Allen-Bradley Dual Redundancy Module - 12...28V, 40 A Reference Manual
Allen-Bradley Dual Redundancy Module - 12...28V, 40 A is a versatile device for building 1+1 and N+1 redundant systems. It has two input channels, each capable of handling up to 20A of current. With a single output channel that can support up to 40A of continuous load, this module is ideal for various industrial applications. It’s designed for use in corrosive and harsh environments and features low power losses, making it compact and energy efficient. The module is also easy to install with large connection terminals and a wide international approval package.
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Dual Redundancy Module 12...28V, 40 A Catalog Number 1606-XLSRED40HE Reference Manual Original Instructions Dual 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. 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. These labels may also be on or inside the equipment to provide specific precautions. 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). The following icon may appear in the text of this document. Identifies information that is useful and can help to make a process easier to do or easier to understand. 2 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Table of Contents Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation in Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . 12 Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 EMC Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Switching Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Approved, Fulfilled, or Tested Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Regulatory Product Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Wall Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Side Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Zero Side Clearance Installation Requirements . . . . . . . . . . . . . . . . . . . . 21 1+1 Redundancy Up to 20 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N+1 Redundancy, Example with 60 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 3 Table of Contents Notes: 4 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Terms PE Descriptions The abbreviation for Protective Earth. PE has the same meaning as the symbol. The symbol for Protective Earth. Earth, Ground DC 24V 24V DC 1+1 Redundancy N+1 Redundancy nom typ — (alone in table cell) This document uses the term “earth” which is the same as the U.S. term “ground”. 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). A value with the unit (V DC) at the end is a momentary value without any additional tolerances included. Use of two identical power supplies in parallel to provide continued operation following most failures in a single power supply. The two power supply outputs should be isolated 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. 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. All power supply outputs should be isolated 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. Make sure that the power supplies are allowed to be connected in parallel to increase the output power. Indicates a nominal value. Indicates a typical value. A dash alone in a table cell indicates that there is no information to be included in that cell. Figure 1 - 1+1 Redundancy AC DC Figure 2 - N+1 Redundancy AC AC DC AC DC AC DC AC DC AC DC AC DC IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 OUT OUT OUT OUT - Load + IN 1 IN 2 + Terminology and Abbreviations DC - Load All values in this document are typical values under the following conditions unless otherwise noted: 24V, 40 A output current, 25 °C (77 °F) ambient temperature, and after a 5 minutes run-in time. Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 5 Product Overview Figure 3 - 1606-XLSRED40HE Redundancy Module The 1606-XLSRED40HE is a redundancy module that can be used to build 1+1 and N+1 redundant systems. It has two input channels, which can be connected to power supplies with up to 20 A output current. It has one output, which can carry nominal currents up to 40 A. In addition to the 1606-XLSRED40HE, the 1606-XLSRED40 is also available. The 1606XLSRED40 has an additional circuit included, which generates a supply voltage for the internal MOSFETs even when the output of the unit is in a short circuit condition. This makes the 1606-XLSRED40 suitable for any power supplies. The 1606-XLSRED40HE redundancy module uses MOSFETs instead of diodes for the decoupling of the two input channels. This reduces 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 36 mm (1.42 in.) width on the DIN rail. Large connection terminals allow for a safe and fast installation. The large international approval package makes this unit suitable for nearly every application. Product features: • • • • • • • • • • • Intended Use For N+1 and 1+1 redundant systems Dual-input with single output Suitable for use with all Bulletin 1606 power supplies with the following exceptions: - 1606-XLS480E-3 - 1606-XLS480E-3C - 1606-XLS480G-3 - 1606-XLS480F-3 - 1606-XLS480E-D Only 72 mV voltage drop at 20 A output current Only 1.7 W loss at 20 A and 5.9 W at 40 A output current 160% (65 A) peak load capability Reverse input polarity protection Full power from -40…+60 °C (-40…+140 °F) Width only 36 mm (1.42 in.) Rugged metal housing Easy wiring: distribution terminal for negative pole included This redundancy module is designed for installation in an enclosure and is intended for general use, such as in industrial control, office, communication, and instrumentation equipment. This device is designed for use in hazardous, non-hazardous, ordinary, or unclassified locations. Do not use this redundancy module in equipment, where malfunction may cause severe personal injury or threaten human life. 6 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Specifications Attributes Values Notes Input voltage DC 12…28V ±30% Input voltage range 9…36V DC — 2 x 0…20 A continuous Input current Output current Input to output voltage drop Power losses 2 x 20…32.5 A for 5 s 0…40 A continuous 40…65 A for 5 s 26 A max in overload(1) or short circuit mode 72 mV typ input: 2 x 10 A 112 mV typ input: 1 x 20 A 140 mV typ input: 2 x 20 A 230 mW typ at no load 1.7 W typ input: 2 x 10 A 2.4 W typ input: 1 x 20 A 5.9 W typ input: 2 x 20 A Temperature range -40…+70 °C (-40…+158 °F) operational Derating 1 A/1 °C (1 A/ 1.8 °F) (output) 60…70 °C (140…158 °F) Dimensions(2) 36 x 124 x 127 mm (1.42 x 4.88 x 5.00 in.) WxHxD Weight 280 g (0.62 lb) — (1) Currents at voltages below 6V (2) Plus 4 mm (0.16 in.) in depth for the screw terminal Catalog Numbers Catalog Number 1606-XLSRED40HE 1606-XLC 1606-XLA-S37 Description 12…28V 40 A dual redundancy module Wall Mounting Bracket on page 20 Side Mounting Bracket on page 20 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 7 Installation Instructions 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 help prevent 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. Only qualified personnel may install this device and put this device into operation. 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 the unit back for inspection. Install the device in an enclosure providing protection against electrical, mechanical, and fire hazards. Do not ground or earth the positive output pole, which could prevent redundancy if there is a ground failure. Ground the negative output pole, when needed. Use only power supplies with a negligible output ripple voltage in the low frequency range between 50 Hz and 10 kHz when used in marine applications according to the GL regulations. Install the device onto a DIN rail according to EN 60715 with the input terminals on the top of the device. Other mounting orientations require a reduction in output current. 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 (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) Make sure that all strands of a stranded wire enter the terminal connection. Securely tighten unused screw terminals. The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed. The enclosure of the device provides a degree of protection of IP20. The input must be powered from a PELV or SELV source, or an isolated secondary circuit to maintain an SELV or PELV output. Check correct input polarity. The device does not operate when input voltage is reversed. The device is designed as Class of Protection III equipment according to IEC 61140. 8 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 A PE (ground) connection is not required. However, connecting the chassis ground terminal to ground can be beneficial to gain a high EMI immunity. The device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover the ventilation grid. 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). Keep the following minimum installation clearances: 40 mm (1.57 in.) on top, 20 mm (0.79 in.) on the bottom, 5 mm (0.2 in.) left and right side. If the adjacent device is a heat source, increase the side clearances from 5 mm (0.2 in.) to 15 mm (0.59 in.). Under special circumstances, clearances can be reduced. See Zero Side Clearance Installation Requirements on page 21. 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 (0.79 in.) below the device. The device is designed to operate in areas between 5% and 95% relative humidity. Installation in Hazardous Locations The device is suitable for use in Class I Division 2 Groups A, B, C, and D locations and for use in Group II Category 3 (Zone 2) environments. Hazardous location classification: ATEX: EPS 11 ATEX 1 312 X, II 3G EX ec IIC T4 Gc WARNING: Risk of explosion in hazardous locations. • Substitution of components may impair suitability for this environment. • Do not disconnect the device in this environment 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. The enclosure must have a minimum protection of IP54 and fulfill the requirements of the EN 60079-0. Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 9 Input and Output Characteristics Attributes Values Notes Number of inputs — 2 — Suitable power supplies — Use only Bulletin 1606 power supplies with the HiccupPLUS overload feature. Number of outputs — 1 — Nom DC 12…28V ±30% The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL 60950-1. Input voltage Input voltage range Voltage drop, input to output — 9…36V DC — Typ 140 mV input: 2 x 20 A, see Figure 4 Typ 72 mV input: 2 x 10 A, see Figure 4 input: 1 x 20 A, see Figure 5 Typ 112 mV Nom 2 x 0…20 A continuous Input current Nom 2 x 20…32.5 A for 5 s Max 2 x 13 A in overload (voltage < 6V) or short circuit mode Peak input current Max 1000 A for 1 ms max per input Nom 40 A continuous Output current Nom 40…65 A for 5 s Max 26 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 4 - Input to Output Voltage Drop when Both Inputs Draw Current 1606-XLSRED40HE Voltage Drop, typ 160 mV 140 mV 120 mV 100 mV 80 mV 60 mV 40 mV 20 mV 0 mV Output: Input: Output Power Supply B A: 25 °C (77 °F) B: 60 °C (140 °F) A V U1 Input 1 Output Variable Load, 0...40 A U OUT V - Power Supply I2 A 24V, 20 A + V U2 Input / Output Current 0 0 I OUT A I1 A 24V, 20 A + Input 2 - 10 A 30 A 40 A 20 A 2 x 5 A 2 x 10 A 2 x 15 A 2 x 20 A I1 = I2 U1 = U2 Voltage Drop = U 1 - U OUT Figure 4 shows a typical 1+1 redundant setup, when the output voltages of the two units are equal. Figure 5 - Input to Output Voltage Drop when Only One Input Draws Current 1606-XLSRED40HE Voltage Drop, typ 160 mV 140 mV 120 mV 100 mV 80 mV 60 mV 40 mV 20 mV 0 mV V U1 B A 5A 10 A 15 A Input 1 Output Variable Load, 0...20 A U OUT V - Not used or power supply with lower voltage Output Current I OUT A I1 A 24V, 20 A + A: 25 °C (77 °F) B: 60 °C (140 °F) 0 10 Output Power Supply 20 A Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Input 2 Voltage Drop = U 1 - U OUT Power Losses Values Attribute Power losses Standby power losses Notes DC 12V DC 24V Typ 1.6 W 1.7 W input: 2 x 10 A Typ 5.8 W 5.9 W input: 2 x 20 A Typ 2.3 W 2.4 W input: 1 x 20 A (only one input is connected to input voltage) Typ 0.07 W 0.15 W at no output current (only one input is connected to input voltage) Typ 0.12 W 0.23 W at no output current (both inputs are connected to input voltages) Figure 6 - Power Losses when Both Inputs Draw Equal Current 1606-XLSRED40HE Power Losses, typ 7W 6.0 5.0 4.0 3.0 2.0 1.0 0 Output Power Supply 24V, 20 A + set to 24.5V A: 25 °C (77 °F) B: 60 °C (140 °F) 10 15 Input 1 Output U OUT V B A 24V, 20 A + set to 24.5V Output Current 5 V U1 Variable Load, 0...40 A - Power Supply 0 I OUT A I1 A 20 25 30 I2 A V U2 Input 2 - 35 40 A Losses = ( U 1 * I 1 + U 2 * I 2 ) - U OUT * I OUT U1 = U2 I1 = I2 Figure 7 - Power Losses when Only One Input Is Used 1606-XLSRED40HE Power Losses, typ 4W 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 Output Power Supply 24V, 20 A + V U1 A: 25 °C (77 °F) B: 60 °C (140 °F) I OUT A I1 A Input 1 Output Variable Load, 0...20 A U OUT V - B A Input 2 Output Current 0 2.5 5 7.5 10 12.5 15 17.5 20 A Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Losses = U 1 * I 1 - U OUT * I OUT 11 Lifetime Expectancy and Mean Time Between Failure The redundancy module has two input channels, which are completely independent from each other. Each control circuit, auxiliary voltage source, or other circuitry in the module are designed separately for each input. The dualinput redundancy module can be considered as two single redundancy modules combined in one housing. The only common point is the circuit trace that ties the two separate circuits together at the output. The Mean Time Between Failure (MTBF) values in the following table are for the entire dual-input module. If you need the MTBF number of only one path, double the value from the table. Input/output Current Conditions Lifetime expectancy(1) MTBF(2) SN 29500, IEC 61709 MTBF (2) MIL HDBK 217F Input: 2 x 10 A Output: 20 A Input: 2 x 20 A Output: 40 A Notes 672,000 h 255,000 h at 24V and 40 °C (104 °F) 1,900,000 h 720,000 h at 24V and 25 °C (77 °F) 7,234,000 h 4,533,000 h at 24V 40 °C (104 °F) 12,445,000 h 8,218,000 h at 24V 25 °C (77 °F) 325,000 h 294,000 h at 24V and 40 °C (104 °F) (Ground Fixed GF40) 438,000 h 392,000 h at 24V and 25 °C (77 °F) (Ground Fixed GF25) 1,588,000 h 1,457,000 h at 24V and 40 °C (104 °F) (Ground Benign GB40) 2,159,000 h 1,964,000 h at 24V and 25 °C (77 °F) (Ground Benign GB25) (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. (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. 12 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field installation. Values and Descriptions Attributes Input Type Output screw termination screw termination 2 0.5…16 mm2 2 0.5…4 mm 0.5…10 mm2 American Wire Gauge 20…10 AWG 22…8 AWG Wire diameter max 2.8 mm (0.110 in.) (including ferrules) 5.2 mm (0.204 in.) (including ferrules) Wire stripping length 7 mm (0.28 in.) 12 mm (0.5 in.) Solid wire 0.5…6 mm Stranded wire Screwdriver 3.5 mm (0.138 in.) slotted or Pozidriv No 2 3.5 mm (0.138 in.) slotted or Pozidriv No 2 Recommended tightening torque 0.8 N•m, 7 lb•in 1.2 N•m, 10.6 lb•in To connect the chassis to ground, use a ring-type terminal (ring cable lug) that is suitable for an M4 screw and connect it to the chassis ground terminal on top of the unit. Wiring rules: • • • • • • • Functional Diagram 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 (158 °F) Follow national installation codes and installation regulations. Make sure that all strands of a stranded wire enter the terminal connection. Screws of unused terminal compartments should be securely tightened. Ferrules are allowed. Do not connect or disconnect the wires from the terminals below -25 °C (-13 °F). Figure 8 - Functional Diagram control + + - - Input 1 Output Chassis Ground + Input 2 - control Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 13 Front Side and User Elements Figure 9 - Front Side User Elements 1 Chassis ground terminals: to be connected on the top side of the housing with a ring-type terminal (ring cable lug) which is suitable for an M4 screw. Connection of the chassis is optional and not required since the unit fulfills the requirements according to protection class III. 2 Output terminals (screw terminals) 3 Input terminals for Input 1 (screw terminals) 4 Input terminals for Input 2 (screw terminals) 1 2 3 14 4 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Electromagnetic Compatibility The redundancy module is suitable for applications in industrial, residential, commercial, and light industrial environments without any restrictions. The following table shows electromagnetic compatibility (EMC) immunity according to generic standards EN 61000-6-1 and EN 61000-6-2. Attributes Standards Electrostatic discharge EN 61000-4-2 Electromagnetic RF field EN 61000-4-3 Fast transients (Burst) EN 61000-4-4 Surge voltage on input lines EN 61000-4-5 Criteria(1) Values Contact discharge 8 kV Criterion A Air discharge 15 kV Criterion A 80 MHz…2.7 GHz 20V/m Criterion A Input lines 2 kV Criterion A Output lines 2 kV Criterion A +- 500V Criterion A +/- chassis ground 1 kV Criterion A +- 500V Criterion A Surge voltage on output lines EN 61000-4-5 +/- chassis ground 1 kV Criterion A Conducted disturbance EN 61000-4-6 0.15…80 MHz 20V Criterion A EN 61000-4-8 50 Hz 30 A/m Criterion A Power-frequency magnetic field (2) (1) Criteria A: Redundancy module shows normal operation behavior within the defined limits. (2) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic fields, for example hall elements and electrodynamic microphones. EMC Emission The following table shows EMC emission according to generic standards EN 61000-6-3 and EN 61000-6-4. Attributes Standards Notes Conducted emission IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 limits for DC power ports according to EN 61000-6-3 fulfilled(1) Radiated emission EN 55011, EN 55032 Class B This device complies with FCC Part 15 rules. Operation is subjected to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any interference received, including interference that may cause undesired operation. (1) For information only, not mandatory for EN 61000-6-3 if power sources that are connected on the inputs fulfill the requirements too. Switching Frequency The internal auxiliary supply is generated with a boost converter. The switching frequency varies 140...500 kHz depending on the input voltage. Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 15 Environment Attributes Values Notes Operational temperature(1) -40…+70 °C (-40…+158 °F) — Storage temperature -40…+85 °C (-40…+185 °F) For storage and transportation Output derating 1 A/1 °C (1 A/ 1.8 °F) 60…70 °C (140…158 °F) Humidity(2) 5…95% r.H. IEC 60068-2-30 Vibration sinusoidal(3) 2…17.8 Hz: ±1.6 mm (0.063 in.) 17.8…500 Hz: 2 g (64.3 ft/s2) 2 hours / axis IEC 60068-2-6 Shock (acceleration)(3) 30 g (965.2 ft/s2) 6 ms, 20 g (643.5 ft/s2) 11 ms, 3 bumps / direction, 18 bumps in total IEC 60068-2-27 0…2000 m (0…6560 ft) Without any restrictions 2000…6000 m (6560…20,000 ft) Reduce output power or ambient temperature, see Figure 11 Altitude derating 2.5 A/1000 m (2.5 A/3281 ft), or 5 °C/1000 m (9 °F/3281 ft) > 2000 m (6500 ft), see Figure 11 Overvoltage category not applicable The concept of the overvoltage category is used for equipment that is 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 Altitude (1) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2 cm (0.79 in.) below the unit. (2) Do not energize while condensation is present. (3) Tested in combination with DIN rails according to EN 60715 with a height of 15 mm (0.59 in.) and a thickness of 1.3 mm (0.051 in.) and standard mounting orientation. Figure 10 - Output Current Versus Ambient Temperature Figure 11 - Output Current Versus Altitude Allowed Output Current Allowed Output Current 65 A 65 A short term (< 5 s) 50 short term (< 5 s) 50 normal mode 40 normal mode 40 30 30 20 20 10 10 A A: Tamb < 70 °C (158 °F) B: Tamb < 60 °C (140 °F) C: Tamb < 50 °C (122 °F) Ambient Temperature 0 B C Altitude 0 -40 -25 0 20 40 60 70 °C 0 2000 4000 6000 m Protection Features Attributes Descriptions Output overcurrent protection not included Notes — Reverse input polarity protection included The unit does not start when input voltage is reversed. Degree of protection IP 20 EN/IEC 60529 Penetration protection > 3.6 mm (0.142 in.) Examples: screws, small parts Over-temperature protection not included — Input transient protection not included — Output transient protection included See Electromagnetic Compatibility on page 15 for details and values. Internal input fuse not included — Safety Features 16 Attributes Descriptions Input/output separation no galvanic separation Notes MOSFET between input and output Class of protection III Protective earth or chassis connection not required PE resistance < 0.1 Ohms Between housing and chassis-ground terminal Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Dielectric Strength The input and output voltages have the same reference, are floating and have no ohmic connection to ground. The manufacturer conducts type and factory tests. Field tests may be conducted in the field using the appropriate test equipment, which applies the voltage with a slow ramp (2 s up and 2 s down). Connect input/output terminals together before conducting the test. When testing, set the cutoff current settings to the value in the following table. Figure 12 - Dielectric Strength In- / Output + Chassis A - Approved, Fulfilled, or Tested Standards Approval Names Approval Symbols IND. CONT. EQ. Class I Div 2 ATEX IECEx Marine (DNV) Time A Type test 60 s 500V AC Factory test 5s 500V AC Field test 5s 500V AC Cutoff current setting > 2 mA Product certification information, including certificates and declarations of conformity, can be found at rok.auto/certifications. UL 508 UL 60950-1 Test or Setting Notes UL Certificate • Listed equipment for category NMTR - Industrial Control Equipment • Applicable for US and Canada • E-File: E198865 UL Certificate • Recognized component for category QQGQ - Information Technology Equipment (ITE) • Applicable for US and Canada • E-File: E137006 CSA Certificate • Power Supplies for Hazardous Location • Applicable for Canada and US • CSA Class: 5318-01 (Canada), 5318-81 (USA) • Temperature Code: T4 • Groups: A, B, C, and D Agency Certificate (Bureau Veritas) • EN 60079-0 Explosive atmospheres - General requirements • EN 60079-7, EN 60079-15 Equipment protection by type of protection "e" and "n" • Certificate: EPS 11 ATEX 1 312 X • Temperature Code: T4 • Type of Protection: ec IECEx Certificate • IEC 60079-0 Explosive atmospheres - General requirements • IEC 60079-7, IEC 60079-15 Equipment protection by type of protection "e" and "n" • Certificate: IECEx EPS 12.0032 X • Temperature Code: T4 • Type of Protection: ec DNV Certificate • DNV Type approved product • Certificate: TAA00002A7 • Temperature: Class D • Humidity: Class B • Vibration: Class C • EMC: Class B • Enclosure: Class A Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 17 Regulatory Product Compliance Product certification information, including certificates and declarations of conformity, can be found at rok.auto/certifications. Standard Names 18 Standard Symbols Notes EU Declaration of Conformity The CE marking indicates conformance with the following: • EMC Directive • ATEX directive • RoHS directive REACH Directive Manufacturer's Statement EU-Directive regarding the Registration, Evaluation, Authorization, and Restriction of Chemicals WEEE Directive Manufacturer's Statement EU-Regulation on Waste Electrical and Electronic Equipment Registered in Germany as business to business (B2B) products. KC Korean Certificate KC Registration • Korean registration of Broadcasting and Communication Equipment • Registered under Clause 3, Article 58-2 of Radio Waves Act. EAC TR Registration EAC Certificate • EAC EurAsian Conformity - Registration Russia, Kazakhstan, and Belarus Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Physical Dimensions and Weight Attributes Values and Descriptions Weight 280 g (0.62 lb) DIN rail Use 35 mm (1.38 in.) DIN rails according to EN 60715 or EN 50022 with a height of 7.5 mm (0.295 in.) or 15 mm (0.59 in.). The DIN rail height must be added to the unit depth (127 mm, [5.0 in.]) to calculate the total required installation depth. Installation Clearances Keep the following installation clearances: • 40 mm (1.57 in.) on the top • 20 mm (0.79 in.) on the bottom • Side clearance varies depending on the situation: – 5 mm (0.20 in.) on the left and right sides when the device is loaded permanently with more than 50% of the rated output current. – 15 mm (0.59 in.) on the left and right sides when the adjacent device is a heat source, such as a power supply. – In certain circumstances described in Zero Side Clearance Installation Requirements on page 21, the side clearance can be reduced to zero. Figure 13 - Front View Dimensions 12.3 (0.48) Figure 14 - Side View Dimensions 20.4 (0.80) 124 (4.88) 5.3 (0.21) DIN rail depth 25.4 (1.00) 127 (5.0) 4 (0.16) Dimensions are in mm (in.) 36 (1.42) Dimensions are in mm (in.) Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 19 Wall Mounting Bracket This standard bracket is used to mount the 1606-XLSRED40HE redundancy module onto a flat surface without using a DIN rail. Figure 15 - 1606-XLC Wall Mounting Bracket Side Mounting Bracket Figure 16 - Assembled 1606-XLC Wall Mounting Bracket The 1606-XLA-S37 side mounting bracket is used to mount the 1606-XLSRED40HE redundancy module sideways with or without a DIN rail. To mount the steel brackets, the two aluminum brackets and the black plastic slider of the unit have to be detached. For sideways DIN rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on the steel bracket. Figure 17 - 1606-XLA-S37 Side Mounting without a DIN Rail Recommendations for Redundancy 20 Figure 18 - 1606-XLA-S37 Side Mounting with a DIN Rail Recommendations for the configuration of redundant power systems: • Use separate input fuses for each power supply. • Use three-phase power supplies to gain functional safety if one phase fails. • When single-phase power supplies are used, connect them to different phases or mains circuits if possible. • Set the power supply in “Parallel-Use” mode if this feature is available • It is desirable to set the output voltages of all power supplies to the same value. Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Inductive and Capacitive Loads Zero Side Clearance Installation Requirements The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads. Normally, the following installation clearances are recommended: • 40 mm (1.57 in.) on the top • 20 mm (0.79 in.) on the bottom • Side clearance varies depending on the situation: - 5 mm (0.20 in.) on the left and right sides when the device is loaded permanently with more than 50% of the rated output current. - 15 mm (0.59 in.) on the left and right sides when the adjacent device is a heat source, such as a power supply. The clearance between the power supplies and the redundancy module can be reduced to zero when all the following conditions are true: • 1+1 redundancy application with maximum 20 A output current. • The power supplies are from the Bulletin 1606-XLS or -XLE family. • The redundancy module is placed between the two power supplies. • The output voltage is set to the same level on both power supplies. Figure 19 - Zero Side Clearance Installation 0 mm 0 mm 20 A Load Power Supply + - Power Supply Output Redundancy Module L N PE + + - - Input Input 2 1 + - + - L N PE + + - - Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 21 1+1 Redundancy Up to 20 A 1+1 redundancy up to 20 A requires two 20 A power supplies and one 1606-XLSRED40HE redundancy module. Use separate mains systems for each power supply whenever it is possible. Figure 20 - Wiring Diagram, 1+1 Redundancy, 20 A Output Current 20 A Load Failure Monitor + - Output DC-OK DC-OK Redundancy Module Power Supply + + - - L N PE Power Supply Input Input 2 1 + - + - I L N PE + + - - I L N PE N+1 Redundancy, Example with 60 A N+1 Redundancy up to 60 A requires four 20 A power supplies and two 1606-XLSRED40HE redundancy modules. Use separate mains systems for each power supply whenever it is possible. Figure 21 - Wiring Diagram, N+1 Redundancy, 60 A Output Current 60 A Load Failure Monitor + DC-OK I + DC-OK Redundancy Module Power Supply L N PE - Output + + - - DC-OK Power Supply Input Input 2 1 + - + - L N PE I L N PE + + - - I L N PE 22 DC-OK Redundancy Module Power Supply + + - - - Output Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Power Supply Input Input 2 1 + - + - L N PE I + + - - Mounting orientations other than A and B require a reduction in continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction influences the lifetime expectancy of the power supply. Therefore, the figures for orientations C, D, and E show two different derating curves for continuous operation: • Curve A1: Recommended output current. • Curve A2: Maximum allowed output current (results in approximately half the lifetime expectancy of A1). Figure 22 - Mounting Orientation A: Standard Orientation Output Current 40 A OUTPUT A1 30 Redundancy Module 20 10 Ambient Temperature 0 INPUTS 10 20 30 40 50 60 °C 50 60 °C Figure 23 - Mounting Orientation B: Upside Down Output Current INPUTS 40 A A1 30 Redundancy Module 20 10 OUTPUT Ambient Temperature 0 10 20 30 40 Figure 24 - Mounting Orientation C: Table-top Mounting Output Current 40 A 30 A2 20 A1 10 Ambient Temperature 0 10 20 30 40 50 60 °C Figure 25 - Mounting Orientation D: Horizontal with Inputs on the Left Output Current 40 A A2 OUTPUT Redundancy Module INPUTS 30 20 A1 10 Ambient Temperature 0 10 20 30 50 40 60 °C Figure 26 - Mounting Orientation E: Horizontal with Inputs on the Right Output Current A2 30 INPUTS Redundancy Module 40 A OUTPUT Mounting Orientations 20 A1 10 Ambient Temperature 0 10 20 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 30 40 50 60 °C 23 Notes: 24 Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 Dual Redundancy Module - 12...28V, 40 A Reference Manual Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Switched Mode Power Supply Specifications Technical Data, publication 1606-TD002 Description Provides specifications for Bulletin 1606 products and applications. Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access, and dispose of equipment. Provides a quick reference tool for Allen-Bradley industrial automation controls and Industrial Components Preventive Maintenance, Enclosures, and Contact assemblies. Ratings Specifications, publication IC-TD002 Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general guidelines for the application, installation, and maintenance of solid-state control in Safety Guidelines for the Application, Installation, and Maintenance of the form of individual devices or packaged assemblies incorporating solid-state Solid-State Control, publication SGI-1.1 components. Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details. Product Certifications website, rok.auto/certifications. System Security Design Guidelines Reference Manual, SECURE-RM001 You can view or download publications at rok.auto/literature. Rockwell Automation Publication 1606-RM038A-EN-P - September 2021 25 Rockwell Automation Support Use these resources to access support information. Technical Support Center Knowledgebase Local Technical Support Phone Numbers Literature Library Product Compatibility and Download Center (PCDC) Find help with how-to videos, FAQs, chat, user forums, and product notification updates. Access Knowledgebase articles. Locate the telephone number for your country. Find installation instructions, manuals, brochures, and technical data publications. Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes. rok.auto/support rok.auto/knowledgebase rok.auto/phonesupport rok.auto/literature rok.auto/pcdc Documentation Feedback Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our content, complete the form at rok.auto/docfeedback. Waste Electrical and Electronic Equipment (WEEE) At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, expanding human possibility, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.Ş. Kar Plaza İş Merkezi E Blok Kat:6 34752, İçerenköy, İstanbul, Tel: +90 (216) 5698400 EEE Yönetmeliğine Uygundur Publication 1606-RM038A-EN-P - September 2021 Copyright © 2021 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A. ">

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Key features
- Dual-input, single output
- 1+1 & N+1 Redundancy
- Up to 40A continuous output
- Low voltage drop
- Compact design
- Easy to install
Frequently asked questions
The input voltage range of the 1606-XLSRED40HE redundancy module is DC 12…28V with ±30% tolerance. It can operate with input voltages from 9V to 36V DC.
Each input channel can handle a continuous current of 0…20A. For a short period (5 seconds), it can handle up to 20…32.5A.
The module can deliver a continuous output current of up to 40A. For short periods (5 seconds), it can handle a peak load of up to 65A.
The typical voltage drop between the input and output depends on the current being drawn. For an input current of 2 x 10A, the voltage drop is 72 mV. For an input current of 2 x 20A, the voltage drop is 140 mV.
The maximum operating temperature for the module is +70 °C (+158 °F). However, the output current needs to be derated by 1A for every 1 °C (+1.8 °F) increase in temperature above +60 °C (+140 °F).