Rockwell Automation Allen-Bradley 1606-XLSREDS40HE User manual

Reference Manual Original Instructions
Single Input Redundancy
Module - 12…28V, 40 A
Catalog Number 1606-XLSREDS40HE

2Rockwell Automation Publication 1606-RM041A-EN-P - September 2021
Single Input Redundancy Module - 12…28V, 40 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.
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-RM041A-EN-P - September 2021 3
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . . 8
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instructions to Insert and Remove the Pluggable Outlet Terminal . 9
Replace Units While the System Is Running . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Approved, Fulfilled, or Tested Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Regulatory Product Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wall/Panel Mount Bracket (Cat. No. 1606-XLC) . . . . . . . . . . . . . . . . . 15
Side Mount Bracket (Cat. No. 1606-XLA-S44) . . . . . . . . . . . . . . . . . . . 15
Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Sidewards Installation Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example: Redundancy for Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Example: 1+1 Redundancy Up To 40 A. . . . . . . . . . . . . . . . . . . . . . . . . . 17
Example: N+1 Redundancy With 120 A. . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4Rockwell Automation Publication 1606-RM041A-EN-P - September 2021
Table of Contents
Notes:

Rockwell Automation Publication 1606-RM041A-EN-P - September 2021 5
Single Input Redundancy Module - 12…28V, 40 A Reference Manual
Terminology and
Abbreviations
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”.
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 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. Isolate the two power supply outputs 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. Isolate all power supply outputs 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. Confirm 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-RM041A-EN-P - September 2021
Single Input Redundancy Module - 12…28V, 40 A Reference Manual
Product Overview The 1606-XLSREDS40HE is a redundancy module,
which can be used to build redundant systems. The
module has one input and one output, and can carry
nominal currents up to 40 A. The output is equipped
with a plug-connector, which allows for replacement
of the power supply or redundancy module while the
system is running (hot swapping).
The novelty of this redundancy module is that it uses
mosfets instead of diodes to decouple the output,
which helps reduce the heat generation and the
voltage drop between input and output. The
redundancy module does not require an additional
auxiliary voltage.
Due to the low-power losses, the unit is slender and
only requires 46 mm (1.81 in.) width on the DIN rail.
Large connection terminals provide a safe and fast
installation. The large international approval
package makes this module suitable for nearly every application.
Product features:
• Single input with single output
• Equipped with plug-connector for 'hot swapping'
• Suitable for all 1606 power supplies except 1606-XLS960E-3 and
1606-XLS960F-3
• Only 150 mV voltage drop at 40 A
•Only6.2Wat40A
• 160% (65 A) peak load capability
• Reverse input polarity protection
• Full power between -40…+60 °C (-40…+140 °F)
• Width only 46 mm (1.81 in.)
• Rugged metal housing
Specifications Attributes Values Notes
Input voltage DC 12…28V ±30%
Input voltage range 8.4…36.4V DC —
Input current 0…40 A Continuous for 5 seconds
40…65 A
Output current
0…40 A Continuous for 5 seconds
40…65 A
22 A, max In overload(1) or short circuit mode
(1) Currents at voltages below 6V.
Input to output voltage drop 80 mV typical At 20 A
150 mV typical At 40 A
Power losses
120 mV typical At no load
1.8 W typical At 24V, 20 A
6.2 W typical At 24V, 40 A
Temperature range -40…+70 °C (-40…+158 °F) Operational
Derating 1 A/1 °C (1 A/1.8 °F) 60…70 °C (140…158 °F)
Dimensions 46 x 124 x 127 mm
(1.81 x 4.88 x 5 in.)(2)
(2) Plus height for plug-in connector.
W x H x D
Weight 340 g (0.75 lb) —

Rockwell Automation Publication 1606-RM041A-EN-P - September 2021 7
Single Input Redundancy Module - 12…28V, 40 A Reference Manual
Catalog Number
Input and Output
Characteristics
Power Losses
Figure 4 - Power Losses When Both Inputs Draw Equal Current
Catalog Number Description
1606-XLSREDS40HE Redundancy module
Attributes Values Notes
Number of inputs — 1 —
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…36.4 V DC —
Voltage drop, input to output Typ 80 mV At 20 A; see Figure 3
Typ 150 mV At 40 A; see Figure 3
Input current
Nom 0…40 A Continuous
Nom 40…65 A For 5 seconds
Max 22 A In overload (voltage <6V) or short circuit mode
Peak input current Max 1500 A For maximum 1 ms per input
Output current
Nom 40 A Continuous
Nom 40…65 A For 5 seconds
Max 22 A In overload (voltage <6V) or short circuit mode
Reverse current Max 1 mA At 24V per input, -40…+70 °C (-40…+158 °F)
Reverse voltage Max 40V DC Voltage applied to the output, continuously allowed
Output capacitance Typ 320 µF —
Figure 3 - Input to Output Voltage Drop When Both Inputs Draw Current
(Typical 1+1 redundant case when the output voltages of both units are equal)
Voltage Drop, mV (typ)
0
10 30
25
50
75
100
125
150
4020
Output Current, A
0
175
200
A
B
V
A
Power
Supply
24V, 40 A
+
-
A
V
U
OUT
I
OUT
U
IN
I
IN
Variable Load,
0…40 A
Input Output
A: 25 °C (77 °F)
B:60 °C (140 °F)
1606-XLSREDS40HE
Voltage Drop = UIN - UOUT
Attribute 12V DC 24V DC Notes
Power losses Typ 1.7 W 1.8 W At 20 A
Typ 6.1 W 6.2 W At 40 A
Standby power losses Typ 0.06 W 0.12 W At no output current
Power Losses, W (typ)
Output Current, A
V
A
+
-
A
V
U
OUT
I
OUT
U
IN
I
IN
Variable Load,
0…40 A
Input Output
1606-XLSREDS40HE
Losses = (UIN x IIN) - UOUT x IOUT
0
105030
1
4
5
8
402515 20 35
A
2
6
B
7
3
A: 24V, 25 °C (77 °F)
B:24V, 60 °C (140 °F)
Power
Supply
24V, 40 A

8Rockwell Automation Publication 1606-RM041A-EN-P - September 2021
Single Input Redundancy Module - 12…28V, 40 A Reference Manual
Lifetime Expectancy and
Mean Time Between Failure
Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field wiring.
To connect the chassis to the ground, use a ring-type terminal (ring cable lug)
that is suitable for an M4 screw. Connect this terminal to the chassis ground
terminal on top of the unit.
Wiring rules:
• The external circuitry of all terminals must meet the safety requirements
stipulated by IEC/EN/UL 60950-1: SELV.
• Use appropriate copper cables that are designed for minimum operating
temperatures of:
- 60 °C (140 °F) for ambient up to 45 °C (113 °F)
- 75 °C (167 °F) for ambient up to 60 °C (140 °F)
- 90 °C (194 °F) for ambient up to 70 °C (167 °F) minimum
• Do not connect or disconnect wires from the terminals below -25 °C
(-13 °F)
• Follow national installation codes and installation regulations.
• Verify that all strands of a stranded wire enter the terminal connection.
• Unused terminal compartments should be securely tightened.
• Ferrules are allowed.
Load Conditions Output: 20 A Output: 40 A Notes
Lifetime expectancy(1)
(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.
557,000 h 134,000 h At 24V and 40 °C (104 °F)
1,576,000 h 378,000 h At 24V and 25 °C (77 °F)
MTBF(2) SN 29500,
IEC 61709
(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.
13,290,000 h 6,357,000 h At 24V and 40 °C (104 °F)
22,628,000 h 12,238,000 h At 24V and 25 °C (77 °F)
MTBF (2) MIL HDBK 217F
381,000 h 278,000 h At 24V and 40 °C (104 °F) (Ground Fixed GF40)
518,000 h 366,000 h At 24V and 25 °C (77 °F) (Ground Fixed GF25)
1,816,000 h 1,401,000 h At 24V and 40 °C (104 °F) (Ground Benign GB40)
2,486,000 h 1,861,000 h At 24V and 25 °C (77 °F) (Ground Benign GB25)
Attributes Input Output
Type Screw terminals Pluggable screw terminals
Solid wire 0.5…16 mm20.2…16 mm2
Stranded wire 0.5…10 mm20.5…10 mm2
American Wire Gauge 22…8 AWG 22…6 AWG
Wire diameter max 5.2 mm (0.204 in.) (including ferrules) 5.4 mm (0.212 in.) (including ferrules)
Wire stripping length 12 mm (0.47 in.) 12 mm (0.47 in.)
Screwdriver 3.5 mm (0.138 in.) slotted or cross-head No 2 5.5 mm (0.217 in.) slotted or cross-head No 2
Recommended tightening torque 1.2 N•m (10.6 lb•in) 1.4 N•m (12.4 lb•in)

Rockwell Automation Publication 1606-RM041A-EN-P - September 2021 9
Single Input Redundancy Module - 12…28V, 40 A Reference Manual
Instructions to Insert and Remove the Pluggable Outlet Terminal
To avoid an accidental disconnection of the output, the plug connector is
equipped with a locking system.
To remove the latch mechanism, perform the following steps.
1. To unlock the red sliders, push the tabs down (A in Figure 5).
2. While pushing down, slide the tabs forward (B in Figure 5).
3. Pull out the connector to unplug it (C in Figure 5).
4. To inset the plug connector, reverse the above steps.
Figure 5 - Remove the Latch Mechanism
Replace Units While the
System Is Running
To replace the power supply or redundancy module while the system is
running, perform the following steps.
1. Switch off the circuit breaker (3a or 3b in Figure 6).
2. Remove the plug (4a or 4b), which helps prevent the cables from shorting.
3. Change the power supply (1a or 1b), or the redundancy module (2a or 2b),
or both (1a/2a or 1b/2b).
4. Reinstall the plug (4a or 4b).
5. Switch on the circuit breaker (3a or 3b).
Figure 6 - Functional Diagram
Load
Power Supply #1 Power Supply #2
Output
LNPE 24V DC
++ --
LNPE
L
II
N
PE
24V DC
++ --
+-
Input
+-
Output
+-
Input
+-
1a
3a 3b
2a
4a
1b
2b
4b
1606-XLSREDS40HE
Redundancy
Module #1
1606-XLSREDS40HE
Redundancy
Module #2

10 Rockwell Automation Publication 1606-RM041A-EN-P - September 2021
Single Input Redundancy Module - 12…28V, 40 A Reference Manual
Functional Diagram Figure 7 - Functional Diagram
Front Side and User
Elements
+
-
Input
+
-
Output
Control
Chassis
Ground
Figure 8 - Front Side User Elements
AOutput terminals
Pluggable screw terminals
B Chassis ground terminal
To be connected on the top side of the housing with a ring-type terminal (ring
cable lug) that is suitable for a M4 screw. Chassis connection is optional and not
required since the unit fulfills the requirements according to protection class III.
C Input terminals
Screw terminals