Allen-Bradley 1606-XLE240E Power Supply Module – 1606-XLE Series

Allen-Bradley 1606-XLE240E: 240W Switched-Mode Power Supply for Industrial Control Architectures

The Allen-Bradley 1606-XLE240E is a 240W, 24 VDC switched-mode power supply (SMPS) engineered by Rockwell Automation for deployment in high-demand industrial control panels, machine automation enclosures, and process control infrastructure. Within a control loop, this module occupies the foundational power-conditioning layer — converting wide-range AC mains (85–264 VAC) into a regulated, low-ripple 24 VDC bus that feeds PLCs, distributed I/O racks, field sensors, solenoid valves, and HMI terminals simultaneously. Its role is not passive; the 1606-XLE240E actively maintains bus stability under transient load events, inrush conditions, and mains fluctuations that would otherwise propagate faults upstream into the controller logic.

The module’s 10 A continuous output rating, combined with a 150% peak-current boost capability sustained for up to 4 seconds, allows it to absorb motor-start inrush and capacitive load surges without triggering overcurrent shutdown — a characteristic that directly reduces nuisance tripping in mixed-load panels. Parallel operation support enables N+1 redundancy configurations using the companion 1606-XLSRED redundancy module, making the 1606-XLE240E a viable backbone for SIL-rated and high-availability control architectures.

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Technical Parameters

Hardware Logical Analysis

The 1606-XLE240E is built on an active power factor correction (PFC) front-end topology, which maintains a power factor of > 0.95 across the full input range. This is not merely a regulatory compliance measure — it reduces reactive current draw on the facility’s distribution network, lowering I²R losses in cable runs and minimising voltage sag at the panel’s incoming terminals during load steps. The PFC stage also extends the hold-up capacitor’s effective energy reservoir, contributing to the ≥ 20 ms hold-up time that bridges mains interruptions without triggering a controller restart.

The DC-DC conversion stage employs a phase-shifted full-bridge (PSFB) resonant topology operating at a fixed switching frequency above 100 kHz. This architecture achieves zero-voltage switching (ZVS) on the primary-side MOSFETs, eliminating switching losses that would otherwise manifest as heat and conducted EMI. The result is a measured output ripple below 50 mVpp — a figure that matters when powering 24 VDC analog input modules where supply noise directly floors the signal-to-noise ratio of 4–20 mA or 0–10 V field signals.

EMC performance is addressed at three levels: a multi-stage LC input filter suppresses conducted emissions to CISPR 11 Class B limits; the transformer’s Faraday shield interrupts capacitive coupling between primary and secondary windings; and the PCB layout enforces strict separation between high-dV/dt switching nodes and the output sense lines. The unit meets EN 61000-4-5 surge immunity at 2 kV (line-to-earth) and 1 kV (line-to-line), which covers the transient environment of most industrial distribution panels without requiring external surge protection devices on the AC input.

The overvoltage protection (OVP) circuit uses a latching SCR crowbar referenced to a precision voltage reference, not a simple comparator threshold. This means OVP activation is deterministic and does not exhibit the threshold drift over temperature that characterises simpler designs. Once triggered, the latch-off state requires a deliberate power cycle, preventing automatic restart into a faulted load — a behaviour that aligns with IEC 60204-1 requirements for controlled shutdown in machine safety contexts.

System Integration Benefits

• Deterministic bus voltage under transient loads: The closed-loop regulation bandwidth (> 1 kHz) ensures output voltage recovers to within ±1% of setpoint within 1 ms of a 50% load step, preventing brown-out resets in ControlLogix or CompactLogix CPUs sharing the same 24 VDC rail.
• N+1 redundancy without external OR-ing diodes: Parallel operation with the 1606-XLSRED module uses active current sharing, eliminating the forward-voltage drop and thermal asymmetry introduced by passive diode OR-ing circuits.
• DC-OK contact for PLC diagnostic integration: The volt-free relay output can be wired directly to a digital input on a 1756 or 1769 I/O module, enabling the PLC program to log power supply status, generate alarms, and initiate controlled shutdowns without operator intervention.
• Wide input range eliminates site-specific variants: A single part number covers 100–240 VAC and 100–300 VDC inputs, reducing BOM complexity for global machine builders and eliminating the risk of incorrect voltage-selector switch settings.
• Adjustable output voltage for cable-drop compensation: The ±15% output trim range allows the installer to compensate for voltage drop across long 24 VDC distribution runs, ensuring field devices at the end of a 50 m cable receive the minimum 21.6 VDC required by IEC 61131-2.
• 150% peak current for mixed inductive loads: Solenoid valves, relay coils, and small DC motors present inrush currents 3–10× their steady-state draw. The 4-second boost window accommodates simultaneous energisation of multiple inductive loads during machine startup sequences without requiring an oversized supply.
• Compact 55 mm width preserves panel real estate: At 55 mm wide on TH35 DIN rail, the 1606-XLE240E occupies less horizontal space than competing 240W units in the 70–80 mm class, directly reducing enclosure width requirements in space-constrained machine designs.
• ATEX Zone 2 certification for hazardous-area panels: The II 3G rating permits installation in Zone 2 classified areas (gas groups IIA, IIB, IIC) without requiring an additional purged or pressurised enclosure, reducing installation cost in petrochemical and pharmaceutical applications.
• Low output impedance across frequency: The output impedance remains below 50 mΩ up to 10 kHz, ensuring that high-frequency load transients from switching field devices do not couple noise onto the 24 VDC bus and into adjacent analog measurement circuits.
• Thermal derating curve supports 70 °C ambient: Linear derating from 60 °C to 70 °C (to 50% load) allows the unit to operate in sealed enclosures with limited forced-air cooling, a common constraint in outdoor or wash-down rated panels.

Quality Assurance & Global Logistics

Every 1606-XLE240E unit dispatched from our Xiamen, China facility is a genuine Allen-Bradley / Rockwell Automation product. Units are procured through documented supply channels and subjected to incoming inspection that includes label authentication against OEM reference markings, date-code verification, and a functional power-on test under resistive load. A 12-month warranty from dispatch date covers defects in materials and workmanship under normal operating conditions.

Logistics from Xiamen are handled via DHL Express, FedEx International Priority, and UPS Worldwide Express, with typical transit times of 3–5 business days to North America and Europe, and 2–4 business days to Southeast Asia. Export documentation — commercial invoice, packing list, and HS code 8504.40 classification — is prepared for every shipment to facilitate customs clearance. For project orders requiring consolidated freight or air-cargo palletisation, dedicated logistics coordination is available on request. In-stock orders are typically dispatched within 1–2 business days of payment confirmation.

Contact Information

Email: [email protected]
WhatsApp: +86 18359268345
Web: siemensplc.com
Location: Xiamen, China
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