Allen-Bradley Dual Input Redundancy Module - 24…56V, 40 A Reference Manual
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Dual Input Redundancy Module - 24…56V, 40 A Catalog Number 1606-XLSRED40HF Reference Manual Original Instructions Dual Input Redundancy Module - 24…56V, 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-RM042A-EN-P - September 2021 Table of Contents Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . . 8 Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Switching Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Approved, Fulfilled, or Tested Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Regulatory Product Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wall/Panel Mount Bracket (Cat. No. 1606-XLC) . . . . . . . . . . . . . . . . . 14 Side Mount Bracket (Cat. No. 1606-XLA-S44) . . . . . . . . . . . . . . . . . . . 14 Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Sidewards Installation Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Example: Redundancy for Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Example: 1+1 Redundancy Up To 20 A. . . . . . . . . . . . . . . . . . . . . . . . . . 16 Example: N+1 Redundancy With 120 A . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 3 Table of Contents Notes: 4 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Terminology and Abbreviations Terms PE Descriptions 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”. 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. 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. Use of two identical power supplies in parallel to provide continued operation following most failures in one 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. 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 one 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. DC 24V 24V DC nom typ — (alone in table cell) 1+1 Redundancy N+1 Redundancy Figure 1 - 1+1 Redundancy AC AC DC AC DC AC DC AC DC AC DC AC DC AC DC IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 OUT OUT OUT OUT + Load Product Overview Figure 2 - N+1 Redundancy DC + Load The 1606-XLSRED40HF is a redundancy module, which can be used to build 1+1 and N+1 redundant systems. The module has two input channels that can connect to power supplies with up to 20 A output current 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 two input channels, which help 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. Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 5 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Product features: • For 1+1 and N+1 redundant systems • Dual-input with single output • Suitable for all 1606 power supplies • Only 60 mV voltage drop at 20 A output current • Only 1.8 W loss at 20 A and 5.4 W at 40 A output current • 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 • Easy wiring; distribution terminal for negative pole included Specifications Attributes Values Notes Input voltage DC 24…56V ±15% Input voltage range 20.4…64.4V DC — Input current 2 x 0…20 A 2 x 20…32.5 A 0…40 A Output current 40…65 A 45 A, max Input to output voltage drop Power losses Continuous for 5 seconds Continuous for 5 seconds In overload(1) or short circuit mode 60 mV typical At 2 x 10 A 95 mV typical At 1 x 20 A 120 mV typical At 2 x 20 A 220 mW typical At 24V, no load 620 mW typical At 48V, no load 1.8 W typical At 48V, 2 x 10 A input 2.3 W typical At 48V, 1 x 20 A input 5.4 W typical At 48V, 2 x 20 A input 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 46 x 124 x 127 mm (1.81 x 4.88 x 5 in.) WxHxD Weight 360 g (0.79 lb) — (1) Currents at voltages below 6V. Catalog Number 6 Catalog Number 1606-XLSRED40HF Description Dual redundancy module Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Input and Output Characteristics Attributes Values Notes Number of inputs — 2 — Number of outputs — 1 — DC 24…56V ±15% The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL 60950-1. Input voltage Nom Input voltage range Voltage drop, input to output — 20.4…64.4 V DC — Typ 120 mV At 2 x 20 A; see Figure 3 Typ 60 mV At 2 x 10 A; see Figure 3 Typ 95 mV At 1 x 20 A; see Figure 3 Nom 2 x 0…20 A Continuous Nom 2 x 20…32.5 A For 5 seconds Max 2 x 22.5 A In overload (voltage <6V) or short circuit mode Max 1000 A For maximum 1 ms per input Nom 40 A Continuous Nom 40…65 A For 5 seconds Max 45 A In overload (voltage <6V) or short circuit mode Reverse current Max 1 mA At 48V per input, -40…+70 °C (-40…+158 °F) Reverse voltage Max 65V DC Voltage applied to the output, continuously allowed Output capacitance Typ 310 µF — Input current Peak input current Output current 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) A: 25 °C (77 °F) B: 60 °C (140 °F) Voltage Drop, mV (typ) 160 140 120 100 80 60 40 20 0 Output: 0 Input: 0 1606-XLSRED40HF B Power Supply + 48V, 20 A max A - 10 20 30 2x5 2 x 10 2 x 15 Input/Output Current, A 40 2 x 20 Power Supply + 48V, 20 A max - I1 A V U1 Input 1 Output I OUT A Output U OUT V Variable Load, 0…40 A I2 A V U2 Input 2 I1 = I2 U1 = U2 Voltage Drop = U1 - UOUT Voltage Drop, mV (typ) Figure 4 - Input to Output Voltage Drop When Only One Input Draws Current 120 105 90 75 60 45 30 15 0 1606-XLSRED40HF A: 25 °C (77 °F) B: 60 °C (140 °F) B Power Supply + 48V, 20 A max A A V U1 Input 1 Not used or power supply with low voltage Input 2 - 0 5 10 15 Output Current, A 20 I1 I1 = I2 U1 = U2 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Output I OUT A Output U OUT V Variable Load, 0…40 A Voltage Drop = U1 - UOUT 7 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Power Losses Attribute Power losses Standby power losses 24V DC 1.4 W 5W 2W 0.14 W 0.22 W Typ Typ Typ Typ Typ 48V DC 1.8 W 5.4 W 2.3 W 0.42 W 0.62 W Notes Input: 2 x 10 A Input: 2 x 20 A Input: 1 x 20 A(1) At no output current(1) At no output current(2) (1) Only one input is connected to input voltage. (2) Both inputs are connected to input voltage. Figure 5 - Power Losses When Both Inputs Draw Equal Current Power Losses, W (typ) 6 D B C A A: 24V, 25 °C (77 °F) B: 24V, 60 °C (140 °F) C: 48V, 25 °C (77 °F) D: 48V, 60 °C (140 °F) 5 4 1606-XLSRED40HF Power Supply + 48V, 20 A max A V U1 - 3 Output I OUT A Output U OUT V I1 Input 1 Variable Load, 0…40 A 2 Power Supply + 48V, 20 A max 1 0 0 5 10 15 20 25 Output Current, A 30 35 I2 A V U 2 Input 2 - 40 Losses = (U1 x I1 + U2 x I2) - UOUT x IOUT I1 = I2 U1 = U2 Figure 6 - Power Losses When Only One Input Is Used Power Losses, W (typ) 3 1606-XLSRED40HF A: 24V, 25 °C (77 °F) B: 24V, 60 °C (140 °F) C: 48V, 25 °C (77 °F) D: 48V, 60 °C (140 °F) 2.5 2.0 D B C - A 1.5 Power Supply + 48V, 20 A max I1 A V U1 Input 1 Output I OUT A Output U OUT V Variable Load, 0…40 A 1.0 0.5 Input 2 0 0 Lifetime Expectancy and Mean Time Between Failure 2.5 5 7.5 10 12.5 Output Current, A 15 17.5 20 Losses = U1 x I1 - UOUT x IOUT The redundancy module has two input channels that 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) figures in the following table are for the entire dual-input module. If the MTBF number of only one path is needed, simply double the value from the table. Input/output Current Conditions Lifetime expectancy(1) MTBF(2) SN 29500, IEC 61709 MTBF (2) MIL HDBK 217F 8 Input: 2 x 10 A Output: 20 A 448,000 h 1,267,000 h 6,656,000 h 11,990,000 h 211,000 h 288,000 h 959,000 h 1,332,000 h Input: 2 x 20 A Output: 40 A 222,000 h 629,000 h 4,098,000 h 7,808,000 h 178,000 h 238,000 h 839,000 h 1,144,000 h Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Notes At 48V and 40 °C (104 °F) At 48V and 25 °C (77 °F) At 48V and 40 °C (104 °F) At 48V and 25 °C (77 °F) At 48V and 40 °C (104 °F) (Ground Fixed GF40) At 48V and 25 °C (77 °F) (Ground Fixed GF25) At 48V and 40 °C (104 °F) (Ground Benign GB40) At 48V and 25 °C (77 °F) (Ground Benign GB25) Dual Input Redundancy Module - 24…56V, 40 A Reference Manual (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. 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. Attributes Type Input • Screw terminals • IP20 fingersafe construction • Suitable for field installation Solid wire 0.5…16 mm2 Stranded wire 0.5…10 mm2 22…8 AWG 5.2 mm (0.2 in.) (including ferrules) 12 mm (0.5 in.) 3.5 mm (0.138 in.) slotted or Pozidrive No 2 1.2 N•m (10.6 lb•in) American Wire Gauge Wire diameter max Wire stripping length Screwdriver Recommended tightening torque 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 • Follow national installation codes and installation regulations. • Verify that all strands of a stranded wire enter the terminal connection. • Verify that unused terminal compartments are securely tightened. • Ferrules are allowed. • Do not connect or disconnect the wires from the terminals below -25 °C (-13 °F). Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 9 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Functional Diagram Figure 7 - Functional Diagram Control + + Input 1 Output - - + Chassis Ground Input 2 - Front Side and User Elements Control Figure 8 - Front Side A B C D Electromagnetic Compatibility User Elements Output terminals Screw terminals 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. Input terminals for input 1 Screw terminals Input terminals for input 2 Screw terminals 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 Surge voltage on output lines EN 61000-4-5 Conducted disturbance (2) Power-frequency magnetic field 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 +/- chassis ground 1 kV Criterion A EN 61000-4-6 0.15…80 MHz 20V Criterion A EN 61000-4-8 50 Hz 30 A/m Criterion A (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. 10 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual The following table shows EMC emission according to generic standards EN 61000-6-3 and EN 61000-6-4. Attributes Standards Notes Conducted emission input lines 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 55022 Class B This device complies with FCC Part 15 rules. Operation is subjected to the following two conditions: 1) This device must not cause harmful interference. 2) This device must accept any interference received, including interference that can cause undesired operation. (1) For information only, not mandatory for EN 61000-6-3. Switching Frequency The internal auxiliary supply is generated with a boost converter. Depending on the input voltage, the switching frequency varies from 55… 180 kHz. Environment Attributes Values Notes Operational temperature -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 2 hours / axis IEC 60068-2-6 Shock(3) 30 g 6 ms, 20 g 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 10 Altitude derating 2.5 A/1000 m (2.5 A/3281 ft), or 5 °C/1000 m (41 °F/3281 ft) >2000 m (6500 ft); see Figure 10 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 (1) 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 9 - Output Current Versus Ambient Temperature 65 Short Term (< 5s) Allowed Output Current, A Allowed Output Current, A 65 Figure 10 - Output Current Versus Altitude 50 Normal Mode 40 30 20 10 0 -40 -25 (-40) (-13) Short Term (<5 s) 50 Normal Mode 40 A 30 20 20 40 (68) (104) Ambient Temperature, °C (°F) 60 70 (140) (158) Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 C A: Tamb <70 °C (<158 °F) B: Tamb <60 °C (<140 °F) C: Tamb <50 °C (<122 °F) 10 0 0 B 0 2000 4000 (6562) (13,123) Altitude, m (ft) 6000 (19,685) 11 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Protection Features Safety Features Dielectric Strength Attributes Output overcurrent protection Descriptions Not included Notes — Reverse input polarity protection Included Unit does not start when input voltage is reversed Degree of protection IP 20 EN/IEC 60529 Penetration protection >3.6 mm (0.14 in.) For screws and small parts Over-temperature protection Not included — Input transient protection Not included — Output transient protection Included See Electromagnetic Compatibility on page 10 for details and values. Internal input fuse Not included — Attributes Input/output separation Class of protection PE resistance Descriptions No galvanic separation III <0.1 Ω Notes Mosfet between input and output PE (Protective Earth) or chassis connection not required Between housing and chassis ground terminal 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 can be conducted in the field using the appropriate test equipment that 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 Figure 11. Figure 11 - Dielectric Strength In- / Output + - Approved, Fulfilled, or Tested Standards For the most current information, visit rok.auto/literature. Use 1606-XLSRED40HF as your search criterion; 1606-CT identifies the certifications in your search results. Approval Names UL 508 UL 60950-1 12 Attributes Time (seconds) A in Figure 11 Type test 60 Factory test 5 500V AC Field test 5 Cut-off current setting >2 mA Chassis A Approval Symbols Notes UL certificate Applicable for US and Canada See 1606-CT039 at rok.auto/literature UL certificate Applicable for US and Canada See 1606-CT034 at rok.auto/literature ATEX Agency Certificate (Bureau Veritas) See 1606-CT012 at rok.auto/literature IECEx IECEx Certificate See 1606-CT031 at rok.auto/literature Class I Div 2 CSA Certificate Power Supplies for Hazardous Location See 1606-CT046 at rok.auto/literature Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Approval Names Approval Symbols Notes Marine (DNV) DNV Certificate DNV Type approved product Marine (ABS) ABS Design Assessment Certificate ABS (American Bureau of Shipment) assessed product RCM Australian Declaration of Conformity See 1606-CT024 at rok.auto/literature Regulatory Product Compliance Standard Names Standard Symbols Notes The CE marking indicates conformance with the following: • EMC Directive • ATEX directive • RoHS directive See 1606-CT017 at rok.auto/literature EU Declaration of Conformity Physical Dimensions and Weight REACH Directive Manufacturer’s Statement EU-Directive regarding the Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH) WEEE Directive Manufacturer’s Statement EU-Regulation on Waste Electrical and Electronic Equipment (WEEE) Registered in Germany as business to business (B2B) products EAC Registration EAC Certificate EAC Eurasian Conformity-Registration Russia, Kazakhstan, and Belarus 8504408200, 8504409000 Attributes Width Height Values and Descriptions 46 mm (1.81 in.) 124 mm (4.88 in.) 127 mm (5 in.) The DIN rail height must be added to the unit depth to calculate the total required installation depth. 360 g (0.79 lb) 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.). Keep the following installation clearances: • 40 mm (1.57 in.) on the top • 20 mm (0.79 in.) on the bottom • 5 mm (0.20 in.) on the left and right sides are recommended when the device is loaded permanently with more than 50% of the rated output current. Increase the side clearances to 15 mm (0.59 in.) if the adjacent device is a heat source, such as a power supply. Depth Weight DIN rail Installation Clearances Figure 12 - Dimensions, Front and Side Views 12.7 (0.5) 20.4 (0.8) Dimensions are in mm (in.) + VOUT 124 (4.88) VIN1 VIN2 + 40.6 (1.6) 46 (1.81) DIN Rail Depth 127 (5) Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 13 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Accessories The following accessories are available for the 1606-XLSRED40HF redundancy module. Wall/Panel Mount Bracket (Cat. No. 1606-XLC) This bracket mounts the device on a flat surface or panel without using a DIN rail. The bracket can be mounted without detaching DIN rail brackets. This bracket kit contains the two brackets that are needed for one device. Figure 13 - Cat. No. 1606-XLC Wall/Panel Mount Bracket Side Mount Bracket (Cat. No. 1606-XLA-S44) This bracket mounts the device sideways with or without using a DIN rail to save installation depth. The two aluminum brackets and the black plastic slider of the device must be detached so that the steel bracket can be mounted. For sideway DIN rail mounting, mount the removed aluminum brackets and the black plastic slider on the side mount bracket. Figure 14 - Cat. No. 1606-XLA-S44 Side Mount Bracket Side Mounting Without DIN rail Brackets Recommendations for Redundancy 14 Side Mounting With DIN rail Brackets Recommendations for the configuration of redundant power systems: • 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. • Use separate input fuses for each power supply. • 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-RM042A-EN-P - September 2021 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Inductive and Capacitive Loads Sidewards Installation Clearance 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 on top • 20 mm on the bottom • 5 mm on the left and right sides when the device is loaded permanently with more than 50% of the rated power. Increase this clearance to 15 mm in case the adjacent device is a heat source (for example, another power supply). The clearance between the power supplies and the redundancy module can be reduced to zero under the following conditions: • 1+1 redundancy application with a maximum 20 A output current. • The power supplies are from the 1606-XLS or 1606-XLE family series. • The redundancy module is placed between the two power supplies. • The output voltage is set to the same level on both power supplies. Figure 15 - Sidewards Installation Clearance Example 20 A Load Power Supply Power Supply +Output1606-XLSRED40HF Redundancy Module AC Input L N PE 48V, 20A + + - - 0 mm Input 1 Input 2 + - + - Parallel Use Single Use AC Input L N PE 48V, 20A + + - - 0 mm Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 15 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Example: Redundancy for Controls In many cases, two power supplies are used, one for the demanding loads and another for the controls and sensitive loads. With the 1606-XLSRED40HF redundancy module, the power supply for the demanding loads can be used as a redundant source to supply the controls. This provides a cost-effective solution to get redundant power for a PLC or controller system. Example: 1+1 Redundancy Up To 20 A 1+1 Redundancy up to 20 A requires two 48V, 20 A power supplies and one 1606-XLSRED40HF redundancy module. Use separate mains systems for each power supply whenever it is possible. Figure 16 - Wiring Diagram, 1+1 Redundancy, Up to 40 A Output Current Failure Monitor 20 A Load Power Supply Power Supply +OutputDC - OK Parallel Use Single Use AC Input L N PE Parallel Use Single Use 1606-XLSRED40HF Redundancy Module Input 1 24V, 40A Input 2 AC Input L N PE + - + - + + - - DC - OK 24V, 40A + + - - I I L N PE Example: N+1 Redundancy With 120 A N+1 Redundancy up to 60 A requires four 44V, 20 A power supplies and two 1606-XLSRED40HF redundancy modules. Use separate mains systems for each power supply whenever it is possible. Figure 17 - Wiring Diagram, N+1 Redundancy With 60 A Output Current 60 A Load Power Supply Parallel Use Single Use L N PE I +Output- Power Supply DCOK 1606-XLSRED40HF Parallel Use Single Use 48V, 20 A Input 1 Input 2 + + - - Redundancy Module Power Supply DCOK Parallel Use Single Use 48V, 20 A +- +- L N PE I + + - - L N PE +Output- Power Suppl DCOK 1606-XLSRED40HF Parallel Use Single Use 48V, 20 A Input 1 Input 2 + + - - I L N PE 16 Failure Monitor Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Redundancy Module DCOK 48V, 20 A +- +- L N PE I + + - - Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Mounting orientations other than input terminals on the bottom and output on the top 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, there are 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) The following curves indicate the allowed output currents for altitudes up to 2000 m (6562 ft). Figure 18 - Mounting Orientation A (upright; standard) 40 Output Current, A Output 1606-XLSRED40HF Redundancy Module A1 30 20 10 0 10 (50) Inputs 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) Ambient Temperature, °C (°F) Figure 19 - Mounting Orientation B (upside down) Output Current, A 40 Inputs 1606-XLSRED40HF Redundancy Module A1 30 20 10 0 10 (50) Output 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) Ambient Temperature, °C (°F) Figure 20 - Mounting Orientation C (table-top) Output Current, A 40 30 A2 A1 20 10 0 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) Ambient Temperature, °C (°F) Figure 21 - Mounting Orientation D (horizontal with input on the left) A2 40 Output 1606-XLSRED40HF Redundancy Module Inputs Output Current, A Mounting Orientations 30 A1 20 10 0 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) Ambient Temperature, °C (°F) Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 17 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Figure 22 - Mounting Orientation E (horizontal with input on the right) A2 18 Output Current, A sInput 1606-XLSRED40HF Redundancy Module Output 40 30 A1 20 10 0 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) Ambient Temperature, °C (°F) Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description Switched Mode Power Supply Specifications Technical Data, publication Provides specifications for Bulletin 1606-XL, -XLE, -XLP, and -XLS products and applications. 1606-TD002 Provides information on properly configured redundancy modules, buffer modules, DC-UPS, and Designing More Reliable 24V DC Systems Application Techniques, publication DC/DC converters. 1606-AT003 Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies. Specifications, publication IC-TD002 Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general Safety Guidelines for the Application, Installation, and Maintenance of Solidguidelines for the application, installation, and maintenance of solid-state control in the form of State Control, publication SGI-1.1 individual devices or packaged assemblies incorporating solid-state 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. You can view or download publications at rok.auto/literature. Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 19 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-RM042A-EN-P - September 2021 Supersedes Publication XXXX-X.X.X - Month Year Copyright © 2021 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A. ">

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