a device to fail. An MTBF figure of for
example, 1 000 000h 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 000h or only for 100 h.
SN 29500, IEC 61709 649,000 h Power supply mode, 20 A and 40 °C
1,097,000 h Power supply mode, 20 A and 25 °C
MIL HDBK 217F 372,000 h Power supply mode, 20 A and 40 °C; Ground Benign GB40
498,000 h Power supply mode, 20 A and 25 °C; Ground Benign GB25
MIL HDBK 217F 107,000 h Power supply mode, 20 A and 40 °C; Ground Fixed GF40
137,000 h Power supply mode, 20 A and 25 °C; Ground Fixed GF25

Rockwell Automation Publication 1606-RM008A-EN-P - November 2021 19
DC-UPS - 24V, 20 A, 480 W Reference Manual
Functional Diagram Figure 14 - Functional Diagram
Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field and
factory wiring.
Instructions:
1. 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
2. Follow national installation codes and installation regulations.
3. Verify that all strands of a stranded wire enter the terminal connection.
4. Unused terminal compartments should be securely tightened or closed.
5. Ferrules are allowed.
-
+
DC- UPS
24V
Power
Supply
Buck/Boost
Converter
Battery
Charger
1
Battery
Diagnosis
1
+
-
24V
Battery
+
-
Input
Batt
+-
BAT2
12V
+-
BAT1
12V
CT
Battery
Charger
2
Current
Limiter
Battery
Diagnosis
2
(13)
-
Current
Measure-
ment
+
-
Buffered
Load
Output
Diagnosis LED (yellow)
Status LED Batt 2 (green)
Inhibit +
Controller
Error LED (red)
Replace Battery
Buffering
Contact
Ready Contact
Buffer Time Limiter
10s, 30s, 1m, 3m, 10m,
(7)
Inhibit -
(8)
(1)
(2)
(3)
(4)
(5)
(6)
Status LED Batt 1 (green)
Buffer Voltage
22.5V, 24V, 25V, 26V
Temp. Sensor (11)
Center
Tap
Back
Feeding
Protection
Battery Size Selector
<10Ah / > 10Ah
Temp. Sensor (12)
Batt
Input and Output Signals
Type screw terminals pluggable screw terminals
Solid wire 0.5…6 mm20.2…1.5mm2
Stranded wire 0.5…4 mm20.2…1.5mm2
American Wire Gauge AWG 20…10 AWG 22…14
Max wire diameter 2.8 mm (including ferrules) 1.5 mm (including ferrules)
Wire stripping length 7 mm / 0.28 in 6 mm / 0.25 inch
Tightening torque 1 Nm / 9 lb. in 0.4 Nm / 3.5 lb.inch
Screwdriver 3.5 mm slotted or cross-head No 2 3 mm slotted

20 Rockwell Automation Publication 1606-RM008A-EN-P - November 2021
DC-UPS - 24V, 20 A, 480 W Reference Manual
Front User Elements
Photo No. Description
1Input Terminal (screw terminal)
2Output Terminal (screw terminal) One extra (-) pole for easy grounding. The minus-pole is internally hard-wired with the minus-pole of the input
and battery terminals.
3
Signal Connector (8-pole plug connector) comprises the following
connections:
•Readyrelaycontact
• Buffering relay contact
• Inhibit input signal
• Replace battery
4Battery Terminal (screw terminal)
5Battery Monitoring Connector (3-pole plug connector) - Connection for temperature sensor for battery temperature.
- “Center-Tap” connection - middle point of the two batteries.
6
Red Error light-emitting diode (LED) – This light-emitting diode (LED)
indicates that charging or buffering is not possible.
The updating pattern reports the following reasons:
•Checkwiring
• Insufficient input voltage
• Temperature exceeded
7
Yellow Diagnosis light-emitting diode (LED) – This light-emitting diode
(LED) helps troubleshooting and the updating pattern indicates the
following:
• Output overloaded (current)
• Battery replacement required
• Expired buffer time due to buffer time selector or discharged battery
Activated inhibit input
8
Green light-emitting diode (LED) – Each battery has its own status LED.
Battery 1 represents the battery, which is electrically closer to the (+) pole
and battery 2, which is closer to the (-) pole.
The updating pattern of this light-emitting diode (LED) reports the
following information:
•Ready
•Charging
•Buffering
9
Battery Size Selector (pluggable jumper). Two positions to select battery
sizes > and <10 Ah. Influences the charging current, the allowed battery
temperature range and the battery quality tests. Factory set: <10 Ah. A
missing jumper equals a <10 Ah setting.
10
Buffer Time Limiter (rotary switch with 6 dents). Limits the maximum
buffer time in a buffer event to save battery energy. Selectable between
10 s 30s, 60 s, 3 minutes, and 10 minutes. If no limitation is selected
(infinite period), the buffering will end by the deep discharge protection.
Factory set: infinite.
11 Buffer Voltage Selector (rotary switch with 4 dents). Allows setting the output voltage in battery mode to 22.5V, 24V, 25V, or 26V. Factory set:
22.5V
12 Chassis Ground (screw) Use a M4 ring-type terminal to connect the
housing to ground, when required.
2
3
4
5
6
7
8
1
9
10
11
12