Rockwell Automation Allen-Bradley 1606-XLSCAP24-6 User manual

Capacitor-based DC Uninterruptible Power Supplies
Catalog Numbers 1606-XLSCAP24-6, -XLSCAP24-12
Reference Manual
Original Instructions

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-RM054A-EN-P - September 2016 3
Table of Contents
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
Topic Page Topic Page
Additional Resources 3 Ready and Buffer Relay Contact 15
Terminology and Abbreviations 4 Inhibit Input 16
Product Overview 5 PC-mode 16
Front Side and User Elements 6 Efficiency and Power Loss 17
Accessories 7 Lifetime Expectancy and Mean Time Between
Failure 17
Protection Features 7 Functional Diagram 19
Safety Features 8 EMC 20
Installation Notes 8 Application Notes 21
Terminals and Wiring 10 Troubleshooting 26
Input 11 Specifications 26
Output 12 Environment 27
Charging 14 Standards Compliance and Certifications 28
Buffer Time 14 Approximate Dimensions and Weight 29
Resource Description
Switched Mode Power Supply Technical Data, publication
1606-TD002 Provides specifications and approximate dimensions
for full line of switched mode power supplies.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1 Provides general guidelines forinstalling a Rockwell Automation industrial system.
Product Certifications website, http://
www.rockwellautomation.com/global/certification/
overview.page
Provides declarations of conformity, certificates, and
other certification details.

4Rockwell Automation Publication 1606-RM054A-EN-P - September 2016
Capacitor-based DC UPS Power Supplies
Terminology and
Abbreviations Term Definition
Normal mode Describes a condition where the capacitor is charged,
the input voltage is in range, and the output is loaded
within the allowed limits.
Buffer mode Describes a condition where the input voltage is below
the transfer threshold level, the unit is running on
capacitor (buffering) and the output is loaded within
the allowed limits.
Charging mode Describes a condition where the capacitor is being
charged, the input voltage is in range and the output is
loaded within the allowed limits.
Inhibit mode Describes a condition where buffering is disabled on
purpose (service actions)
AC 24V A figure 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 AC A figure with the unit (V AC) at the end is a momentary
figure without any additional tolerances included.
DC-UPS Direct Current- Uninterruptible Power Supplies
ELDC Electrochemical Double Layer Capacitors
EMC Electromagnetic Compatibility
VRLA Valve-regulated Lead-acid
PELV Protected Extra-low Voltage
SELV Separated Extra-low Voltage

Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 5
Capacitor-based DC UPS Power Supplies
Product Overview Bulletin 1606 DC- Uninterruptible Power Supplies (DC-UPSs) use
electrochemical double-layer capacitors (EDLC), commonly known as
ultracapacitors or supercapacitors, that are installed inside. They can bridge
power failures or voltage fluctuation and supply voltage to the DC 24V bus for
a certain period, which allows for a controlled shut-down of the system.
Expensive downtimes, long restart cycles, and loss of data can be avoided.
The power supply provides sufficient voltages, the DC-UPS stores energy in
the capacitors. If there is a mains voltage fault, this energy is released to the DC
bus in a regulated process.
The DC-UPSs require no maintenance and have a similar lifetime expectancy
as standard power supplies. No regular replacement of the capacitors is
necessary as is required for battery-based DC-UPS systems. The wide
temperature range makes the unit suitable for many applications.
Two versions of the DC-UPSs are available and differ by the size of the
installed capacitor.
• Built-in capacitors as energy source, EDLC
• Wide temperature range: -40…+60 °C (-40…+140 °F)
• Typically >10 years operational lifetime expectancy
•RegulatedoutputvoltageinBuffermode
• No ventilated cabinets required, no generation of hydrogen as valve-
regulated lead-acid (VRLA) batteries do
• Active balancing for longest life and buffer times
• Short charging time, unit is rapidly back in Ready mode
• Output is decoupled from the input to separate load
• Circuits into buffered and non-buffered sections
• Supports PC-mode function
• One year warranty

6Rockwell Automation Publication 1606-RM054A-EN-P - September 2016
Capacitor-based DC UPS Power Supplies
Front Side and User Elements
Figure 1 - Front Side of DC-UPS A. Input Terminals (quick-connect spring-clamp terminal)
B. Output Terminals (quick-connect spring-clamp terminal)
Minus-pole has the same reference as the minus-pole of the input terminals
C. Signal Connector (plug connector)
• Ready: contact is closed when status indicator shows ready
• Buffering: contact is closed during buffering
• Inhibit: a voltage applied on this input signal disables buffering (during
service)
• PC-mode: To activate the PC-mode connect the two pins of the signal
connector together (See PC-mode on page 16)
D. Status Indicator (green) Figure 2
• Ready: capacitors are fully charged, no failures detected.
• Charging: capacitors are being charged
• Buffering: capacitors are being discharged
Figure 2 - Updating pattern for the green
status indicator
E. Diagnosis status indicator (yellow) Figure 3
Helps troubleshooting and indicates the following:
• Current Overload: output voltage below 20V DC due to a too high
output current, ready contact is open
• High Temperature: signals capacitor temperature is too high(>65 ºC),
charging and buffering is still possible, ready contact is open
• Buffer Time Expired: buffering stopped due to discharged capacitors -
Inhibit Active: buffering is blocked by the inhibit signal
Figure 3 - Updating Pattern for the Yellow
Diagnosis Status Indicator:
F. Warning status indicator (red) Figure 4
• Check Input Voltage: Indicates a too low or too high input voltage. The
input voltage must be between 23V DC and 30V DC to turn-on the
output and to start charging of the capacitors.
• PC-mode activated indicates, that the PC-mode (See PC-mode on
page 16) is activated.
Figure 4 - Updating pattern for the Red
Warning Status Indicator: G. Chassis Ground (screw)
Use a M4 ring-type terminal to connect the housing to ground, when required
1
0
Ready
1
0Charging
1
0Buering
1
0
Current
Overload
1
0
High
Temperature
1
0
Buer time
expired
1
0
Inhibit
active
Check input
voltage
1
0
1
0PC-Mode
activated

Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 7
Capacitor-based DC UPS Power Supplies
Accessories Wall Mounting Bracket
This bracket is used to mount the DC-UPS on to a flat surface without using a
DIN rail.
Protection Features
With Cat. No. 1606-XLSCAP24-6 With Cat. No. 1606-XLSCAP24-12
Cat. No. 1606-XLC
Feature Description
Output protection Electronically protected against overload, no-load and Short Circuits(1)
Output Overvoltage protection in
buffer mode typ 32V DC
max 35V DC
In case of an internal DC-UPS Anomaly, a redundant circuit
limits the Maximum output voltage. The output shuts down
and automatically attempts to restart.
Degree of protection IP 20 EN/IEC 60529 For use in a controlled environment according
to CSA 22.2 No 107.1-01.
Penetration protection > 3.5 mm screws, small parts
Over-temperature protection included Output shuts down with automatic restart
Input Overvoltage protection - Max. 35V DC, no harm or Anomaly of the unit
Internal input fuse Included Non-user replaceable The tripping of this fuse is caused by
an internal Anomaly. In such cases, send unit to the factory
for inspection.
Internal capacitor fuse Included Non-user replaceableThe tripping of this fuse is caused by
an internal Anomaly. In such cases, send unit to the factory
for inspection.
Overcharging of capacitors Included The capacitors are permanently monitored. In case of a too
high charging voltage, the charger will be switched off with
redundant protection measures.
Balancing of capacitors Included An active balancing circuit Confirms uniform capacitor
voltages. If necessary, the charging current will be reduced
to a safe value.
Failing of one or more capacitors in
the capacitor-string Included Ready contact open, moving light pattern on the three Status Indicators
Temperature of capacitors Included Indicated by the diagnosis Status Indicator, ready contact
open
Internal errors (broken wires, …) Included Charging is stopped, ready contact open, moving light
pattern on the three Status Indicators
(1) In case of a protection event, audible noise may occur.

8Rockwell Automation Publication 1606-RM054A-EN-P - September 2016
Capacitor-based DC UPS Power Supplies
Safety Features
Installation Notes • The DC-UPS can only be installed and put into operation by qualified
personnel.
• The input must be powered from a Separated Extra-low Voltage (SELV)
or Protected Extra-low Voltage (PELV) power source.
• The DC-UPS 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.
• Mount the unit on a DIN rail so that the power terminals are on the top
of the unit.
• The DC-UPS is designed for convection cooling and does not require
an external fan. Do not obstruct airflow and do not cover ventilation
grid (cable conduits) by more than 15%.
• Keep the following installation clearances: 40 mm (1.57 in.) on top,
20 mm (0.79 in.) on the bottom, 5 mm (0.20 in.) on the left and right
sides are recommended when the DC-UPS is loaded permanently with
more than 50% of the rated power. Increase this clearance to 15 mm
(0.59 in.) in case the adjacent device is a heat source, such as a power
supply.
Figure 5 - Typical Wiring Diagram
Attribute Value
Output voltage SELV IEC/EN 60950-1, The input must be powered from a SELV power source.
PELV IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41, The input must be
powered from a PELV power source.
Class of protection III PE (Protective Earth) connection not required
Isolation
resistance > 5 MOhm
> 800 kOhm
> 5 MOhm
Power port to signal port
Power port to housing
Signal port to housing
Dielectric strength 500V AC
500V AC
Power port to signal port
Power port / signal port to housing
Touch current
(leakage current) The leakage current which is produced by the DC-UPS itself depends on the input voltage ripple and need to be investigated in the final application. For a smooth DCinput voltage, the produced
leakage current is less than 100 µA.
buffered branches
non-buffered branches
L N PE
+ +
- -
Power
Supply
+
-
24V Output
DC-UPS
IN
+
-
OUT
Ready
Buffering
Inhibit
PC-Mode
Input
+
-

Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 9
Capacitor-based DC UPS Power Supplies
The EDLC (storage capacitors) contains Acetonitrile and
Tetraethylammonium-tetrafluoroborate. These components are declared as
non-dangerous goods regarding shipment.
Hazardous Location Information
The DC-UPS 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 and are
evaluated according to EN 60079-0 and EN 60079-15.
SHOCK HAZARD: Turn power off before working on the power supply.
Avoid inadvertent repowering.
• 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 hazardous energy can be present inside. Info
for service personnel: Before opening the unit, wait at least 45
minutes after disconnecting the unit from input power so that the
remaining capacitor charge has been fully discharged.
• Use caution so that foreign objects cannot enter the housing.
• Do not use in wet locations or in areas where moisture or
condensation can be expected.
BURN HAZARD: Do not touch components during power-on, and
immediately after power-off. Hot surfaces can cause burns.
WARNING: Explosion Hazard. Substitution of components can impair
suitability for this environment. Do not disconnect the unit 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 that
has a minimum protection of IP54 and fulfills the requirements of the
EN 60079-15.

10 Rockwell Automation Publication 1606-RM054A-EN-P - September 2016
Capacitor-based DC UPS Power Supplies
Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field and factory
wiring.
• Use appropriate copper cables that are designed for minimum operating
temperatures of:
– 60 °C (140 °F) for ambient temperatures up to 45 °C (113 °F)
– 75 °C(167 °F) for ambient temperatures up to 60 °C (140 °F)
– 90 °C (194 °F) for ambient temperatures up to 70 °C (158 °F)
• Follow national installation codes and installation regulations
• Confirm that all strands of a stranded wire enter the terminal
connection
• Unused terminal compartments should be securely tightened or closed
• Ferrules are allowed
Figure 6 - Connecting a Wire
Attribute Input and Output Signals
Type Bi-stable quick-connect spring-clamp terminals Pluggable spring-clamp terminals
Solid wire, max 6 mm max1.5 mm
Stranded wire, max 4 mm max1.5 mm
American wire gauge AWG 20-10 AWG 24-14
Wire diameter, max 2.8mm (including ferrules) 1.5 mm (including ferrules)
Wire stripping length 10mm (0.4 in.) 8 mm (0.3 in.)
Screwdriver - 2.5 mm slotted
1. Insert the wire 2. Close the lever
To disconnect wire:
reverse the procedure