MW ICL-16R Series - User Manual

Installation Manual
 Type：ICL AC inrush current limiter（Series：ICL-16R, ICL-16L ,ICL-28R, ICL-28L）
ICL-16R INPUT: 180-264VAC 50/60Hz AC CURRENT: 16A (Continuous)
ICL-16L INPUT: 180-264VAC 50/60Hz AC CURRENT: 16A (Continuous)
ICL-28R INPUT: 180-264VAC 50/60Hz AC CURRENT: 28A (Continuous)
ICL-28L INPUT: 180-264VAC 50/60Hz AC CURRENT: 28A (Continuous)
 Introduction
The ICL-R/L is an AC inrush current limiter that can be used to reduce the high starting current due to capacitive
load or inductive causing the circuit breaker to be false triggered. Several power supplies can be installed on the
same AC line after the implementation of an ICL-R/L.
 Installation
ICL-R：
（1）Always allow good ventilation clearances, 5mm left and right, 40mm above and 20mm below, around the unit
in use to prevent it from overheating. Also a 10-15 cm clearance must be kept when the adjacent device is a
heat source.
（2）The appropriate mounting orientation for the unit is vertical, the input terminals at the bottom and output on
the top. Mounting orientations other than that, such as upside down, horizontal, or table-top mounting, is not
allowed.
（3）Use copper wire only, and recommended wires are shown as below.
AWG
18
16
14
12
10
Rated Current of Equipment
(Amp)
7
10
15
25
32
Cross-section of Lead(mm
2
)
0.8
1.3
2.1
2.5
4
Note：Current each wire carries should be de-rated to 80% of the current suggested above
when using 4-6 wires connected to the unit.
Make sure that all strands of each stranded wire enter the terminal connection and the screw terminals are
securely fixed to prevent poor contact. If the power supply possesses multi-output terminals, please make
sure each contact is connected to wires to prevent too much current stress on a single contact.
（4）Use wires that can withstand temperatures of at least 80°C, such as UL1007.
（5）Recommended wire strapping length is 6mm (0.236”).
（6）Recommended screwdriver is 3mm, slotted type.
（7）The recommended torque setting for terminals is shown as below.
Model
I/P
O/P
ICL-16R
6.9 kgf‐cm (6 Lb‐in)
6.9 kgf‐cm (6 Lb‐in)
ICL-28R
5.1kgf‐cm (4.43 Lb‐in)
5.1kgf‐cm (4.43 Lb‐in)

Summary

Installation

DIN Rail Mounting Instruction

ICL-L Installation Guidelines

Warning; Caution

General Safety Precautions

Covers risks of electrical shock, burn hazards, fire, and proper handling.

Installation Environment

Install in controlled environments, pollution degree 2, avoid moisture and high temperatures.

Pre-Installation Safety

Disconnect system from supply voltage before installation or maintenance.

Application Diagram

Single Phase Application

Three Phase Application

Application Manual

Capacitive Load Limits

Understanding capacitive load limits for power supplies connected to ICL.

Calculating Connected PSUs

Process for evaluating the quantity of power supplies connectable.

Calculating Connected PSUs (ICL-16 R)

Step 2: PSU Product Spec Review

Step 3: PSU Test Report Review

Summary Calculation

Overview

1. Function Description
2. Important Technical Specifications
3. Key Electrical Specifications (for ICL-16R as an example)
4. Usage Features
5. Installation (ICL-R - Vertical Mounting)
6. Installation (ICL-L - DIN Rail Mounting)
7. Application Diagram
8. Application Manual (Connecting Multiple Power Supplies)
9. Maintenance Features
10. Warning / Caution
11. Conformity Declarations

The MEAN WELL ICL-R/L is an AC inrush current limiter designed to mitigate high starting currents caused by capacitive or inductive loads, preventing false triggering of circuit breakers. This device allows multiple power supplies to be installed on the same AC line after its implementation.

Function Description:

The ICL-R/L series acts as an AC inrush current limiter, reducing the initial surge of current when power supplies or other devices with capacitive or inductive loads are switched on. This is crucial for maintaining system stability and preventing circuit breakers from tripping prematurely. The ICL-R/L is available in two main types: ICL-R (for vertical mounting) and ICL-L (for DIN rail mounting), each with specific installation guidelines.

Important Technical Specifications:

The ICL series includes the following models with their respective specifications:

• ICL-16R / ICL-16L:
  • Input: 180-264VAC, 50/60Hz
  • AC Current: 16A (Continuous)
• ICL-28R / ICL-28L:
  • Input: 180-264VAC, 50/60Hz
  • AC Current: 28A (Continuous)

Key Electrical Specifications (for ICL-16R as an example):

• AC Input Voltage: 180-264VAC
• AC Line Frequency: 47-63Hz
• AC Peak Current: 23A±5%
• AC Continuous Rated Current: 16A continuous
• AC Input Power: 3680W (16A x 230VAC)
• AC Input Consumption: <1W at 264VAC input
• Internal Relay Limiting Time (TON Power On): 300±50ms
• Internal Relay Limiting Cycles: 10 cycles / minute
• Internal Relay Release Time: 500±50ms
• Internal Relay Limiting Interval: >900ms
• Internal Relay Switching Cycles: 100K times max.
• Internal Protection: Thermal fuse protects overload and fire
• Capacitive Load: 2500µF max.

Usage Features:

Installation (ICL-R - Vertical Mounting):

1. Ventilation: Ensure good ventilation clearances: 5mm left and right, 40mm above, and 20mm below the unit. A 10-15 cm clearance is required if an adjacent device is a heat source.
2. Orientation: The unit must be mounted vertically, with input terminals at the bottom and output terminals at the top. Other orientations (upside down, horizontal, table-top) are not permitted.
3. Wiring (Copper Wire Only):
   • Recommended Wire Sizes:
     • AWG 18: 0.8 mm² (Rated Current: 7A)
     • AWG 16: 1.3 mm² (Rated Current: 10A)
     • AWG 14: 2.1 mm² (Rated Current: 15A)
     • AWG 12: 2.5 mm² (Rated Current: 25A)
     • AWG 10: 4 mm² (Rated Current: 32A)
   • Derating: When using 4-6 wires connected to the unit, the current each wire carries should be derated to 80% of the suggested value.
   • Connection Quality: All strands of stranded wire must enter the terminal connection, and screw terminals must be securely fixed to prevent poor contact. For multi-output terminals, ensure each contact is wired to prevent excessive current stress.
4. Wire Temperature Rating: Use wires capable of withstanding at least 80°C (e.g., UL1007).
5. Wire Stripping Length: Recommended length is 6mm (0.236").
6. Screwdriver: Use a 3mm, slotted type screwdriver.
7. Torque Settings:
   • ICL-16R: I/P: 6.9 kgf-cm (6 Lb-in), O/P: 6.9 kgf-cm (6 Lb-in)
   • ICL-28R: I/P: 5.1 kgf-cm (4.43 Lb-in), O/P: 5.1 kgf-cm (4.43 Lb-in)

Installation (ICL-L - DIN Rail Mounting):

1. Safety First: Disconnect the system from the utility before any installation or maintenance work to prevent inadvertent re-connection.
2. Ventilation: Keep ventilation holes free from obstructions. Maintain a 10-15 cm clearance if an adjacent device is a heat source.
3. Torque Settings:
   • ICL-16L: I/P: 5.7 kgf-cm (5 Lb-in), O/P: 5.7 kgf-cm (5 Lb-in)
   • ICL-28L: I/P: 5.7 kgf-cm (5 Lb-in), O/P: 5.7 kgf-cm (5 Lb-in)
4. Wiring (Copper Wire Only): Same as ICL-R.
5. Mounting Instruction (DIN Rail):
   • Mount only as shown in the figure, with input terminals down, to ensure sufficient cooling.
   • Admissible DIN rail types: TS35/7.5 or TS35/15.
   • Rail Fastening Steps:
     • (a) Tilt the unit slightly rearwards.
     • (b) Fit the unit over the top hat rail.
     • (c) Slide it downward until it hits the stop.
     • (d) Press against the bottom for locking.
     • (e) Shake the unit slightly to check the locking action.

Application Diagram:

• Single-phase application: The ICL-R/L is connected between the circuit breaker and the power supply (or multiple power supplies).
• Three-phase application: For three-phase systems, ICL-16 series is generally not suggested. The diagram shows three ICL-BR units (likely ICL-28R/L or similar) connected to each phase (L1, L2, L3) before a TDR-480 (Load).

Application Manual (Connecting Multiple Power Supplies):

The number of power supplies (SMPs) that can be connected behind an ICL unit depends on the ICL's maximum capacitive load and rated current, and the input capacity of the power supplies.

• Step 1 (ICL-16R Example): Check the ICL-16R specifications for "AC continuous rated current" (16A) and "Capacitive load" (2500µF max).
• Step 2 (SDR-120-24 Example): Check the connected PSU's (e.g., SDR-120-24) AC input current (0.7A/230VAC). Calculate the number of units based on the ICL's rated current: 16A / 0.7A ≈ 22.8, so 22 units.
• Step 3 (SDR-120-24 Example): Check the connected PSU's (e.2., SDR-120-24) C5 capacitor value from the test report (100µF). Calculate the number of units based on the ICL's capacitive load: 2500µF / 100µF = 25 units.
• Summary: The recommended number of units is the smaller value of the results from Step 2 and 3, multiplied by a factor of 0.9. For SDR-120-24, this would be 22 * 0.9 = 19.8, so 19 units.

Maintenance Features:

Warning / Caution:

1. Electrical Shock/Energy Hazard: All failures must be examined by a qualified technician. Do not remove the power supply case yourself.
2. Electric Arcs/Shock: Connecting both primary and secondary sides simultaneously is not allowed.
3. Burn Hazard: Do not touch the unit during operation or shortly after disconnection.
4. Fire/Short Circuit Risk: Protect openings from foreign objects or dripping liquids.
5. Environment: Install only in a pollution degree 2 environment (non-conductive pollution that might temporarily become conductive due to occasional condensation, typically dry, well-ventilated locations like control cabinets).
6. Moisture: Do not install in places with high moisture or near water.
7. Temperature: The maximum operating temperature is 70°C for ICL-16R/16L and 60°C for ICL-28R/28L. Do not install in places with high ambient temperature or near fire sources.
8. Disconnect System: Disconnect the system from the supply voltage before any installation, maintenance, or modification work. Ensure inadvertent connection is impossible.

Conformity Declarations:

• China RoHS Conformity: The product complies with China RoHS regulations, restricting hazardous substances. The "Environment Friendly Use Period Label" indicates a 10-year environmentally friendly use period.
  • Hazardous Substances List: Indicates the presence (X) or absence (O) of Lead, Mercury, Cadmium, Hexavalent chromium, Polybrominated biphenyls (PBB), and Polybrominated diphenyl ethers (PBDE) in various components (PCB, metal structure, plastic structure, accessories, cables). "X" indicates the concentration exceeds limits but follows 2011/65/EU standards.
• China VOC Conformity: The product complies with China's VOC standards for industrial protective coatings (GB 30981-2020), adhesives (GB 33372-2020), printing ink (GB 38507-2020), and cleaning agents (GB 38508-2020).
• Five PBT TSCA Conformity: The product series complies with Use and Risk Management for Five PBT Chemicals under TSCA section 6(h), including Decabromodiphenyl ether (DecaBDE), Phenol, isopropylated, phosphate (3:1) (PIP (3:1)), 2,4,6-Tris (tert-butyl) phenol (2,4,6-TTBP), Pentachlorothiophenol (PCTP), and Hexachlorobutadiene (HCBD).

For additional product information, refer to www.meanwell.com.

MW ICL-16R Series Specifications