Rockwell Automation 1606-XLERED User manual

Reference Manual
Bulletin 1606 Switched Mode Power Supplies
Catalog Number: 1606-XLERED
Index
egaPegaP
1. Intended Use .......................................................3
2. Installation Requirements...................................3
3. Input and Output Characteristics .......................4
4. Power Losses........................................................5
5. Alarm Contacts ....................................................5
6. Reliability .............................................................6
7. Terminals and Wiring..........................................6
8. Functional Diagram.............................................7
9. Front Side and User Elements.............................7
10. EMC......................................................................8
11. Environment ........................................................9
12. Protection Features ...........................................10
13. Safety Features ..................................................10
14. Dielectric Strength ............................................10
15. Certications .....................................................11
16.Environmental Compliance ............................. 11
17. Physical Dimensions and Weight ..................... 12
18. Accessory ........................................................ 13
19. Application Notes ............................................. 14
19.1. Recommendations for Redundancy .........14
19.2. Inductive and Capacitive Loads ................14
19.3. Example: 1+1 Redundancy up to 10A ......14
19.4. Example: N+1 Redundancy up to 30A .....15
19.5. Example: Battery Back-up ........................15
19.6. Example: Redundancy for Controls .........16
19.7. Example: Decouplingof Branches ...........17
19.8. Use in a Tightly Sealed Enclosure ............17
19.9. MountingOrientations ............................18
•PEand symbol—PE is the abbreviation for Protective Earth and has the same meaning as the symbol .
•Earth,Ground—This document uses the term “earth” which is the same as the U.S. term “ground”.
• T.b.d.—To be defined, value or description will follow later.
• AC 230V—A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%)
included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
• 230Vac—A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.
• 50Hz vs. 60Hz—As long as not otherwise stated, AC100V and AC230V parameters are valid at 50Hz and AC120V parameters are valid at 60Hz
mains frequency.
•may—A key word indicating flexibility of choice with no implied preference.
•shall—A key word indicating a mandatory requirement.
•should—A key word indicating flexibility of choice with a strongly preferred implementation.
Terminology and Abbreviations

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
2Rockwell Automation Publication 1606-RM033A-EN-P — March 2014
Bulletin 1606 Switched Mode Power Supplies
Redundancy Module
Cost Effective Solution to Build Redundant Systems
Dual Input with Single Output
Alarm Relay-contacts for each Input Path
Two Diodes (Common Cathode)
DC24-48V ± 25% (18-60Vdc) Wide-range Input
Full Power Between -40°C and +60°C
Width only 32mm
Rugged Metal Housing
Large Screw Terminals
Easy Wiring:
Distribution Terminal for Negative Pole Included
3 Year Warranty
Description
The 1606-XLERED is a redundancy module specically
designed to build 1+1 and N+1 redundant systems.
It is equipped with two input channels which can be
connected to 10A power supplies and one output which
can carry nominal currents up to 20A.
The 1606-XLERED includes a monitoringcircuit and
is the perfect solution when the power supply has no
DC-OK function. Two LEDs and two relay contacts indicate
when one of the two DC input voltages is out of range
due to a non-functioningor disconnected power supply.
In addition to the 1606-XLERED is the 1606-XLSRED that
does not include monitoringcircuitry. It is the perfect
t when the power supply itself is already equipped
with a DC-OK signal.
Large screw terminals allow for an easy installation and
a huge international approval package for a variety of
applications makes this unit suitable for nearly every
situation.
Specication Quick Reference
Input voltage DC 24-48V ±25%
Input voltage
range
18–60Vdc
Input current 2x 0–10A continuous
2x 0–16A for 5 seconds
Output current 0–20A continuous
20–32A for 5 seconds
25A at cont. overload/
short circuit
Input to output
voltage drop
typ. 0.78V
typ. 0.85V
typ. 0.85V
input: 2x5A
input: 1x10A
input: 2x10A
Power losses typ. 1.0W at no load
typ. 8.8W input: 2x5A
typ. 9.5W input: 1x10A
typ. 18W input: 2x10A
Temperature range -40°C to +70°C operational,
Derating0.5A/°C +60 to +70°C
Dimensions 32x124x117mm WxHxD
CatalogNumbers
Redundancy 1606-XLERED 24-48V Standard unit
Module
Accessory 1606-XLB Wall/panel mount
bracket
Certications
IND. CONT. EQ.
18WM
LISTED
UL 508
UL 60950-1
Class I Div 2
ATEX
II 3G Ex nAC II T3
Marine
EMC, LVD
Marine RINA
GOST R
C-TICK

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM033A-EN-P — March 2014 3
Bulletin 1606 Switched Mode Power Supplies
1. Intended Use
•This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office,
communication, and instrumentation equipment.
•Do not use this power supply in aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or
threaten human life.
•This device is designed for use in hazardous, non-hazardous, ordinary or unclassified locations.
2. Installation Requirements
•This device may only be installed and put into operation by qualified personnel.
•This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
•If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.
•Mount the unit on a DIN rail so that the terminals are located on the bottom of the unit. For other mounting orientations, refer to Mounting.
•This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid
(e.g. cable conduits) by more than 15%!
•Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the
device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat
source (e.g. another power supply).
Notes for use in hazardous location areas:
•The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations
SHOCK HAZARD: Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input
block for earth connection and not one of the screws on the housing.
- Turn power off before working on the device. Protect against inadvertent re-powering
- Make sure that the wiring is correct by following all local and national codes
- Do not modify or repair the unit
- Do not open the unit as high voltages are present inside
- Use caution to prevent any foreign objects from entering the housing
- Do not use in wet locations or in areas where moisture or condensation can be expected
- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.
WARNING: EXPLOSION HAZARDS!
Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment or S/P jumper unless
power has been switched off or the area is known to be non-hazardous.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
4Rockwell Automation Publication 1606-RM033A-EN-P — March 2014
Bulletin 1606 Switched Mode Power Supplies
3. Input and Output Characteristics
Number of inputs - 2
Number of outputs - 1
Input voltage nom. DC 24-48V ±25%
The input circuitry must meet the SELV requirements
stipulated by IEC/EN/UL 60950-1.
Input voltage range - 18–60Vdc
Voltage drop, input to output typ. 0.78V at 2x5A, see Fig. 3-1
typ. 0.85V at 1x10A, see Fig. 3-2
typ. 0.85V at 2x10A, see Fig. 3-1
Input current nom. 2x 0–10A continuous
nom. 1x 0–20A continuous, see note 1
nom. 2x 10–16A for up to 5 seconds
Peak input current max. 150A for maximal 10ms per input
Output current nom. 20A continuous
nom. 20–32A for up to 5 seconds
max.
25A at continuous overload or short circuit, see note 2
Reverse current max. 2mA per input, -40°C to +60°C
Reverse voltage max. 200Vdc voltage applied to the output, continuously allowed
Note 1: Each input can be loaded up to 20A. At currents above 10A, the other input should not be loaded. It is preferable to parallel the two
inputs in order to minimize the power loss in such cases.
Note 2: Ensure that the continuous output current does not exceed 25A. Check the short-circuit current of the power sources and if the
power source can deliver more than 25A together, use an appropriate fuse on the output.
Fig. 3-1 Input to output voltage drop when both inputs draw current
(typical 1+1 redundant case, when the output voltages of the two units are equal or set into “parallel use” mode)
Voltage Drop, typ.
0mV
200mV
400mV
600mV
800mV
1000mV
5A 15A 20A10A
Output:
2x5A2x2.5A
Input:
2x10A2x7.5A
0
0
Input, Output Current
A...25°C
B...60°C
AB
V
A
1606-XLS
24V,10A
+
-
1606-XLS
24V,10A
+
-
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,
0-20A
1606-XLSRED/1606-XLERED
Input 1
Input 2
Output
Fig. 3-2 Input to output voltage drop when only one input draws current
Voltage Drop, typ.
0mV
200mV
400mV
600mV
800mV
1000mV
5A 15A 20
A
10A0
Output Current
A...25°C
B...60°C
AB
Voltage Drop U 1 = U OUT -
Not used or
power supply
with lower
voltage
V
A
1606-XLS
24V,20A
+
-
I
1
U 1
Output
A
V
I OUT
U OUT
Variable
Load,
0-20A
Input 1
Input 2
Output
1606-XLSRED/1606-XLERED

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM033A-EN-P — March 2014 5
Bulletin 1606 Switched Mode Power Supplies
4. Power Losses
DC 24V
Power losses typ. 8.8W input: 2x5A
typ.
9.5W input: 1x10A
typ.
18.0W input: 2x10A
Standby power losses typ. 1.0W at no output current
Fig. 4-1 Power losses
Power Losses, typ.
0
0 5 10 20
4
8
12
16
20
24W
25
A
15
Output Current
5. Alarm Contacts
Both input voltages are monitored individually. If one input voltage is too low or completely lost, it will be indicated
by an alarm relay contact.
Each input has its own monitoring circuitry and relay contact.
Alarm threshold nom. 21.5V (±0.5V) Relay contact opens immediately after
the input voltage falls below this value
Contact ratings min. 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A input: 1x10A
max.
1mA at 5Vdc input: 2x10A
Isolation voltage see dielectric strength table in section 14.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
6Rockwell Automation Publication 1606-RM033A-EN-P — March 2014
Bulletin 1606 Switched Mode Power Supplies
6. Reliability
The redundancy module does not include electrolytic capacitors. Therefore, the lifetime expectancy and MTBF
value are extremely high.
Input / output
current conditions
Input: 2x10A
Output: 20A
Input: 2x5A
Output: 10A
Lifetime expectancy *) min. 25 years 25 years at 24V and 40°C
min. 25 years 25 years at 24V and 25°C
MTBF **) SN 29500, IEC 61709 9 100 000h 10 900 000h at 24V 40°C
15 700 000h 18 800 000h at 24V 25°C
MTBF **) MIL HDBK 217F 9 200 000h 11 100 000h at 24Vand 40°C (Ground Benign GB40)
12 600 000h 15 100 000h at 24Vand 25°C (Ground Benign GB25)
3 380 000h 4 060 000h at 24Vand 40°C (Ground Fixed GF40)
4 630 000h 5 570 000h at 24Vand 25°C (Ground Fixed GF25)
*) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life).
**) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a
device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.
7. Terminals and Wiring
Input and output terminals Alarm-signal terminals
Type Screw terminals
IP20 Finger safe construction.
Suitable for eld installation.
Screw terminals, pluggable
IP20 Finger safe construction.
Suitable for eld installation.
Solid wire 0.5-6mm20.2-1.5mm2
Stranded wire 0.5-4mm20.2-1.5mm2
American Wire Gauge 20-10 AWG 22-14 AWG
Wire stripping length 7mm / 0.28inch 6mm / 0.25inch
Screwdriver 3.5mm slotted or Pozidrive No 2 3mm slotted
Recommended tightening torque 0.8Nm / 7lb.in 0.4Nm / 3.5lb.in
Instructions:
a) The external circuitry of all terminals (including signalling contacts) must meet the safety requirements stipulated by
IEC/EN/UL 60950-1: SELV.
b) Use appropriate copper cables that are designed for minimum operating temperatures of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum.
c) Follow national installation codes and installation regulations!
d) Ensure that all strands of a stranded wire enter the terminal connection!
e) Up to two stranded wires with the same cross section are permitted in one connection point.
f) Screws of unused terminal compartments should be securely tightened.
g) Ferrules are allowed, but not required.
h) Do not connect or disconnect the wires from the terminals below -25°C (-13°F).

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM033A-EN-P — March 2014 7
Bulletin 1606 Switched Mode Power Supplies
8. Functional Diagram
Fig. 8-1 Functional diagram
+
-
+
-
+
-
Alarm
Relay
Input
Voltage
Monitor
Input 1
Alarm
contact
Alarm
Relay
Input
Voltage
Monitor
Input 2
Alarm
contact
Input 1
ok
Input 2
ok
Input 1
Input 2
Output
Chassis
Ground
9. Front Side and User Elements
Fig. 9-1 Front side
AOutput terminals
B Chassis ground terminal
Connection of the chassis is optional and not required since the unit fulls the
requirements according to protection class III.
CInput terminals for input 1
DInput terminals for input 2
EAlarm-signal terminals for input 1 monitoring (relay contact)
FAlarm-signal terminals for input 2 monitoring (relay contact)
GGreen LED for input 1 (LED is on, when input voltage is in range)
HGreen LED for input 2 (LED is on, when input voltage is in range)
AB
CD
EF
GH

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
8Rockwell Automation Publication 1606-RM033A-EN-P — March 2014
Bulletin 1606 Switched Mode Power Supplies
10. EMC
This redundancy module is suitable for applications in industrial environment as well as in residential, commercial and
light industry environment without any restrictions (e.g. cable length). The CE Mark indicates conformance with EMC
directive 2004/108/EC and the low-voltage directive (LVD) 2006/95/EC.
A detailed EMC report is available upon request.
EMC Immunity According generic standards: EN 61000-6-1 and EN 61000-6-2
Electrostatic discharge EN 61000-4-2 Contact discharge
Air discharge
8kV
15kV
Criterion A
Criterion A
Electromagnetic RF eld EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Output lines
Alarm contacts
2kV
2kV
2kV
Criterion A
Criterion A
Criterion A
Surge voltage on
input lines
EN 61000-4-5 + -
+/-Chassis ground
200V
1kV
Criterion A
Criterion A
Surge voltage on
output lines
EN 61000-4-5 + -
+/-Chassis ground
200V
1kV
Criterion A
Criterion A
Surge voltage on
alarm contacts
EN 61000-4-5 Alarm contact Chassis ground 1kV Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Power-frequency magnetic
eld *)
EN 61000-4-8 50Hz 30A/m Criterion A
Criteria:
A: Redundancy module shows normal operation behavior within the dened limits.
Notes:
*) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic elds, e.g. hall
elements, electrodynamic microphones, etc.
EMC Emission According generic standards: EN 61000-6-3 and EN 61000-6-4
Conducted emission IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, input lines *)
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, output lines *)
Radiated emission EN 55011, EN 55022 Class B
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.
*) Provided that power sources connected on the inputs fulll the class B requirements as well.

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
Rockwell Automation Publication 1606-RM033A-EN-P — March 2014 9
Bulletin 1606 Switched Mode Power Supplies
11. Environment
Operational temperature *) -40°C to +70°C (-40°F to 158°F) Reduce output power above +60°C
Output de-rating 0.5A/°C 60-70°C (140°F to 158°F), see
Storage temperature -40 to +85°C (-40°F to 185°F) for storage and transportation
Humidity **) 5 to 95% r.H. IEC 60068-2-30
Vibration sinusoidal 2-17.8Hz: ±1.6mm
17.8-500Hz: 1g
2 hours / axis
IEC 60068-2-6
Shock 30g 6ms, 20g 11ms
3 bumps / direction
18 bumps in total
IEC 60068-2-27
Altitude 0 to 6000m (0 to 6 560ft) without any restrictions
2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature,
see Fig. 11-2
Altitude de-rating 1.25A/1000m or 5°C/1000m > 2000m (6500ft), see Fig. 11-2
Over-voltage category not applicable The concept of the overvoltage category is
used for equipment energized directly from
the low voltage mains (IEC 60664-1 §4.3.3.2.1).
Degree of pollution 2 IEC 62103, EN 50178, not conductive
*) Operational temperature is the same as the ambient temperature and is dened as the air temperature 2cm below the unit.
**) Do not energize in the presence of condensation.
Fig. 11-1 Output current vs. ambient temp. Fig. 11-2 Output current vs. altitude
Allowed Output Current
0
-40 0 20 40 70°C
5
10
15
20
25
30A
60-25
normalmode
atoverload/shortcircuit
Ambient Temperature
Allowed Output Current
0
0 2000 4000 6000m
5
10
15
20
25
30A
normalmode
Altitude
overload/shortcircuit
A...Tamb<60°C
B...Tamb<50°C
C...Tamb<40°C
ABC

All parameters are specified at 24V, 2.5A, 230Vac input, 25ªC ambient and after a 5 minutes run-in time unless noted otherwise.
10 Rockwell Automation Publication 1606-RM033A-EN-P — March 2014
Bulletin 1606 Switched Mode Power Supplies
12. Protection Features
Output over-current protection not included
Reverse input polarity protection included unit does not start when input voltage is reversed
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.6mm e.g. screws, small parts
Over-temperature protection not included
Input transient protection not included
Output transient protection included see EMC section
Internal input fuse not included
13. Safety Features
Input / output separation no galvanic separation 200V epitaxial diode between input and output
Safety level of output voltage The output voltage is regarded to be SELV (EN 60950-1) or PELV (EN 60204-1, EN
50178, IEC 60364-4-41) if the input voltage and the voltage which is applied to the
alarm contacts fullls the requirements for a SELV source or PELV source.
Class of protection III PE (Protective Earth) or chassis connection not required
PE resistance < 0.1Ohm between housing and chassis-ground terminal
14. Dielectric Strength
The input and output voltages have the same reference, are oating and have no ohmic connection to ground.
Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the eld using the
appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down).
Connect input/output/signal terminals together before conducting the test.
When testing, set the cut-off current settings to the value in the table below.
Fig. 14-1 Dielectric strength
A B
Type test 60s 500Vac 500Vac
Factory test 5s 500Vac 500Vac
Field test 5s 500Vac 500Vac
Cut-off current setting > 2mA
B
A
DC-ok
ChassisIn- / Output
-
+
B