Reference Manual Original Instructions Capacitor-based DC Uninterruptible Power Supplies Catalog Numbers 1606-XLSCAP24-6, -XLSCAP24-12 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). Table of Contents Topic Page Topic Page Additional Resources 3 Ready and Buffer Relay Contact 15 Terminology and Abbreviations 4 Inhibit Input 16 Product Overview 5 PC-mode 16 Front Side and User Elements 6 Efficiency and Power Loss 17 Accessories 7 Lifetime Expectancy and Mean Time Between 17 Failure Protection Features 7 Functional Diagram 19 Safety Features 8 EMC 20 Installation Notes 8 Application Notes 21 Terminals and Wiring 10 Troubleshooting 26 Input 11 Specifications 26 Output 12 Environment 27 Charging 14 Standards Compliance and Certifications 28 Buffer Time 14 Approximate Dimensions and Weight 29 Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description Switched Mode Power Supply Technical Data, publication Provides specifications and approximate dimensions 1606-TD002 for full line of switched mode power supplies. Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell publication 1770-4.1 Automation industrial system. Product Certifications website, http:// Provides declarations of conformity, certificates, and www.rockwellautomation.com/global/certification/ other certification details. overview.page You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 3 Capacitor-based DC UPS Power Supplies Terminology and Abbreviations Term Definition Normal mode Describes a condition where the capacitor is charged, the input voltage is in range, and the output is loaded within the allowed limits. Buffer mode Describes a condition where the input voltage is below the transfer threshold level, the unit is running on capacitor (buffering) and the output is loaded within the allowed limits. Charging mode Describes a condition where the capacitor is being charged, the input voltage is in range and the output is loaded within the allowed limits. Inhibit mode Describes a condition where buffering is disabled on purpose (service actions) AC 24V A figure 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) 24V AC A figure with the unit (V AC) at the end is a momentary figure without any additional tolerances included. DC-UPS Direct Current- Uninterruptible Power Supplies ELDC Electrochemical Double Layer Capacitors EMC Electromagnetic Compatibility VRLA Valve-regulated Lead-acid PELV Protected Extra-low Voltage SELV Separated Extra-low Voltage 4 Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 Capacitor-based DC UPS Power Supplies Product Overview Bulletin 1606 DC- Uninterruptible Power Supplies (DC-UPSs) use electrochemical double-layer capacitors (EDLC), commonly known as ultracapacitors or supercapacitors, that are installed inside. They can bridge power failures or voltage fluctuation and supply voltage to the DC 24V bus for a certain period, which allows for a controlled shut-down of the system. Expensive downtimes, long restart cycles, and loss of data can be avoided. The power supply provides sufficient voltages, the DC-UPS stores energy in the capacitors. If there is a mains voltage fault, this energy is released to the DC bus in a regulated process. The DC-UPSs require no maintenance and have a similar lifetime expectancy as standard power supplies. No regular replacement of the capacitors is necessary as is required for battery-based DC-UPS systems. The wide temperature range makes the unit suitable for many applications. Two versions of the DC-UPSs are available and differ by the size of the installed capacitor. • Built-in capacitors as energy source, EDLC • Wide temperature range: -40…+60 °C (-40…+140 °F) • Typically >10 years operational lifetime expectancy •Regulated output voltage in Buffer mode • No ventilated cabinets required, no generation of hydrogen as valve- regulated lead-acid (VRLA) batteries do • Active balancing for longest life and buffer times • Short charging time, unit is rapidly back in Ready mode • Output is decoupled from the input to separate load • Circuits into buffered and non-buffered sections • Supports PC-mode function • One year warranty Rockwell Automation Publication 1606-RM054A-EN-P - September 2016 5 Capacitor-based DC UPS Power Supplies Front Side and User Elements Figure 1 - Front Side of DC-UPS A. Input Terminals (quick-connect spring-clamp terminal) B. Output Terminals (quick-connect spring-clamp terminal) Minus-pole has the same reference as the minus-pole of the input terminals C. Signal Connector (plug connector) • Ready: contact is closed when status indicator shows ready • Buffering: contact is closed during buffering • Inhibit: a voltage applied on this input signal disables buffering (during service) • PC-mode: To activate the PC-mode connect the two pins of the signal connector together (See PC-mode on page 16) D. Status Indicator (green) Figure 2 • Ready: capacitors are fully charged, no failures detected. • Charging: capacitors are being charged • Buffering: capacitors are being discharged Figure 2 - Updating pattern for the green E. Diagnosis status indicator (yellow) Figure 3 status indicator 1 Ready 0 Helps troubleshooting and indicates the following: 1 0 Charging 1 • Current Overload: output voltage below 20V DC due to a too high 0 Buffering output current, ready contact is open • High Temperature: signals capacitor temperature is too high(>65 ºC), charging and buffering is still possible, ready contact is open • Buffer Time Expired: buffering stopped due to discharged capacitors - Inhibit Active: buffering is blocked by the inhibit signal Figure 3 - Updating Pattern for the Yellow F. Warning status indicator (red) Figure 4 Diagnosis Status Indicator: 1 Current • Check Input Voltage: Indicates a too low or too high input voltage. The 0 Overload input voltage must be between 23V DC and 30V DC to turn-on the 1 High Temperature 0 output and to start charging of the capacitors. 1 Buffer time 0 expired • PC-mode activated indicates, that the PC-mode (See PC-mode on 1 Inhibit 0 active page 16) is activated. Figure 4 - Updating pattern for the Red G. Chassis Ground (screw) Warning Status Indicator: 1 Check input Use a M4 ring-type terminal to connect the housing to ground, when