Allen-Bradley 1606-XLBRED20 User manual

Dual Input Redundancy Module

- DC 12…28V, 20 A

Catalog Number 1606-XLBRED20

Reference Manual Original Instructions

2Rockwell Automation Publication 1606-RM111A-EN-P - July 2020

Dual Input Redundancy Module - DC 12…28V, 20 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.

Labels may also be on or inside the equipment to provide specific precautions.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential

Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory

requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 3

Table of Contents

Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . . 8

Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Using Only One Input Instead of Both Channels . . . . . . . . . . . . . . . . . . . 14

Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Use In a Tightly Sealed Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Example: Redundancy for Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Example: 1+1 Redundancy Up To 10 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Example: 1+1 Redundancy Up To 20 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4Rockwell Automation Publication 1606-RM111A-EN-P - July 2020

Notes:

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 5

Terminology and

Abbreviations Terms Descriptions

DC 24V 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).

24V DC A value with the unit (V DC) at the end is a momentary value without any additional

tolerances included.

nom Indicates a nominal value.

typ Indicates a typical value.

— (alone in table cell) A single dash alone in a table cell indicates that there is no information to be included

in that cell.

1+1 Redundancy

Use of two identical power supplies in parallel to provide continued operation following

most failures in a single power supply. The two power supply outputs should be

isolated from each other by using diodes or other switching arrangements. For

example, two 10 A power supplies are needed to achieve a 10 A redundant system.

N+1 Redundancy

Use of three or more identical power supplies in parallel, which are allowed to be

connected in parallel for higher output currents, to provide continued operation

following most failures in a single power supply. All power supply outputs should be

isolated from each other by using diodes or other switching arrangements. For

example, to achieve a 40 A redundant system, five 10 A power supplies are needed in

an N+1 redundant system. Ensure that the power supplies are allowed to be connected

in parallel to increase the output power.

Figure 1 - 1+1 Redundancy Figure 2 - N+1 Redundancy

Load

IN 1

OUT

IN 2

IN 1

OUT

IN 2 IN 1

OUT

IN 2 IN 1

OUT

IN 2

Load

6Rockwell Automation Publication 1606-RM111A-EN-P - July 2020

Product Overview The 1606-XLBRED20 is a redundancy module, which can be used to build 1+1

and N+1 redundant systems. The 1606-XLBRED20 redundancy module has two

input channels, which can be connected to power supplies with up to 10 A

output current. The module has one output, which can carry nominal currents

up to 20 A.

The module is suitable for power supplies with constant current overload

behavior and any kind of “hiccup” overload behavior. The 1606-XLBRED20 is

well suited for use in a redundant system in which the power supply itself is

equipped with a DC-OK signal.

Another application for this redundancy module is to separate sensitive loads

from non-sensitive loads. This avoids the distortion of the power quality for

the sensitive loads, which can cause controller failures.

Product features:

• Cost-effective solution to build redundant systems

• Dual-input with single output

• Two diodes (common cathode)

• DC 12…28V ±25% wide-range input

• Full power from -40…+55 °C (-40…+131 °F)

• Width only 39 mm (1.54 in.)

• Large screw terminals

• Easy wiring: distribution terminal for negative pole included

Specifications

Catalog Number

Attributes Values Notes

Input voltage DC 12…28V ±25%

Input voltage range 9…35V DC —

Input current 2 x 0…10 A ambient < 55 °C (131 °F)

2 x 0…6.25 A ambient < +70 °C (158 °F)

Output current

0…20 A ambient < 55 °C (131 °F)

0…12.5 A ambient < +70 °C (158 °F)

26 A at cont. overload/ short circuit

Input to output voltage drop 0.46V typ input: 2 x 5 A

0.56V typ input: 2 x 10 A

Power losses

0 W at no load

4.6 W typ input: 2 x 5 A

11.2 W typ input: 2 x 10 A

Temperature range -40…+70 °C (-40…+158 °F) operational

Derating 0.5 A/1 °C (0.5 A/1.8 °F) 55…70 °C (131…158 °F)

Dimensions 39 x 124 x 124 mm

(1.54 x 4.88 x 4.88 in.) W x H x D

Weight 280 g (0.62 lb) —

Catalog Number Description

1606-XLBRED20 Redundancy module

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 7

Input and Output

Characteristics

In Figure 4, the power supplies can be either 1606-XLX120 or 1606-XLX240. The

redundancy module is 1606-XLBRED20.

Power Losses

Figure 5 - Power Losses at 25 °C (77 °F)

Attributes Values Notes

Number of inputs — 2 —

Number of outputs — 1 —

Input voltage Nom DC 12…28V ±25% —

Input voltage range — 9…35V DC —

Voltage drop, input to output Typ 0.46V at 2 x 5 A, see Figure 3

Typ 0.56V at 2 x 10 A, see Figure 3

Input current Nom 2 x 0…10 A continuous

Nom 2 x 10…16 A for 5 s

Peak input current Max 1000 A for 10 ms max per input

Output current

Nom 20 A continuous

Nom 20…32 A for 5 s

Max 26 A(1)

(1) Ensure that the continuous output current does not exceed 26 A. Check the short-circuit current of the power sources and if

the power source can deliver more than 26 A together, use an appropriate fuse on the output.

at continuous overload or short circuit

Reverse current Max 4 mA per input, -40…+70 °C (-40…+158 °F)

Reverse voltage Max 45V DC voltage applied to the output, continuously allowed

Figure 3 - Input to Output Voltage Drop Figure 4 - Test Setup For Voltage Drop Measurements

Voltage Drop, Typ

100 mV

200 mV

300 mV

400 mV

500 mV

600 mV

5 A 15 A 20 A10 A

Output:

2x5 A2x2.5 A

Input:

2x10 A2x7.5 A

Input, Output Current

A...25°C

B...60°C

Power Supply

24V, 5 A or

24V, 10 A

= Voltage Drop

OUT

Output

OUT

Variable

Load,

0…20 A

Redundancy Module

Input 1

Input 2

Output

Power Supply

24V, 5 A or

24V, 10 A

Attribute Values Notes

Power losses

— 0 W at no load (stand-by)

Typ 4.6 W at 24V and 2 x 5 A input current

Typ 11.2 W at 24V and 2 x 10 A input current

Power Losses, Typ

0510

12 W

20 A15

Output Current

8Rockwell Automation Publication 1606-RM111A-EN-P - July 2020

Lifetime Expectancy and

Mean Time Between Failure

The redundancy module has two input channels, which are completely

independent from each other. The dual-input redundancy module can be

considered as two single redundancy modules combined in one housing. The

only common point is the circuit trace that ties the two separate circuits

together at the output.

The Mean Time Between Failure (MTBF) values in the following table are for

the entire dual-input module. If you need the MTBF number of only one path,

double the value from the table.

Terminals and Wiring The terminals are IP20 fingersafe constructed and suitable for field wiring and

factory wiring.

Wiring rules:

• Use appropriate copper cables that are designed for minimum operating

temperatures of:

- 75 °C (167 °F) for ambient up to 55 °C (131 °F)

- 90 °C (194 °F) for ambient up to 70 °C (158 °F)

• Follow national installation codes and installation regulations.

• Ensure that all strands of a stranded wire enter the terminal connection.

• Unused terminal compartments should be securely tightened.

• Ferrules are allowed.

Input

Output Current Conditions

N+1 Redundancy

Input: 2 x 10 A

Output: 20 A

1+1 Redundancy

Input: 2 x 5 A

Output: 10 A

Notes

Lifetime expectancy(1) Min 113,000 h 309,000 h at 24V and 40 °C (104 °F)

Min 320,000 h 874,000 h at 24V and 25 °C (77 °F)

MTBF(2) SN 29500, IEC 61709 — 7,837,000 h 20,310,000 h at 24V 40 °C (104 °F)

— 19,408,000 h 46,382,000 h at 24V 25 °C (77 °F)

MTBF (2) MIL HDBK 217F

— 1,774,000 h 1,817,000 h at 24V and 40 °C (104 °F) (Ground Fixed GF40)

— 2,709,000 h 2,782,000 h at 24V and 25 °C (77 °F) (Ground Fixed GF25)

— 3,675,000 h 3,707,000 h at 24V and 40 °C (104 °F) (Ground Benign GB40)

— 5,620,000 h 5,674,000 h at 24V and 25 °C (77 °F) (Ground Benign GB25)

(1) The Lifetime expectancy values that are shown in the table indicate the minimum operating hours (service life) and are determined by the

lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours and is calculated according to

the manufacturer specification of the capacitor. The manufacturer of the electrolytic capacitors only states a maximum life of up to 15 years

(131,400 h). Any number that exceeds this value is a calculated theoretical lifetime, which can be used to compare devices.

(2) Mean Time Between Failure (MTBF) is calculated according to statistical device failures, and indicates reliability of a device. It is the statistical

representation of the likelihood of a unit to fail and does not necessarily represent the life of a product. The MTBF value is a statistical

representation of the likelihood of a device to fail. An MTBF value of, for example, 1,000,000 h means that statistically one unit fails every 100

hours if 10,000 units are installed in the field. However, it cannot be determined if the failed unit has been running for 50,000 h or only for 100 h.

Attributes Values and Descriptions

Type screw terminals

Solid wire 6 mm2max

Stranded wire 4 mm2max

American Wire Gauge AWG20…10

Wire diameter max 2.8 mm (0.110 in.) (including ferrules)

Wire stripping length 7 mm (0.28 in.)

Screwdriver 3.5 mm (0.138 in.) slotted or cross-head No 2

Recommended tightening torque 1 N•m, 9 lb•in

Rockwell Automation Publication 1606-RM111A-EN-P - July 2020 9

Functional Diagram Figure 6 - Functional Diagram

Front Side and User

Elements

Input 1

Input 2

Output

Surge

Protection

Surge

Protection

Surge

Protection

Figure 7 - Front Side User Elements

1 Input terminals for input 1 and input 2

2Outputterminals

Two identical (+) poles

10 Rockwell Automation Publication 1606-RM111A-EN-P - July 2020

Electromagnetic

Compatibility

The redundancy module is suitable for applications in industrial, residential,

commercial, and light industrial environments without any restrictions.

The following table shows electromagnetic compatibility (EMC) immunity

according to generic standards EN 61000-6-1 and EN 61000-6-2.

The following table shows EMC emission according to generic standards

EN 61000-6-3 and EN 61000-6-4. The redundancy module incorporates only

diodes and no RF-generating circuits and does not contribute to EMC

emissions.

Attributes Standards Values Criteria(1)

Electrostatic discharge EN 61000-4-2

Contact discharge

on indirect coupling plane 8 kV Criterion A

Air discharge 15 kV Criterion A

Electromagnetic RF field EN 61000-4-3 80 MHz…2.7 GHz 20V/m Criterion A

Fast transients (Burst) EN 61000-4-4 Input lines 2 kV Criterion A

Output lines 2 kV Criterion A

Surge voltage on input lines EN 61000-4-5 + -500V Criterion A

+/- earthed DIN rail 1 kV Criterion A

Surge voltage on output lines EN 61000-4-5 + -500V Criterion A

+/- earthed DIN rail 1 kV Criterion A

Conducted disturbance on input lines EN 61000-4-6 0.15…80 MHz 20V Criterion A

Conducted disturbance on output lines EN 61000-4-6 0.15…80 MHz 20V Criterion A

Power-frequency magnetic field(2) 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.

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) (2)

Conducted emission

output lines

IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 limits for DC power ports according to EN 61000-6-3 fulfilled(1) (2)

Radiated emission EN 55011, EN 55022 Class B(2)

This device complies with FCC Part 15 rules.

Operation is subjected to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any

interference received, including interference that may cause undesired operation.

(1) For information only, not mandatory for EN 61000-6-3.

(2) if power sources that are connected on the inputs fulfill the requirements too.

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