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Rockwell Automation Publication 1606-RM008A-EN-P - November 2021

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Table of Contents

Terminology and Abbreviations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6
Catalog Numbers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6
Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9
Batteries and Battery Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   13
Buffer Time  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15
Ready and Buffering Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   17
Replace Battery Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
Inhibit Input  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   17
Efficiency and Power Losses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
Lifetime Expectancy and MTBF  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19
Front User Elements  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  23
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24
Protection Features  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
Safety Features  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
Dieletric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  26
Certifications and Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . .  26
Approximate Dimensions and Weight  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  28
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   31
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Summary of Contents for 1606-XLS480-UPS

Page 1: ...Reference Manual Original Instructions DC UPS 24V 20 A 480 W Catalog Number 1606 XLS480 UPS ...

Page 2: ...bed 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 These labels may also be on or inside the equipment to provide specific precautions The following icon may appear in the text of this document WARNING Iden...

Page 3: ...y and Buffering Relay Contact 17 Replace Battery Relay Contact 17 Inhibit Input 17 Efficiency and Power Losses 18 Lifetime Expectancy and MTBF 18 Functional Diagram 19 Terminals and Wiring 19 Front User Elements 20 Electromagnetic Compatibility 23 Environment 24 Protection Features 25 Safety Features 25 Dieletric Strength 26 Certifications and Standards Compliance 26 Approximate Dimensions and Wei...

Page 4: ...4 Rockwell Automation Publication 1606 RM008A EN P November 2021 Table of Contents Notes ...

Page 5: ...udes a selectable buffer time limiter and ready buffering and replace battery contacts For safety and maintenance an inhibit input signal is included which helps prevent a battery backup 100 240V wide range input No Change in Output Voltage in Battery Mode Selectable Output Voltages in Battery Mode 1 Battery Concept Each 12V Battery is Charged and Monitored Separately for Longest Battery Life Prec...

Page 6: ... Output current 25 A continuous 30 A for 4 s in power supply mode 20 A continuous 30 A for 4 s in battery mode Allowed battery sizes 3 9 150 Ah 2 batteries in series each 12V Buffer Time 6 min 45 s at 20 A 7 Ah 16 min 47 s at 20 A 12 Ah 2 h 49 min at 20 A 65 Ah 6 h 20 min at 20 A 140 Ah Temperature range 40 70 C 40 158 F operational Derating 0 5 A C 60 70 C Size W x H x D 46 x 124 x 127 mm 1 81 x ...

Page 7: ...287 035 from Little fuse or an UL Listed fuse with the same characteristics in the battery circuit The battery fuse protects the wires between the battery and the DC UPS and shall be located close to the battery The device is designed for pollution degree 2 areas in controlled environments No condensation or frost is allowed The device is designed as Class of Protection III equipment according to ...

Page 8: ...d in the original battery modules Installation Instructions for Hazardous Location Areas The device is suitable for use in Class I Division 2 Groups A B C D locations and for use in Group II Category 3 Zone 2 environments Hazardous Location Classification ATEX EPS 15 ATEX 1 025 X II 3G EX EC nC IIC T4 Gc Figure 1 Typical Wiring Diagram WARNING Explosion Hazards Substitution of components may impai...

Page 9: ...ange describes the input voltage which supports the full functionality of the DC UPS including charging but without entering the battery mode It requires a minimum of 1V higher than the buffer voltage settings and a maximum voltage of not more than 30V DC Buffering and Buffer Voltage Buffering will start immediately without interruption after the input voltage falls below the lower end of the norm...

Page 10: ... 4 Buffer Voltage Settings on the Front Temporarily allowed No Charging no Buffering D 26V C 25V B 24V A 22 5V 27V 26V 25V 23 5 V 30V 30V 30V 30V 30V 18V 35V Buffer Voltage Settings Four Ranges 26V 25V 24V 22 5V Normal Operating Voltage 4 Ranges Buffer Voltage Rated Input Voltage Range Battery Mode 0V D C B A Range A Range B Range C Range D ...

Page 11: ...endent of the value of the input voltage See Figure 5 and Figure 6 on page 12 in battery mode Nom 22 5V DC 3 The buffer voltage is the output voltage in battery mode selectable in four steps via rotary switch on the front of the unit and will not change as the batteries discharge See Figure 3 on page 10 Nom 24 0V DC 3 Nom 25 0V DC 3 Nom 26 0V DC 3 Ripple and noise voltage in power supply mode not ...

Page 12: ...he power supply has a continuous output current capability of more than 28 A 3 HiccupPLUS Mode In battery mode the DC UPS can deliver 50 more output current for up to 4 s before it reduces the output current automatically to the nominal output current If the current requirement is continuously higher than the nominal current the current regulation of the DC UPS reduces the output voltage As soon a...

Page 13: ...ery to the DC UPS can be higher than the load current due to the buffer voltage transformation which restores the battery voltage to a constant buffer voltage The 1606 XLS480 UPS has a battery size selector included that allows an optimal use of small and large battery sizes It is not recommended to connect multiple batteries or battery modules in parallel Choose larger sized battery instead Charg...

Page 14: ... temperature sensor of the battery and is not the surrounding air temperature of the DC UPS Frequent charging below 5 C 41 F reduced the lifetime of the battery and should be avoided Low temperatures increase the battery impedance and also change the battery characteristics This could result in a false replace battery signal or an unexpected interruption of a buffer event especially with small bat...

Page 15: ...ule and the DC UPS Due to long term aging effects of batteries consider a buffer time reduction of 30 50 over time The shown buffer times only apply for Rockwell Automation battery modules or from Rockwell Automation recommended batteries The buffer time is defined for a fully charged battery The buffer time can be 10 20 shorter for buffer events which start immediately after the Ready signal beco...

Page 16: ... Modules Buffer Time 10A 12A 14A 16A 18A 20A 6A 8A 4A 2A 0A Buffer Current 20 30 10 0 60 70 50 40 90 80 Minutes B 1 5 3 5 2 8 10 7 6 Hours 4 9 Batteries A 7Ah 1606 XLSBATASSY3 B 12Ah 1606 XLSBATASSY4 A A B 10A 12A 14A 16A 18A 20A 6A 8A 4A 2A 0A Buffer Current 2 3 1 0 6 7 5 4 10 11 9 8 14 15 13 12 18 19 17 16 20 hours Buffer Time A Batteries A 7Ah B 12Ah C 26Ah D 65Ah E 100Ah F 140Ah B C D E F ...

Page 17: ...ttery should be replaced as soon as possible Inhibit Input The inhibit input disables buffering In power supply mode a static signal is required In battery mode a pulse with a minimum length of 250 ms is required to stop buffering See Using the Inhibit Input on page 36 for details Contact Ratings Max 60V DC 0 3 A 30V DC 1 A 30V AC 0 5 A resistive load Min 1 mA at 5V DC Min permissible load Isolati...

Page 18: ...es a maximum life of up to 15 years 131 400 h Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices 440 000 h Power supply mode 10 A and 40 C 1 244 000 h Power supply mode 10 A and 25 C 122 000 h Power supply mode 20 A and 40 C 345 000 h Power supply mode 20 A and 25 C MTBF 2 2 MTBF represents Mean Time Between Failure which is calculated accordi...

Page 19: ...ter Battery Charger 1 Battery Diagnosis 1 24V Battery Input Batt BAT2 12V BAT1 12V CT Battery Charger 2 Current Limiter Battery Diagnosis 2 13 Current Measure ment Buffered Load Output Diagnosis LED yellow Status LED Batt 2 green Inhibit Controller Error LED red Replace Battery Buffering Contact Ready Contact Buffer Time Limiter 10s 30s 1m 3m 10m 7 Inhibit 8 1 2 3 4 5 6 Status LED Batt 1 green Buf...

Page 20: ...wing Output overloaded current Battery replacement required Expired buffer time due to buffer time selector or discharged battery Activated inhibit input 8 Green light emitting diode LED Each battery has its own status LED Battery 1 represents the battery which is electrically closer to the pole and battery 2 which is closer to the pole The updating pattern of this light emitting diode LED reports...

Page 21: ...the output current is permanently above 20 A in battery mode or 25 A in power supply mode Replace Battery The light emitting diode LED is updating with a low frequency when one battery has failed the periodically performed battery quality test In case the center tap connection is present the battery that has failed is indicated by the green light emitting diode LED which is off Otherwise both ligh...

Page 22: ...ates that the input voltage is 30V or the input voltage is too low for the adjusted buffer voltage The input voltage must be at least 1V higher than the selected buffer voltage Temperature A double flash indicates that the temperature of the DC UPS is too high 70 C or that the temperature of the battery is too high 50 C or too low 10 C in setting 10 Ah Battery temperatures indications require a co...

Page 23: ...rds for the device occur Electrostatic discharge 2 2 Chassis ground connection earthed grounded EN 61000 4 2 Contact discharge 8 kV Criterion A Air discharge 15 kV Criterion A Electromagnetic RF field EN 61000 4 3 80 MHz 2 7 GHz 10V m Criterion A Fast transients Burst EN 61000 4 4 Input lines 2 kV Criterion A Output lines 2 kV Criterion A Signals 3 3 Tested with coupling clamp 2 kV Criterion A Sur...

Page 24: ...educe continuous output current according See Figure 18 The operational temperature range can be reduced by the battery specification The DC UPS includes some safety features which reduce the temperature range for charging See Batteries and Battery Charging on page 13 Storage temperature 40 70 C 40 158 F For storage and transportation Output derating 2 5 C Between 60 70 C 140 158 F Humidity 5 95 r...

Page 25: ... Charging on page 13 Input overvoltage protection Max 35V DC No harm or anomaly of the unit Internal input fuse no Reverse input polarity protection included Max 40V Reverse battery polarity protection included Max 35V DC Protection against wrong battery voltage included Max 35V DC Battery deep discharge protection included Bufferingstopswhendeep discharge protection is active Battery will be disc...

Page 26: ...t Output Battery Temperature Sensor Center tap Chassis Signal Port A C B UL 508 UL Certificate Listed equipment for category NMTR Industrial Control Equipment Applicable for US and Canada UL 60950 1 UL Certificate Recognized component for category QQGQ Information Technology Equipment ITE Applicable for US and Canada ATEX 1606 XLS480 UPS Agency Certificate Bureau Veritas EN 60079 0 Explosive atmos...

Page 27: ...on of Conformity The CE marking indicates conformance with the EMC Directive Low Voltage 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 pr...

Page 28: ...N railsaccording toEN 60715or EN 50022 witha heightof7 5 mm 0 295 in or 15 mm 0 59 in Housing material Body Aluminum alloy Cover Zinc plated steel Installation clearances Keep the following min 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 side 5 mm 0 20 in on the right side If the adjacent device is a heat source increase the side clearances...

Page 29: ...deways with or without using 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 sideway DIN rail mounting the removed aluminum brackets and the black plastic slider must be mounted on the steel bracket a Power supply that is shown is for illustration purposes only Figure 22 Wall Mounting Bracket Figure 23 ...

Page 30: ...ts of the 1 Battery Concept This makes the use of matched replacement batteries unnecessary and allows a precise battery charging and testing which results in the longest possible battery life The battery module is available in two different options It can be ordered with assembled batteries 1606 XLSBATASSY3 or as a battery bracket without batteries 1606 XLSBATBR3 allowing for different battery op...

Page 31: ...ngs Battery tests start as soon as the batteries are fully charged the green status indicator must be on solid Battery dynamic impedance tests must fail several times in a row before replace battery is reported This can take up to 14 additional hours after the batteries are fully charged Wear out failures The electrical characteristics of batteries degrade slowly over time Main causes are chemical...

Page 32: ...age starts Effects which shorten the service life of the battery and requires an earlier battery replacement Temperature The temperature has the biggest impact in the service life The higher the temperature the earlier the wear out phase of the battery begins The wear out results in a degradation of battery capacity See Figure 26 for details Number of discharging cycles The number and the depth of...

Page 33: ...er event every 2 days 182 cycles year Calculation A Ambient temperature influence According to Figure 26 curve C a 5 years service life can be expected for an ambient temperature of 30 C B Number of discharging cycles 5 years 182 cycles 910 cycles in 5 years According to Figure 27 curve C has to be used only 25 of battery capacity is required 910 cycles have only a negligible influence in a batter...

Page 34: ...by the same source a fast magnetic tripping of the MCB is desired A quick shutdown within 10 ms is necessary corresponding roughly to the ride through time of PLCs This requires high peak currents to open the circuit breaker in the required time Furthermore the impedance of the faulty branch must be sufficiently small in order for the current to actually flow For this discipline two cases must be ...

Page 35: ... Parallel Use to Increase the Output Current Parallel Use For Redundancy Use the same schematic as for parallel use for higher output current Figure 29 and follow additional the following recommendations a Use separate input fuses for each power supply b Set the power supply into Parallel use mode if available c Use a redundancy module to decouple the two power sources d Monitor the individual sou...

Page 36: ...y mode a short voltage pulse with a minimum length of 250 ms is applied to the inhibit input terminals the output switches off and stay off until the input voltage recovers Batteries are charged when the inhibit mode is activated or a voltage is applied to the inhibit input terminals See Inhibit Input on page 17 and Dielectric Strength on page 26 for electrical details of the inhibit input Power S...

Page 37: ...age is still below the deep discharge protection level DC UPS stopped buffering Deep discharge protection stopped buffering Use a larger battery or allow sufficient time for charging the battery End of service life of the battery Battery did not have enough time to be charged Inhibit input was activated Buffer time limiter stopped buffering Change the settings of the buffer time limiter on the fro...

Page 38: ...38 Rockwell Automation Publication 1606 RM008A EN P November 2021 DC UPS 24V 20 A 480 W Reference Manual Notes ...

Page 39: ...sures and Contact Ratings Specifications publication IC TD002 Provides a quick reference tool for Allen Bradley industrial automation controls and assemblies Safety Guidelines for the Application Installation and Maintenance of Solid State Control publication SGI 1 1 Designed to harmonize with NEMA Standards Publication No ICS 1 1 1987 and provides general guidelines for the application installati...

Page 40: ...wledgebase Access Knowledgebase articles rok auto knowledgebase Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Download firmware associated files such as AOP EDS and DTM and a...

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