Allen-Bradley DC/DC Converter 24V, 5 A Reference Manual

DC/DC Converter 24V, 5 A
Catalog Number 1606-XLDF120E
Reference Manual
Original Instructions
DC/DC Converter 24V, 5 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.
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).
2
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Table of Contents
Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Input Inrush Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Soft Start Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Peak Current Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hold-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Efficiency and Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifetime Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mean Time Between Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fulfilled Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1606-XLB Wall Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1606-XLA-S37 Side Mount Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Peak Current Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Back-feeding Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Charging of Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
External Input Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Requirements for the Supplying Source . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parallel Use to Increase Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parallel Use for Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Daisy Chaining of Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Series Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Use in a Tightly Sealed Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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3
Notes:
4
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
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
DC 24V
24V DC
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 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 AC or 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.
All values in this document are specified under the following conditions unless
otherwise noted:
•
•
•
24V, 5 A, 48V DC input voltage
25 °C (77 °F) ambient temperature
after a 5 minutes run-in time
Product Overview
Figure 1 - 1606-XLDF120E
The 1606-XLDF120E is a DIN rail DC/DC
converter in the 92…120 W output power range
in a compact housing. This DC/DC converter can
run with a battery or similar sources. The
1606-XLDF120E converts a 48V voltage to a 24V
voltage.
The 1606-XLDF120E includes a power reserve of
20%. This extra power can be used continuously
up to 45 °C (113 °F).
The output is safely electrically isolated from the
input. The input is protected against reversed
voltages, and includes a soft start function.
Product features:
•
•
•
•
•
•
•
•
•
48V DC input
Isolated 24V DC output
Efficiency up to 90.3%
Width only 32 mm (1.26 in.)
20% output power reserves
Full power between -25…+60 °C (-13…+140 °F)
Soft start function included
Minimal inrush current surge
Reverse input polarity protection
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
5
Specifications
Attributes
Values
Notes
Output voltage
DC 24V
—
Adjustment range(1)
24…28V
—
Output current
Output power
5…4.3 A
Ambient < 60 °C (140 °F)
6…5.2 A
Ambient < 45 °C (113 °F)
120 W
Ambient < 60 °C (140 °F)
144 W
Ambient < 45 °C (113 °F)
Output ripple
< 50 mVpp
20 Hz…20 MHz
Input voltage
DC 48V
—
36…60V DC
Full specified
30.5…36V DC
With derating
Input voltage range
Input current
2.75 A typ
At 48V DC input
Input inrush current
0.6 A peak typ
—
Efficiency
90.3%
At 48V DC input
Losses
12.9 W
At 48V DC input
Temperature range
-25…+70 °C
(-13…+158 °F)
Operational
Derating
3 W/1 °C
(3 W/1.8 °F)
60…70 °C (140…158 °F)
Hold-up time
5.6 ms typ
At 48V DC input
Dimensions
32 x 124 x 102 mm
(1.26 x 4.88 x 4.02 in.)
WxHxD
Weight
425 g (0.94 lb)
—
(1) Extended guaranteed adjustment range down to 23V.
Catalog Numbers
Catalog Numbers
1606-XLDF120E
1606-XLB
1606-XLA-S37
1606-XLERED
6
Descriptions
DC/DC Converter
Wall or panel mount bracket
Side mount bracket
Redundancy module
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Input Voltage
Attributes
Values
Notes
Nom
DC 48V
—
—
36.0…60.0V DC
Full specified
—
30.5…36.0V DC
Maximal 60 seconds or with derating see Figure 3
Max
63.0V DC
Absolute max continuous input voltage with no
damage to the DC/DC converter
Allowed voltage between
Max
input and earth
60V DC, or
42.2V AC
In case the output voltage is not grounded
Allowed input ripple
voltage
5Vpp
47…500 Hz. The momentary input voltage must always
be within the specified limits.
Input voltage
Input voltage range
Turn-on voltage
Shut-down voltage
Input current
Startup delay
Rise time
Turn-on overshoot
Input capacitance
Max
Typ
34.5V DC
Steady-state value, see Figure 2
Typ
30.5V DC
Steady-state value, see Figure 2
Typ
63.5V DC
Steady-state value, see Figure 2
Typ
2.75 A
At 48V DC input and output 24V, 5 A, see Figure 5
Typ
670 ms
See Figure 4
Typ
80 ms
0 mF, 24V, constant current load 5 A, see Figure 4
Typ
150 ms
5 mF, 24V, constant current load 5 A, see Figure 4
Max
500 mV
See Figure 4
800 µF
External capacitors on the input voltage bus are
allowed without any limitations.
Typ
Figure 3 - Allowable Output Current Below 36V Input
Voltage
Figure 2 - Input Voltage Range
Rated input range
Output Current
6A
(a)
5
(b)
Turn-on
Shut-down
POUT
4
3
Figure 4 - Turn-on Behavior, Definitions
(a) Ambient < 45 °C
(b) Ambient < 60 °C
2
63.5V DC
60.0V DC
34.5V DC
36.0V DC
30.5V DC
V IN
1
Input Voltage
0
30
32
34
36
38
40V DC
Figure 5 - Input Current Versus Output Load
Input
Voltage
4A
3
Input
Current,
typ
DC
6V
t: 3
u
C
Inp
VD
t: 48
u
p
In
Output
Voltage
Start-up
delay
Rise
Time
Overshoot
2
- 5%
1
0
Output Current
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 A
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
7
Input Inrush Current
An active inrush limitation circuit (inrush limiting resistor which is bypassed
by a relay contact) limits the input inrush current after turn-on of the input
voltage. The charging current into EMI suppression capacitors is disregarded
in the first microseconds after switch-on.
Attributes
Inrush current
Inrush energy
Values
Notes
0.8 Apeak
-25…+70 °C (-13…+158 °F), input: 48V DC
Typ
0.6 Apeak
-25…+70 °C (-13…+158 °F), input: 48V DC
Typ
Negligible
-25…+70 °C (-13…+158 °F), input: 48V DC
Max
Figure 6 - Input Inrush Current, Typical Behavior
•
•
•
•
•
•
•
Soft Start Function
Input: 48V DC
Output: 24V, 5 A, constant current load
Ambient: 25 °C (77 °F)
Input current: 1 A / DIV
Input voltage: 50V / DIV
Output voltage: 20V / DIV
Time basis: 100 ms / DIV
After the DC/DC converter is turned on, the internal output current rises
slowly to its nominal value. This method charges the output capacitors
(internal and external capacitors) slowly and avoids high input currents
during turn-on. High input currents can produce a high voltage drop on the
input wiring (especially with long and thin cables) which reduces the terminal
voltage on the DC/DC converter. If the terminal voltage is below the shutdown
voltage, the DC/DC converter turns off and then makes a new startup attempt.
This effect is avoided with the integrated soft start function. Please note that
this function increases the rise time of the output voltage by a small amount.
Figure 7 - Soft Start Behavior
•
•
•
•
•
•
•
8
Input: 48V DC
Output: 24V, 5 A, constant current load
Ambient: 25 °C (77 °F)
No additional external output capacitors
Input current: 2 A / DIV
Output voltage: 10V / DIV
Time basis: 20 ms / DIV
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Output
Attributes
Values
Output voltage
Adjustment range
Notes
Nom
24V
—
Min
24…28V
Extended guaranteed adjustment range down to 23V
At clockwise end position of potentiometer
Max
30V
Factory setting
—
24.1V
±0.2%, at full load, cold unit
Line regulation
Max
25 mV
Input voltage variations between 36…60V DC
Load regulation
Max
100 mV
Static value, 0 A  5 A
Ripple and noise voltage
Max
50 mVpp
20 Hz…20 MHz, 50 Ω
Output capacitance
Typ
2200 µF
—
Output current
Output power
Short-circuit current
Nom
6A
At 24V, ambient < 45 °C (113 °F), see Figure 8
Nom
5A
At 24V, ambient < 60 °C (140 °F), see Figure 8
Nom
5.2 A
At 28V, ambient < 45 °C (113 °F), see Figure 8
Nom
4.3 A
At 28V, ambient < 60 °C (140 °F), see Figure 8
Nom
144 W
For ambient temperatures < 45 °C (113 °F)
Nom
120 W
For ambient temperatures < 60 °C (140 °F)
Min
7A
Continuous current, short circuit impedance 200 mΩ
Max
10 A
Continuous current, short circuit impedance 200 mΩ
Figure 8 - Output Voltage Versus Output Current, at
48V DC Input Voltage, Typ
Output Voltage
Output Current
Adjustment
Range
28V
7.0 A
6.9
6.8
6.7
6.6
6.5
6.4
6.3
6.2
24
20
16
12
8
4
0
Output Current
0
2
4
6
8
10
Figure 9 - Current Limitation Versus Input Voltage
(23V Constant Voltage Load), Typ
Input Voltage
30
12 A
36
42
48
54
60V DC
Peak Current Capability
The peak current capability lasts up to several milliseconds. The DC/DC
converter can deliver a peak current, which is higher than the specified
short-term current. This helps to start loads that have a high demand for
current, and operate subsequent circuit breakers safely.
The extra current is supplied by the output capacitors inside the DC/DC
converter. During this event, the capacitors are discharged and cause a voltage
dip on the output. Detailed curves can be found in Peak Current Capability on
page 20.
Attributes
Peak current voltage dips
Values
Notes
Typ
24V dips to 17.1V
At 10 A for 50 ms, resistive load
Typ
24V dips to 15V
At 20 A for 2 ms, resistive load
Typ
24V dips to 11V
At 20 A for 5 ms, resistive load
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
9
Hold-up Time
The input side of the DC/DC converter is equipped with a bulk capacitor. This
capacitor keeps the output voltage alive for a certain period of time when the
input voltage dips or is removed. The bulk capacitor can be discharged by
loading the DC/DC converter on the output side or through a load that is
parallel to the input. There is no protection in the DC/DC converter that
prevents current from flowing back to the input terminals. If the application
requires such prevention use an external diode. At no load, the hold-up time
can be up to several seconds. The green DC OK status indicator is also on
during this time.
Attributes
Hold-up Time
Values
Notes
Typ
10.5 ms
Input 48V DC, output: 24V DC, 2.5 A, see Figure 10
Typ
5.6 ms
Input 48V DC, output: 24V DC, 5 A, see Figure 10
Figure 10 - Hold-up Time Versus Input Voltage
Figure 11 - Shutdown Test Setup
Hold-up Time
12 ms
10
S1
(a)
8
+
(b)
(c)
6
4
0
36
Input Voltage
40
48
44
52
56V DC
Figure 12 - Shutdown Behavior, Definitions
Intput
Voltage
S1 opens
- 5%
Output
Voltage
Hold-up Time
10
+
DC
Source
(d)
(a) 24V, 2.5 A, typ
(b) 24V, 2.5 A, min
(c) 24V, 5 A, typ
(d) 24V, 5 A, min
2
DC/DC
Converter
Input
+
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
-
Load
Output -
-
Efficiency and Power
Losses
Values for
Input 48V DC
Attributes
Efficiency
Power losses
Notes
Typ
90.3%
At 24V, 5 A
Typ
0.9 W
At no output load
Typ
6.9 W
At 24V, 2.5 A
Typ
12.9 W
At 24V, 5 A
Typ
16.4 W
At 24V, 6 A
Figure 13 - Efficiency Versus Output Current at 24V
Output and 48V DC Input Voltage, Typ
Figure 14 - Losses Versus Output Current at 24V
Output and 48V DC Input Voltage, Typ
Efficiency
Power Losses
91%
18 W
90
15
89
12
88
9
87
6
86
3
Output Current
85
1
3
2
4
Output Current
0
5
6A
Figure 15 - Efficiency Versus Input Voltage at 24V, 5 A,
Typ
0
2
4
3
5
6A
Figure 16 - Losses Versus Input Voltage at 24V, 5 A,
Typ
Efficiency
Power Losses
91%
18 W
90.5
15
90.0
12
89.5
9
89.0
6
88.5
1
3
Input Voltage
88.0
36
40
44
48
52
Input Voltage
0
56 60V DC
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
36
40
44
48
52
56 60V DC
11
Functional Diagram
Figure 17 - Functional Diagram
Output
Voltage
Regulator
+
-
Reverse
Polarity
Protection
&
Inrush
Limiter
Input Fuse
&
Input Filter
Chassis
Ground
OverTemperature
Protection
Power
Converter
Output
OverVoltage
Protection
Output
Filter
V OUT
+
+
DC
OK
Front Side and User
Elements
Figure 18 - Front Side
1
1
2
3
4
2
3
User Elements
Output terminals (screw terminals)
Dual terminals per pole, both pins are equal
+ Positive output
- Negative (return) output
Output voltage potentiometer
Open the flap to set the output voltage. Factory set: 24.1V
DC OK status indicator (green)
On when the voltage on the output terminals is > 21V
Input terminals (screw terminals)
+ Positive input
- Negative (return) input
Chassis Ground: can be used to bond the Housing to PE
Ground this terminal to minimize high-frequency emissions.
4
12
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Terminals and Wiring
Attributes
Values
Input
Output
Type
Screw terminals
Screw terminals
Solid wire
6 mm2 max
6 mm2 max
Stranded wire
4 mm2 max
4 mm2 max
American Wire Gauge
20…10 AWG
20…10 AWG
Wire stripping length
7 mm (0.28 in.)
7 mm (0.28 in.)
Screwdriver
3.5 mm (0.138 in.) slotted
or Pozidrive No 2
3.5 mm (0.138 in.) slotted
or Pozidrive No 2
Recommended
tightening torque
1 N•m (9 lb•in)
1 N•m (9 lb•in)
Instructions:
•
•
•
•
•
•
•
•
Lifetime Expectancy
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 a minimum
operating temperature 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)
Follow national installation codes and installation regulations.
Ensure that all strands of a stranded wire enter the terminal connection.
Do not load the terminals with more than 25 A. See Daisy Chaining of
Outputs on page 23.
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).
The lifetime expectancies the following 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 prediction model allows a calculation of up to 15 years (131,400
hr) from date of shipment.
Attribute
Lifetime expectancy
Values for
Notes
Input 48V DC
169,000 hr
At 24V, 2.5 A and 40 °C (104 °F)
64,000 hr
At 24V, 5 A and 40 °C (104 °F)
39,000 hr
At 24V, 6 A and 40 °C (104 °F)
181,000 hr
At 24V, 5 A and 25 °C (77 °F)
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
13
Mean Time Between Failure
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. An MTBF value of, for example, 1,000,000 hr
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 hr or only for 100 hr.
Attribute
MTBF SN 29500, IEC 61709
MTBF MIL HDBK 217F
Electromagnetic
Compatibility
Values for
Input 48V DC
Notes
951,000 hr
At 24V, 5 A and 40 °C (104 °F)
1 560,000 hr
At 24V, 5 A and 25 °C (77 °F)
559,000 hr
At 24V, 5 A and 40 °C (104 °F); Ground Benign GB40
749,000 hr
At 24V, 5 A and 25 °C (77 °F); Ground Benign GB25
The DC/DC converter is suitable for applications in industrial, residential,
commercial, and light industrial environments without any restrictions.
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
EN 61000-4-5
Surge voltage on output
EN 61000-4-5
Conducted disturbance
EN 61000-4-6
Criteria(1)
Values
Contact discharge
8 kV
Criterion A
Air discharge
15 kV
Criterion A
80 MHz…2.7 GHz
10V/m
Criterion A
Input lines
4 kV
Criterion A
Output lines
2 kV
Criterion A
Criterion A
+-
1 kV
+/-  chassis ground
2 kV
Criterion A
+-
500V
Criterion A
+ / -  chassis ground
1 kV
Criterion A
0.15…80 MHz
10V
Criterion A
(1) Criterion A: DC/DC converter shows normal operation behavior within the defined limits.
EMC Emission According to Generic standards: EN 61000-6-3 and EN 61000-6-4
Attributes
Standards
Notes
Conducted emission on input
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
Limits for DC power ports according to EN 61000-6-3
fulfilled
Radiated emission
EN 55011, EN 55022
Class B
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may cause undesired operation.
Switching Frequency
Attribute
Main converter
14
Values
Notes
90...140 kHz
Dependent on output load and input
voltage (output current > 0.5 A)
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Environment
Attributes
Values
Notes
Operational temperature(1)
-25…+70 °C (-13…+158 °F)
Reduce output power according to Figure 19
Storage temperature
-40…+85 °C (-40…+185 °F)
For storage and transportation
1.6 W/1 °C (1.6 W/1.8 °F)
Between 45…60 °C (113…140 °F)
3 W/1 °C (3 W/1.8 °F)
Between 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
30 g 6 ms, 20 g 11 ms
3 bumps / direction,
18 bumps in total
IEC 60068-2-27
Altitude
0…6000 m (0…20,000 ft)
Reduce output power or ambient temperature in
applications 2000 m (6500 ft) above sea level
Altitude derating
7.5 W/1000 m (7.5 W/3280 ft), or
5 °C/1000 m (9 °F/3280 ft)
Above 2000 m (6500 ft), see Figure 20
Output derating
III
IEC 62477-1, EN 50178, altitudes up to 2000 m (6500 ft)
II
Altitudes from 2000…6000 m (6500…20,000 ft)
Degree of pollution
2
IEC 62477-1, EN 50178, not conductive
LABS compatibility
The unit does not release any silicone or other LABS-critical substances and is suitable for use
in paint shops.
Overvoltage category
(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
(0.05 in.) and standard orientation.
Figure 19 - Output Current Versus Ambient Temp.
Allowable Output
Current at 24V
6A
short
term
continuous
Figure 20 - Output Current Versus Altitude at 24V
Allowable Output
Current at 24V
6A
5
5
4
4
3
3
2
2
1
1
Ambient Temperature
0
-25
0
20
40
short term
B
C
A
A: Tamb < 60 °C
B: Tamb < 50 °C
C: Tamb < 40 °C
Altitude
0
60 70 °C
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
0
2000
4000
6000 m
15
Protection Features
Attributes
Values
Notes
Output protection
Electronically protected against overload, no-load, and short-circuits(1)
Output overvoltage
protection
31V DC typ
32V DC max
If there is an internal DC/DC converter anomaly, a redundant
circuit limits the maximum output voltage. The output shuts
down and automatically attempts to restart.
Reverse input polarity
protection
Included
Unit does not start when input voltage is reversed
Output overcurrent
protection
Electronically limited(1)
See Figure 8 on page 9
Degree of protection
IP 20
EN/IEC 60529
Penetration protection
> 3.5 mm (0.138 in.)
For example, screws, small parts
Over-temperature
protection
Yes
Output shutdown with automatic restart
Input transient protection
MOV
Metal Oxide Varistor
Internal input fuse
Included
Not user-replaceable
(1) If there is a protection event, audible noise may occur.
Safety Features
The input must be powered from a SELV source (according to IEC 60950-1), a
PELV source (according to IEC 62477-1), or an Isolated Secondary Circuit
(according to UL 508). If these input requirements are met, the following
safety features apply.
Dielectric Strength
Attributes
Values
Classification of output
voltage
SELV
Notes
IEC/EN 60950-1
PELV
IEC/EN 60204-1, EN 50178, IEC 62477-1, IEC 60364-4-41
Class of protection
III
PE (Protective Earth) connection not required. A connection of the
“Chassis Ground” pin to earth is recommended for best EMI performance
Isolation resistance
> 5 MΩ
Input to output, 500V DC
PE resistance
< 0.1 Ω
Between housing and Chassis Ground terminal
Touch current
(leakage current)
The leakage current that is produced by the DC/DC converter itself depends on the
input voltage ripple and must be investigated in the final application.
For a smooth DC input voltage, the produced leakage current is less than 100 µA.
The output voltage is floating and has no ohmic connection to the ground. The
manufacturer conducts type and factory tests. Field tests can 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 all input terminals together, and all
output poles before conducting the test. When testing, set the cutoff current
settings to the values in the following table.
Figure 21 - Dielectric Strength
Input
+
B
-
Output
A
Chassis
ground
16
+
C
-
Test or Setting
Time
A
B
Type test
60 s
1500V AC
1500V AC
C
500V AC
Factory test
5s
1500V AC
1500V AC
500V AC
Field test
5s
1000V AC
1000V AC
500V AC
Cutoff current
setting
—
> 30 mA
> 30 mA
> 12 mA
To fulfill the PELV requirements according
to EN60204-1 § 6.4.1, we recommend that
you connect the protective earth system to
the + pole, the – pole, or any other part of
the output circuit. This helps to avoid
situations in which a load starts
unexpectedly or cannot be switched off
when unnoticed earth faults occur.
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Approvals
Approval Names
Approval Symbols
Notes
EC Declaration of Conformity
The CE marking indicates conformance with the following:
– EMC Directive
– ATEX directive
IEC 60950-1
2nd Edition
CB Scheme,
Information Technology Equipment
UL 508
LISTED for use as Industrial Control Equipment;
U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01);
E-File: E56639
IND. CONT. EQ.
UL 60950-1
RECOGNIZED for the use as Information Technology
Equipment, Level 3; U.S.A. (UL 60950-1) and Canada (C22.2
No. 60950-1); E-File: E168663
EN 60079-0, EN 60079-7
ATEX
Approval for use in hazardous locations Zone 2 Category 3G.
Number of ATEX certificate: EPS 08 ATEX 1 142 X
The device must be built-in, in an IP54 enclosure.
II 3G Ex ec nC II T 4 Gc
IEC 60079-0, IEC 60079-7
IECEx
Suitable for use in Class 1 Zone 2 Groups IIa, IIb, and IIc
locations. Number of IECEx certificate: IECEx EPS 14.0001X
ANSI / ISA 12.12.01-2007
Class I Div 2
Recognized for use in Hazardous Location Class I Div 2 T4
Groups A,B,C,D systems; U.S.A. (ANSI / ISA 12.12.01) and
Canada (C22.2 No. 213-M1987)
Marine
GL (Germanischer Lloyd) classified and
ABS (American Bureau for Shipping) PDA
Environmental category: C, EMC2
Marine and offshore applications
EAC TR Registration
Registration for the Eurasian Customs Union market (Russia,
Kazakhstan, Belarus)
Fulfilled Standards
Standard Names
Standard Symbols
Notes
RoHS Directive
Directive 2011/65/EU of the European Parliament and the Council
of June 8, 2011 on the restriction of the use of certain hazardous
substances in electrical and electronic equipment.
REACH Directive
Directive 1907/2006/EU of the European Parliament and the
Council of June 1, 2007 regarding the Registration, Evaluation,
Authorization, and Restriction of Chemicals (REACH)
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
17
Physical Dimensions and
Weight
Attributes
Values and Descriptions
Width
32 mm (1.26 in.)
Height
124 mm (4.88 in.)
Depth
102 mm (4.02 in.)
Weight
425 g (0.94 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 (0.30 in.) or 15 mm (0.59 in.). The DIN rail height must be added to the unit
depth to calculate the total required installation depth.
Installation
clearances
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 side and 5 mm (0.20 in.) on the right side are
recommended when the device is loaded permanently with more than 50% of
the rated power. If the adjacent device is a heat source, such as another DC/DC
converter, increase the side clearances from 5 mm (0.20 in.) to 15 mm (0.59 in.).
The dimensions in the following figures are in millimeters.
Figure 22 - Front View
18
Figure 23 - Side View
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Accessories
This section provides information about devices that can be used with the
1606-XLDF120E DC/DC converter.
1606-XLB Wall Mounting Bracket
This bracket is used to mount the DC/DC converter onto a flat surface without
using a DIN rail. The two aluminum brackets and the black plastic slider of the
unit have to be removed, so that the two steel brackets can be mounted.
Figure 24 - Wall Mounting Bracket
Attached to DC/DC Converter(1)
Figure 25 - Wall Mounting Bracket
(1) The drawing of the DC/DC converter is only intended to show mounting functionality.
1606-XLA-S37 Side Mount Bracket
This bracket is used to mount the DC/DC converter sideways with or without a
DIN rail. The two aluminum brackets and the black plastic slider of the unit
have to be detached, so that the steel brackets can be mounted. For sideways
DIN rail mounting, the removed aluminum brackets and the black plastic
slider must be mounted on the steel bracket.
Figure 26 - Side Mounting
Without DIN Rail Brackets(1)
Figure 27 - Side Mounting With
DIN Rail Brackets(1)
(1) The drawings of the DC/DC converter are only intended to show mounting functionality.
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
19
Peak Current Capability
Solenoids, contactors, and pneumatic modules often have a steady state coil
and a pick-up coil. The inrush current demand of the pick-up coil is several
times higher than the steady-state current and usually exceeds the nominal
output current (including the PowerBoost). The same situation applies when
starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. If there is a
short or an overload in the branch circuit, the fuse needs a certain amount of
overcurrent to trip or to blow. The peak current capability helps ensure the safe
operation of subsequent circuit breakers.
If the input voltage is turned on before such an event, the built-in large sized
output capacitors inside the DC/DC converter can deliver extra current.
Discharging this capacitor causes a voltage dip on the output. The following
two examples show typical voltage dips:
Back-feeding Loads
Figure 28 - Peak Loading with 2x the Nominal
Current for 50 ms, Typ
Figure 29 - Peak Loading with 4x the Nominal
Current for 5 ms, Typ
Peak load 10 A (resistive load) for 50 ms
Output voltage: 24V dips to 17.1V.
Peak load 20 A (resistive load) for 5 ms
Output voltage: 24V dips to 11V.
Loads such as decelerating motors and inductors can feed voltage back to the
DC/DC converter. This feature is also called return voltage immunity or
resistance against Back Electromagnetic Force (Back EMF).
This DC/DC converter is resistant and does not show malfunctioning when a
load feeds back voltage to the DC/DC converter. It does not matter, whether
the DC/DC converter is on or off.
The maximum allowed feedback-voltage is 30V DC. The absorbing energy can
be calculated according to the built-in large sized output capacitance, which is
specified in Output on page 9.
20
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Inductive and Capacitive
Loads
The unit is designed to supply any kind of loads, including unlimited
capacitive and inductive loads.
Charging of Batteries
The DC/DC converter can be used to charge lead-acid or maintenance free
batteries, by charging two 12V batteries in series.
Instructions for charging batteries:
•
•
•
End-of-charge voltage
27.8V
27.5V
27.15V
26.8V
Battery temperature
10 °C (50 °F)
20 °C (68 °F)
30 °C (86 °F)
40 °C (104 °F)
•
•
•
•
External Input Protection
Ensure that the ambient temperature of the DC/DC converter is below
45 °C (113 °F)
Do not use DC/DC converters in mounting orientations other than the
standard mounting orientation (input terminals on the bottom and
output terminals on top of the unit).
Set output voltage (measured at no load and at the battery end of the
cable) precisely to the end-of-charge voltage.
Use a 6 A or 10 A circuit breaker (or blocking diode) between the DC/DC
converter and the battery.
Ensure that the output current of the DC/DC converter is below the
allowed charging current of the battery.
Use only matched batteries when putting 12V types in series.
The return current to the DC/DC converter (battery discharge current) is
26.4 mA typ when the DC/DC converter is switched off (except in case a
blocking diode is used).
The unit is tested and approved for branch circuits up to 50 A. An external
protection is only required if the supplying branch has an ampacity greater
than this. Check also local codes and local requirements. In some countries
local regulations might apply.
If an external fuse is used, minimum requirements must be considered to
avoid nuisance tripping of the circuit breaker. A minimum value of 6 A B- or
6 A C-Characteristic breaker should be used.
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
21
Requirements for the
Supplying Source
In certain circumstances, the input filter of the DC/DC converter can show a
resonant effect that is caused by the supplying network. Especially when
additional external input filters are used, a superimposed AC voltage can be
generated on the input terminals of the DC/DC converter. This superimposed
AC voltage might cause a malfunction of the unit. Therefore, additional input
filters are not recommended. To avoid the resonant effects, the minimal
resistance of the supplying network which depends on the inductance of the
input network, shall be above the boundary curve in Figure 30.
Figure 30 - External Input Filter Requirements to Avoid Filter Instabilities
Resistance of the
supplying network
1Ω
(a)
(b)
100 mΩ
10 mΩ
(a) max
(b) typ
1 mΩ
0.1 mH
1 mH
10 mH
Inductance of the supplying network
Parallel Use to Increase
Output Power
Figure 31 - Parallel Use to Increase Output Power
Unit A
Input
+
-
Output
Unit B
Input
Load
+
+
-
Output
-
The DC/DC-converter can be
paralleled to increase the output
power. The converter does not
have a feature that balances the
load current between the DC/DC
converters. Therefore, some
restrictions and limitations
apply. The DC/DC converter
with the higher adjusted output
voltage draws current until it
goes into current limitation.
This means no harm or switch-off to this DC/DC converter as long as the
ambient temperature stays below 45 °C (113 °F).
Adjust the output voltages of all DC/DC converters to the same value (±100 mV)
at full load. A fuse or diode on the output of each unit is only required if more
than three units are connected in parallel. This ensures that if the output stage
of the DC/DC converter has an anomaly, more than two times the nominal
output current will not flow backwards into the DC/DC converter. If a fuse (or
circuit breaker) is used, choose one with approximately 150% of the rated
output current of one DC/DC converter. Keep an installation clearance of
15 mm (0.59 in.) (left / right) between two DC/DC converters and avoid
installing the DC/DC converters on top of each other. Do not use DC/DC
converters in parallel in mounting orientations other than the standard
mounting orientation (input terminals on the bottom and output terminals on
top of the unit).
22
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Parallel Use for Redundancy The DC/DC converters can be paralleled for 1+1 redundancy to gain higher
system availability. Redundant systems require a certain amount of extra
power to support the load in case one DC/DC converter fails. The simplest way
is to put two DC/DC converters in parallel. This is called a 1+1 redundancy. In
case one DC/DC converter fails, the other one is automatically able to support
the load current without any interruption. Redundant systems for a higher
power demand are usually built in an N+1 method. For example, five DC/DC
converters, each rated for 5 A are paralleled to build a 20 A redundant system.
Furthermore, 1+1 redundant systems can be built by using a DC/DC converter
that is powered from a battery and a power supply with AC input.
IMPORTANT
This simple way to build a redundant system does not cover failures
such as an internal short circuit in the secondary side of the DC/DC
converter. In such a case, the unit with the anomaly becomes a load for
the other DC/DC converters and the output voltage cannot be
maintained. This can only be avoided by using decoupling diodes, which
are included in the decoupling module 1606-XLERED.
Recommendations for building redundant power systems:
•
•
•
•
Daisy Chaining of Outputs
Use separate input fuses for each DC/DC converter.
Monitor the individual DC/DC converter units. A DC OK status indicator
and a DC OK contact is included in the redundancy module 1606XLERED. This feature reports a faulty unit.
1+1 Redundancy is allowed up to an ambient temperature of 60 °C (140 °F)
N+1 Redundancy is allowed up to an ambient temperature of 45 °C (113 °F)
It is desirable to set the output voltages of all units to the same value (±
100 mV) or leave it at the factory setting.
Daisy chaining (jumping from one DC/DC converter output to the next) is
allowed as long as the average output current through one terminal pin does
not exceed 25 A. If the current is higher, use a separate distribution terminal
block.
Figure 32 - Daisy Chaining of Outputs
Figure 33 - Using Distribution Terminals
25 A max
Output
++ - -
Output
++ - -
DC/DC
Converter
Input
+
-
Output
++ - -
Output
++ - -
DC/DC
Converter
DC/DC
Converter
DC/DC
Converter
Input
Input
Input
Load
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
+
-
Load
Distribution
Terminals
23
Series Operation
Figure 34 - Series Operation
Unit A
Input
+
Load
-
+
Output
Unit B
Input
+
Output
-
-
DC/DC converters of the exact
same type can be connected in
series for higher output voltages. It
is possible to connect as many units
in series as needed, providing the
sum of the output voltage does not
exceed 150V DC. Voltages with a
potential above 60V DC are not
SELV and can be dangerous. Such
voltages must be installed with a
protection against touching.
Earthing of the output is required when the sum of the output voltage is above
60V DC. Avoid return voltage (for example, from a decelerating motor or
battery) which is applied to the output terminals. Keep an installation
clearance of 15 mm (0.59 in.) (left / right) between two DC/DC converters and
avoid installing the DC/DC converters on top of each other. Do not use DC/DC
converters in series in mounting orientations other than the standard
mounting orientation (input terminals on the bottom and output terminals on
top of the unit).
Use in a Tightly Sealed
Enclosure
When the DC/DC converter is installed in a tightly sealed enclosure, the
temperature inside the enclosure is higher than outside. In such situations, the
inside temperature defines the ambient temperature for the DC/DC converter.
The following measurement results can be used as a reference to estimate the
temperature rise inside the enclosure. These measurements are taken under
the following conditions:
•
•
•
24
The DC/DC converter is placed in the middle of the enclosure, with no
other heat producing items inside the enclosure.
The load is placed outside the enclosure.
The temperature sensor inside the enclosure is located in the middle of
the right side of the DC/DC converter, at a distance of 2 cm (0.79 in.)
from the converter.
Attributes
Values
Enclosure size
110 x 180 x 165 mm
(4.33 x 7.09 x 6.50 in.)
Rittal Typ IP66 Box
PK 9516 100, plastic
Input voltage
48V DC
Load
24V, 4 A; (=80%)
Temperature inside enclosure
42.8 °C (109.04 °F)
Temperature outside enclosure
24.0 °C (75.2 °F)
Temperature rise
18.8 K (33.84 °F)
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
Mounting Orientations
The lifetime expectancy and MTBF values in this document apply only for
Mounting Orientation A, Standard Orientation (Figure 35). Non-standard
mounting orientations 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 DC/DC converter.
Two derating curves for continuous operation are provided for the
non-standard mounting orientations:
•
•
Curve A1: Recommended output current.
Curve A2: Max allowed output current (results in approximately half the
lifetime expectancy of A1).
Output Current
6A
5
4
3
2
1
0
10
OUTPUT
Figure 35 - Mounting Orientation A:
Standard Orientation
DC/DC
Converter
INPUT
A1
Ambient Temperature
20
30
40
60 °C
50
Output Current
6A
5
4
3
2
1
0
10
INPUT
Figure 36 - Mounting Orientation B:
Upside Down
A2
A1
Ambient Temperature
20
30
40
50
60 °C
50
60 °C
50
60 °C
DC/DC
Converter
OUTPUT
Output Current
6A
5
4
3
2
1
0
10
Figure 37 - Mounting Orientation C:
Table-top Mounting
A2
A1
Ambient Temperature
20
30
40
Output Current
OUTPUT
DC/DC
Converter
INPUT
Figure 38 - Mounting Orientation D:
Horizontal with Input on the Left
6A
5
4
3
2
1
0
10
A2
A1
Ambient Temperature
20
30
40
INPUT
DC/DC
Converter
Figure 39 - Mounting Orientation E:
Horizontal with Input on the Right
OUTPUT
Output Current
6A
5
4
3
2
1
0
10
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
A2
A1
Ambient Temperature
20
30
40
50
60 °C
25
Notes:
26
Rockwell Automation Publication 1606-RM114A-EN-P - September 2020
DC/DC Converter 24V, 5 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-RM114A-EN-P - September 2020
27
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Technical Support Center
Knowledgebase
Local Technical Support Phone Numbers
Literature Library
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(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.
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rok.auto/knowledgebase
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rok.auto/literature
rok.auto/pcdc
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At the end of life, this equipment should be collected separately from any unsorted municipal waste.
Rockwell Automation maintains current product environmental information on its website at rok.auto/pec.
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Trademarks not belonging to Rockwell Automation are property of their respective companies.
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