Dual Input Redundancy Module

- 24…56V, 40 A
Catalog Number 1606-XLSRED40HF

Reference Manual Original Instructions

Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

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

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

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

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

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

The following icon may appear in the text of this document.

Identifies information that is useful and can help to make a process easier to do or easier to understand.

2 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021

 Table of Contents

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

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input and Output Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lifetime Expectancy and Mean Time Between Failure . . . . . . . . . . . . . . . 8
Terminals and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Switching Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dielectric Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Approved, Fulfilled, or Tested Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Regulatory Product Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wall/Panel Mount Bracket (Cat. No. 1606-XLC) . . . . . . . . . . . . . . . . . 14
Side Mount Bracket (Cat. No. 1606-XLA-S44) . . . . . . . . . . . . . . . . . . . 14
Recommendations for Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inductive and Capacitive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sidewards Installation Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Example: Redundancy for Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example: 1+1 Redundancy Up To 20 A. . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example: N+1 Redundancy With 120 A . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Table of Contents

Notes:

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 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Terminology and Terms Descriptions

Abbreviations PE The abbreviation for Protective Earth. PE has the same meaning as the symbol.

The symbol for Protective Earth.

Earth, Ground This document uses the term “earth,” which is the same as the U.S. term “ground”.
A value that is displayed with the AC or DC before the value represents a nominal voltage
DC 24V with standard tolerances (usually ±15%) included. For example: DC 12V describes a 12V
battery disregarding whether it is full (13.7V) or flat (10V).
A value with the unit (V DC) at the end is a momentary value without any additional
24V DC tolerances included.
nom Indicates a nominal value.
typ Indicates a typical value.
— (alone in table cell) A dash alone in a table cell indicates that there is no information to be included in that cell.
Use of two identical power supplies in parallel to provide continued operation following
most failures in one power supply. Isolate the two power supply outputs from each other
1+1 Redundancy by using diodes or other switching arrangements. For example, two 10 A power supplies
are needed to achieve a 10 A redundant system.
Use of three or more identical power supplies in parallel, which are allowed to be
connected in parallel for higher output currents, to provide continued operation following
most failures in one power supply. Isolate all power supply outputs from each other by
N+1 Redundancy using diodes or other switching arrangements. For example, to achieve a 40 A redundant
system, five 10 A power supplies are needed in an N+1 redundant system. Confirm that the
power supplies are allowed to be connected in parallel to increase the output power.

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

AC AC AC AC AC AC AC AC
DC DC DC DC DC DC DC DC

IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 IN 1 IN 2

OUT OUT OUT OUT

+ - + -
Load Load

Product Overview The 1606-XLSRED40HF is a redundancy module,

which can be used to build 1+1 and N+1
redundant systems. The module has two input
channels that can connect to power supplies with
up to 20 A output current and one output, and
can carry nominal currents up to 40 A. The
output is equipped with a plug-connector, which
allows for replacement of the power supply or
redundancy module while the system is running
(hot swapping).

The novelty of this redundancy module is that it

uses mosfets instead of diodes to decouple the
two input channels, which help reduce the heat
generation and the voltage drop between input
and output. The redundancy module does not
require an additional auxiliary voltage.
Due to the low-power losses, the unit is slender
and only requires 46 mm (1.81 in.) width on the
DIN rail. Large connection terminals provide a safe and fast installation. The
large international approval package makes this module suitable for nearly
every application.

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Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Product features:
• For 1+1 and N+1 redundant systems
• Dual-input with single output
• Suitable for all 1606 power supplies
• Only 60 mV voltage drop at 20 A output current
• Only 1.8 W loss at 20 A and 5.4 W at 40 A output current
• 160% (65 A) peak load capability
• Reverse input polarity protection
• Full power between -40…+60 °C (-40…+140 °F)
• Width only 46 mm (1.81 in.)
• Rugged metal housing
• Easy wiring; distribution terminal for negative pole included

Specifications
Attributes Values Notes
Input voltage DC 24…56V ±15%
Input voltage range 20.4…64.4V DC —
2 x 0…20 A
Input current Continuous for 5 seconds
2 x 20…32.5 A
0…40 A
Continuous for 5 seconds
Output current 40…65 A
45 A, max In overload(1) or short circuit mode
60 mV typical At 2 x 10 A
Input to output voltage drop 95 mV typical At 1 x 20 A
120 mV typical At 2 x 20 A
220 mW typical At 24V, no load
620 mW typical At 48V, no load
Power losses 1.8 W typical At 48V, 2 x 10 A input
2.3 W typical At 48V, 1 x 20 A input
5.4 W typical At 48V, 2 x 20 A input
Temperature range -40…+70 °C (-40…+158 °F) Operational
Derating 1 A/1 °C (1 A/1.8 °F) output 60…70 °C (140…158 °F)
46 x 124 x 127 mm
Dimensions WxHxD
(1.81 x 4.88 x 5 in.)
Weight 360 g (0.79 lb) —
(1) Currents at voltages below 6V.

Catalog Number
Catalog Number Description
1606-XLSRED40HF Dual redundancy module

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Input and Output

Characteristics Attributes
Number of inputs —
Values
2
Notes
—
Number of outputs — 1 —
The input circuitry must meet the SELV requirements
Input voltage Nom DC 24…56V ±15%
stipulated by IEC/EN/UL 60950-1.
Input voltage range — 20.4…64.4 V DC —
Typ 120 mV At 2 x 20 A; see Figure 3
Voltage drop, input to output Typ 60 mV At 2 x 10 A; see Figure 3
Typ 95 mV At 1 x 20 A; see Figure 3
Nom 2 x 0…20 A Continuous
Input current Nom 2 x 20…32.5 A For 5 seconds
Max 2 x 22.5 A In overload (voltage <6V) or short circuit mode
Peak input current Max 1000 A For maximum 1 ms per input
Nom 40 A Continuous
Output current Nom 40…65 A For 5 seconds
Max 45 A In overload (voltage <6V) or short circuit mode
Reverse current Max 1 mA At 48V per input, -40…+70 °C (-40…+158 °F)
Reverse voltage Max 65V DC Voltage applied to the output, continuously allowed
Output capacitance Typ 310 µF —

Figure 3 - Input to Output Voltage Drop When Both Inputs Draw Current
(Typical 1+1 redundant case when the output voltages of both units are equal)
160
A: 25 °C (77 °F) 1606-XLSRED40HF Output
140 Variable Load,
B: 60 °C (140 °F) Power
Voltage Drop, mV (typ)

120 I1 I OUT 0…40 A

B A Supply + A A
100 48V, Input 1 Output
20 A max V U1 U OUT V
80 -
60
40
Power I2
20 Supply + A
0 48V,
20 A max V U2 Input 2
Output: 0 10 20 30 40 -
Input: 0 2x5 2 x 10 2 x 15 2 x 20
Input/Output Current, A I1 = I2 U1 = U2 Voltage Drop = U1 - UOUT

Figure 4 - Input to Output Voltage Drop When Only One Input Draws Current

120 1606-XLSRED40HF
A: 25 °C (77 °F) Output Variable Load,
105 Power I1 I OUT 0…40 A
B: 60 °C (140 °F) Supply +
Voltage Drop, mV (typ)

90 A A A
B 48V, Input 1 Output
75 20 A max V U1 U OUT V
60
-
45
30
Not used or
15 power supply
with Input 2
0
0 5 10 15 20 low voltage
Output Current, A I1 = I2 U1 = U2 Voltage Drop = U1 - UOUT

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Power Losses
Attribute 24V DC 48V DC Notes
Typ 1.4 W 1.8 W Input: 2 x 10 A
Power losses Typ 5W 5.4 W Input: 2 x 20 A
Typ 2W 2.3 W Input: 1 x 20 A(1)
Typ 0.14 W 0.42 W At no output current(1)
Standby power losses
Typ 0.22 W 0.62 W At no output current(2)
(1) Only one input is connected to input voltage.
(2) Both inputs are connected to input voltage.

Figure 5 - Power Losses When Both Inputs Draw Equal Current

D
6 B 1606-XLSRED40HF
A: 24V, 25 °C (77 °F) C Output Variable Load,
5 B: 24V, 60 °C (140 °F) A Power I1 I OUT 0…40 A
C: 48V, 25 °C (77 °F) Supply +
Power Losses, W (typ)

A A
4 D: 48V, 60 °C (140 °F) 48V, Input 1 Output
20 A max V U1 U OUT V
3 -
2
Power I2
1 Supply + A
48V,
0 20 A max V U 2 Input 2
0 5 10 15 20 25 30 35 40 -
Output Current, A I1 = I2 U1 = U2 Losses = (U1 x I1 + U2 x I2) - UOUT x IOUT

Figure 6 - Power Losses When Only One Input Is Used

3 1606-XLSRED40HF Output
A: 24V, 25 °C (77 °F) Variable Load,
Power I1 I OUT 0…40 A
2.5 B: 24V, 60 °C (140 °F) B Supply +
Power Losses, W (typ)

C: 48V, 25 °C (77 °F) D C A A

48V, Input 1 Output
2.0 D: 48V, 60 °C (140 °F) 20 A max V U1 U OUT V
A -
1.5
1.0
0.5
Input 2
0
0 2.5 5 7.5 10 12.5 15 17.5 20
Output Current, A Losses = U1 x I1 - UOUT x IOUT

Lifetime Expectancy and The redundancy module has two input channels that are completely
Mean Time Between Failure independent from each other. Each control circuit, auxiliary voltage source, or
other circuitry in the module are designed separately for each input. 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) figures in the following table are for
the entire dual-input module. If the MTBF number of only one path is needed,
simply double the value from the table.
Input/output Input: 2 x 10 A Input: 2 x 20 A Notes
Current Conditions Output: 20 A Output: 40 A
448,000 h 222,000 h At 48V and 40 °C (104 °F)
Lifetime expectancy(1)
1,267,000 h 629,000 h At 48V and 25 °C (77 °F)
MTBF(2) SN 29500, 6,656,000 h 4,098,000 h At 48V and 40 °C (104 °F)
IEC 61709 11,990,000 h 7,808,000 h At 48V and 25 °C (77 °F)
211,000 h 178,000 h At 48V and 40 °C (104 °F) (Ground Fixed GF40)
288,000 h 238,000 h At 48V and 25 °C (77 °F) (Ground Fixed GF25)
MTBF (2) MIL HDBK 217F
959,000 h 839,000 h At 48V and 40 °C (104 °F) (Ground Benign GB40)
1,332,000 h 1,144,000 h At 48V and 25 °C (77 °F) (Ground Benign GB25)

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(1) The Lifetime expectancy values that are shown in the table indicate the minimum operating hours (service life) and are
determined by the lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours
and is calculated according to the manufacturer specification of the capacitor. The manufacturer of the electrolytic capacitors
only states a maximum life of up to 15 years (131,400 h). Any number that exceeds this value is a calculated theoretical lifetime,
which can be used to compare devices.
(2) Mean time between failure (MTBF) is calculated according to statistical device failures, and indicates reliability of a device. It is the
statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product. The MTBF value
is a statistical representation of the likelihood of a device to fail. An MTBF value of, for example, 1,000,000 h means that
statistically one unit fails every 100 hours if 10,000 units are installed in the field. However, it cannot be determined if the failed
unit has been running for 50,000 h or only for 100 h.

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

To connect the chassis to the ground, use a ring-type terminal (ring cable lug)
that is suitable for an M4 screw. Connect this terminal to the chassis ground
terminal on top of the unit.
Attributes Input
• Screw terminals
Type • IP20 fingersafe construction
• Suitable for field installation
Solid wire 0.5…16 mm2
Stranded wire 0.5…10 mm2
American Wire Gauge 22…8 AWG
Wire diameter max 5.2 mm (0.2 in.) (including ferrules)
Wire stripping length 12 mm (0.5 in.)
Screwdriver 3.5 mm (0.138 in.) slotted or Pozidrive No 2
Recommended tightening torque 1.2 N•m (10.6 lb•in)

Wiring rules:
• The external circuitry of all terminals must meet the safety requirements
stipulated by IEC/EN/UL 60950-1: SELV.
• Use appropriate copper cables that are designed for minimum operating
temperatures of:
- 60 °C (140 °F) for ambient up to 45 °C (113 °F)
- 75 °C (167 °F) for ambient up to 60 °C (140 °F)
- 90 °C (194 °F) for ambient up to 70 °C (167 °F) minimum
• Follow national installation codes and installation regulations.
• Verify that all strands of a stranded wire enter the terminal connection.
• Verify that unused terminal compartments are securely tightened.
• Ferrules are allowed.
• Do not connect or disconnect the wires from the terminals below
-25 °C (-13 °F).

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Functional Diagram Figure 7 - Functional Diagram

Control

+ +
Input 1 Output
- -

+ Chassis
Ground
Input 2
- Control

Front Side and User

Figure 8 - Front Side
Elements Output terminals
User Elements

A Screw terminals
B Chassis ground terminal
To be connected on the top side of the housing with a ring-type terminal (ring
cable lug) that is suitable for a M4 screw. Chassis connection is optional and not
required since the unit fulfills the requirements according to protection class III.
C Input terminals for input 1
Screw terminals
D Input terminals for input 2
Screw terminals

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

Compatibility commercial, and light industrial environments without any restrictions.

The following table shows electromagnetic compatibility (EMC) immunity

according to generic standards EN 61000-6-1 and EN 61000-6-2.
Attributes Standards Values Criteria(1)
Contact discharge 8 kV Criterion A
Electrostatic discharge EN 61000-4-2
Air discharge 15 kV Criterion A
Electromagnetic RF field EN 61000-4-3 80 MHz…2.7 GHz 20V/m Criterion A
Input lines 2 kV Criterion A
Fast transients (Burst) EN 61000-4-4
Output lines 2 kV Criterion A
+ - 500V Criterion A
Surge voltage on input lines EN 61000-4-5
+/-  chassis ground 1 kV Criterion A
+ - 500V Criterion A
Surge voltage on output lines EN 61000-4-5
+/-  chassis ground 1 kV Criterion A
Conducted disturbance EN 61000-4-6 0.15…80 MHz 20V Criterion A
(2) EN 61000-4-8 50 Hz 30 A/m Criterion A
Power-frequency magnetic field
(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.

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The following table shows EMC emission according to generic standards

EN 61000-6-3 and EN 61000-6-4.
Attributes Standards Notes
Limits for DC power ports according to
Conducted emission input lines IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
EN 61000-6-3 fulfilled(1)
Radiated emission EN 55011, EN 55022 Class B
This device complies with FCC Part 15 rules.
Operation is subjected to the following two conditions: 1) This device must not cause harmful interference. 2) This device
must accept any interference received, including interference that can cause undesired operation.

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

Switching Frequency
The internal auxiliary supply is generated with a boost converter. Depending
on the input voltage, the switching frequency varies from 55… 180 kHz.

Environment
Attributes Values Notes
(1) -40…+70 °C (-40…+158 °F) —
Operational temperature
Storage temperature -40…+85 °C (-40…+185 °F) For storage and transportation
Output derating 1 A/1 °C (1 A/1.8 °F) 60…70 °C (140…158 °F)
Humidity(2) 5…95% r.H. IEC 60068-2-30
2…17.8 Hz: ±1.6 mm (0.063 in.)
Vibration sinusoidal(3) 17.8…500 Hz: 2 g IEC 60068-2-6
2 hours / axis
30 g 6 ms, 20 g 11 ms,
Shock(3) 3 bumps/direction, 18 bumps in total IEC 60068-2-27
0…2000 m (0…6560 ft) Without any restrictions
Altitude
2000…6000 m (6560…20,000 ft) Reduce output power or ambient temperature; see Figure 10
2.5 A/1000 m (2.5 A/3281 ft), or
Altitude derating >2000 m (6500 ft); see Figure 10
5 °C/1000 m (41 °F/3281 ft)
The concept of the overvoltage category is used for
Overvoltage category Not applicable equipment that is energized directly from the low voltage
mains (IEC 60664-1 §4.3.3.2.1).
Degree of pollution 2 IEC 62103, EN 50178, not conductive
(1) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2 cm (0.79 in.) below the
unit.
(2) Do not energize while condensation is present.
(3) Tested in combination with DIN rails according to EN 60715 with a height of 15 mm (0.59 in.) and a thickness of 1.3 mm (0.051 in.)
and standard mounting orientation.

Figure 9 - Output Current Versus Ambient Temperature Figure 10 - Output Current Versus Altitude
65 65
Short Term (< 5s) Short Term (<5 s)
Allowed Output Current, A
Allowed Output Current, A

50 50
Normal Mode Normal Mode
40 40 C
B
A
30 30
20 20
A: Tamb <70 °C (<158 °F)
10 10 B: Tamb <60 °C (<140 °F)
C: Tamb <50 °C (<122 °F)
0 0
-40 -25 0 20 40 60 70 0 2000 4000 6000
(-40) (-13) (68) (104) (140) (158) (6562) (13,123) (19,685)
Ambient Temperature, °C (°F) Altitude, m (ft)

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Protection Features
Attributes Descriptions Notes
Output overcurrent protection Not included —
Reverse input polarity protection Included Unit does not start when input voltage is reversed
Degree of protection IP 20 EN/IEC 60529
Penetration protection >3.6 mm (0.14 in.) For screws and small parts
Over-temperature protection Not included —
Input transient protection Not included —

Output transient protection Included See Electromagnetic Compatibility on page 10 for

details and values.
Internal input fuse Not included —

Safety Features
Attributes Descriptions Notes
Input/output separation No galvanic separation Mosfet between input and output
Class of protection III PE (Protective Earth) or chassis connection not required
PE resistance <0.1 Ω Between housing and chassis ground terminal

Dielectric Strength The input and output voltages have the same reference, are floating, and have
no ohmic connection to ground. The manufacturer conducts type and factory
tests. Field tests can be conducted in the field using the appropriate test
equipment that applies the voltage with a slow ramp (2 s up and 2 s down).
Connect input/output terminals together before conducting the test. When
testing, set the cutoff current settings to the value in Figure 11.

Figure 11 - Dielectric Strength

In- / Output Chassis Attributes Time (seconds) A in Figure 11

+ A Type test 60
- Factory test 5 500V AC
Field test 5
Cut-off current setting >2 mA

Approved, Fulfilled, or For the most current information, visit rok.auto/literature.

Tested Standards Use 1606-XLSRED40HF as your search criterion; 1606-CT identifies the
certifications in your search results.
Approval Names Approval Symbols Notes
UL certificate
UL 508 Applicable for US and Canada
See 1606-CT039 at rok.auto/literature
UL certificate
UL 60950-1 Applicable for US and Canada
See 1606-CT034 at rok.auto/literature

Agency Certificate (Bureau Veritas)

ATEX See 1606-CT012 at rok.auto/literature

IECEx Certificate
IECEx See 1606-CT031 at rok.auto/literature
CSA Certificate
Class I Div 2 Power Supplies for Hazardous Location
See 1606-CT046 at rok.auto/literature

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Approval Names Approval Symbols Notes

DNV Certificate
Marine (DNV) DNV Type approved product

ABS Design Assessment Certificate

Marine (ABS) ABS (American Bureau of Shipment) assessed product

Australian Declaration of Conformity

RCM See 1606-CT024 at rok.auto/literature

Regulatory Product Compliance

Standard Names Standard Symbols Notes
The CE marking indicates conformance with the following:
• EMC Directive
EU Declaration of
Conformity • ATEX directive
• RoHS directive
See 1606-CT017 at rok.auto/literature
Manufacturer’s Statement EU-Directive regarding the Registration,
REACH Directive Evaluation, Authorization, and Restriction of Chemicals (REACH)

Manufacturer’s Statement
EU-Regulation on Waste Electrical and Electronic Equipment
WEEE Directive (WEEE)
Registered in Germany as business to business (B2B) products
EAC Certificate
EAC Eurasian Conformity-Registration Russia, Kazakhstan, and
EAC Registration Belarus
8504408200, 8504409000

Physical Dimensions and

Attributes Values and Descriptions
Weight Width 46 mm (1.81 in.)
Height 124 mm (4.88 in.)
127 mm (5 in.)
Depth
The DIN rail height must be added to the unit depth to calculate the total required installation depth.
Weight 360 g (0.79 lb)
Use 35 mm (1.38 in.) DIN rails according to EN 60715 or EN 50022 with a height of 7.5 mm (0.295 in.) or 15 mm
DIN rail (0.59 in.).
Keep the following installation clearances:
• 40 mm (1.57 in.) on the top
Installation Clearances • 20 mm (0.79 in.) on the bottom
• 5 mm (0.20 in.) on the left and right sides are recommended when the device is loaded permanently with
more than 50% of the rated output current. Increase the side clearances to 15 mm (0.59 in.) if the
adjacent device is a heat source, such as a power supply.

Figure 12 - Dimensions, Front and Side Views

12.7 (0.5) 20.4 (0.8) Dimensions are in mm (in.)

+ -
VOUT

124
(4.88)

VIN1 VIN2

+ -
40.6 (1.6) DIN Rail
46 (1.81) Depth 127 (5)

Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 13

Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Accessories The following accessories are available for the 1606-XLSRED40HF redundancy
module.

Wall/Panel Mount Bracket (Cat. No. 1606-XLC)

This bracket mounts the device on a flat surface or panel without using a
DIN rail. The bracket can be mounted without detaching DIN rail brackets.

This bracket kit contains the two brackets that are needed for one device.
Figure 13 - Cat. No. 1606-XLC Wall/Panel Mount Bracket

Side Mount Bracket (Cat. No. 1606-XLA-S44)

This bracket mounts the device sideways with or without using a DIN rail to
save installation depth.

The two aluminum brackets and the black plastic slider of the device must be
detached so that the steel bracket can be mounted.

For sideway DIN rail mounting, mount the removed aluminum brackets and
the black plastic slider on the side mount bracket.
Figure 14 - Cat. No. 1606-XLA-S44 Side Mount Bracket

Side Mounting Side Mounting

Without DIN rail Brackets With DIN rail Brackets

Recommendations for Recommendations for the configuration of redundant power systems:

Redundancy • Use three-phase power supplies to gain functional safety if one phase
fails.
• When single-phase power supplies are used, connect them to different
phases or mains circuits if possible.
• Use separate input fuses for each power supply.
• Set the power supply in “Parallel-Use” mode if this feature is available.
• It is desirable to set the output voltages of all power supplies to the same
value.
14 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021
 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Inductive and Capacitive The unit is designed to supply any kind of loads, including unlimited
Loads capacitive and inductive loads.

Sidewards Installation Normally, the following installation clearances are recommended:

Clearance • 40 mm on top
• 20 mm on the bottom
• 5 mm on the left and right sides when the device is loaded permanently
with more than 50% of the rated power.
Increase this clearance to 15 mm in case the adjacent device is a heat
source (for example, another power supply).

The clearance between the power supplies and the redundancy module can be
reduced to zero under the following conditions:
• 1+1 redundancy application with a maximum 20 A output current.
• The power supplies are from the 1606-XLS or 1606-XLE family series.
• The redundancy module is placed between the two power supplies.
• The output voltage is set to the same level on both power supplies.
Figure 15 - Sidewards Installation Clearance Example
20 A
Load

Power Supply Power Supply

+Output-
Parallel Use
1606-XLSRED40HF
Redundancy Module Single Use

AC Input 48V, 20A Input 1 Input 2 AC Input 48V, 20A

L N PE + + - - + - + - L N PE + + - -

0 mm 0 mm

Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 15

Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Example: Redundancy for In many cases, two power supplies are used, one for the demanding loads and
Controls another for the controls and sensitive loads. With the 1606-XLSRED40HF
redundancy module, the power supply for the demanding loads can be used as
a redundant source to supply the controls. This provides a cost-effective
solution to get redundant power for a PLC or controller system.

Example: 1+1 Redundancy Up To 20 A

1+1 Redundancy up to 20 A requires two 48V, 20 A power supplies and one
1606-XLSRED40HF redundancy module. Use separate mains systems for each
power supply whenever it is possible.
Figure 16 - Wiring Diagram, 1+1 Redundancy, Up to 40 A Output Current
Failure
20 A Monitor
Load

Power Supply Power Supply

+Output-
Parallel Use DC - OK Parallel Use DC - OK
1606-XLSRED40HF
Single Use Redundancy Module Single Use

AC Input 24V, 40A Input 1 Input 2 AC Input 24V, 40A

L N PE + + - - + - + - L N PE + + - -

I I
L
N
PE

Example: N+1 Redundancy With 120 A

N+1 Redundancy up to 60 A requires four 44V, 20 A power supplies and two
1606-XLSRED40HF redundancy modules. Use separate mains systems for
each power supply whenever it is possible.
Figure 17 - Wiring Diagram, N+1 Redundancy With 60 A Output Current
60 A Failure
Load Monitor

Power Supply Power Supply Power Supply Power Suppl

+Output- +Output-
Parallel Use DC- 1606-XLSRED40HF Parallel Use DC- Parallel Use DC- 1606-XLSRED40HF Parallel Use DC-
OK Redundancy OK OK OK
Single Use Single Use Single Use Redundancy Single Use
Module Module
48V, 20 A 48V, 20 A 48V, 20 A 48V, 20 A
+ + - - + + - - + + - - + + - -
Input 1 Input 2 Input 1 Input 2
L N PE +- +- L N PE L N PE +- +- L N PE

I I I I
L
N
PE

16 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021

 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Mounting Orientations Mounting orientations other than input terminals on the bottom and output
on the top require a reduction in continuous output power or a limitation in
the maximum allowed ambient temperature.

The amount of reduction influences the lifetime expectancy of the power

supply. Therefore, there are two different derating curves for continuous
operation:
• Curve A1: Recommended output current
• Curve A2: Maximum allowed output current (results in approximately
half the lifetime expectancy of A1)

The following curves indicate the allowed output currents for altitudes up to
2000 m (6562 ft).
Figure 18 - Mounting Orientation A (upright; standard)
40 A1
Output

Output Current, A
30
1606-XLSRED40HF 20
Redundancy
Module 10
0
Inputs 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140)
Ambient Temperature, °C (°F)

Figure 19 - Mounting Orientation B (upside down)

40 A1
Output Current, A

Inputs
30
Module 20
Redundancy
1606-XLSRED40HF 10
0
Output 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140)
Ambient Temperature, °C (°F)

Figure 20 - Mounting Orientation C (table-top)

40
Output Current, A

30 A2
20 A1
10
0
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140)
Ambient Temperature, °C (°F)

Figure 21 - Mounting Orientation D (horizontal with input on the left)

40 A2
Output Current, A

30
1606-XLSRED40HF

20 A1
Redundancy

Output
Inputs

Module

10
0
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140)
Ambient Temperature, °C (°F)

Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 17

Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Figure 22 - Mounting Orientation E (horizontal with input on the right)

40 A2

Output Current, A
30

1606-XLSRED40HF
20 A1

Redundancy
Output

sInput
Module
10
0
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140)
Ambient Temperature, °C (°F)

18 Rockwell Automation Publication 1606-RM042A-EN-P - September 2021

 Dual Input Redundancy Module - 24…56V, 40 A Reference Manual

Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.

Resource
Switched Mode Power Supply Specifications Technical Data, publication
1606-TD002
Designing More Reliable 24V DC Systems Application Techniques, publication
1606-AT003
Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings
Specifications, publication IC-TD002
Safety Guidelines for the Application, Installation, and Maintenance of Solid-
State Control, publication SGI-1.1
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Product Certifications website, rok.auto/certifications.
Description
Provides specifications for Bulletin 1606-XL, -XLE, -XLP, and -XLS products and applications.
Provides information on properly configured redundancy modules, buffer modules, DC-UPS, and
DC/DC converters.
Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.
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 the form of
individual devices or packaged assemblies incorporating solid-state components.
Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at rok.auto/literature.

Rockwell Automation Publication 1606-RM042A-EN-P - September 2021 19

Rockwell Automation Support
Use these resources to access support information.
Technical Support Center Find help with how-to videos, FAQs, chat, user forums, and product notification updates. rok.auto/support
Knowledgebase 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 Download firmware, associated files (such as AOP, EDS, and DTM), and access product rok.auto/pcdc
(PCDC) release notes.

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content, complete the form at rok.auto/docfeedback.

Waste Electrical and Electronic Equipment (WEEE)

At the end of life, this equipment should be collected separately from any unsorted municipal waste.

Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.

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Publication 1606-RM042A-EN-P - September 2021

Supersedes Publication XXXX-X.X.X - Month Year Copyright © 2021 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.