Allen-Bradley 1606-XLE120E Power Supply – 1606-XLE Series

Allen-Bradley 1606-XLE120E — 120W 24VDC Regulated DIN Rail Power Supply for Industrial Control Systems

The Allen-Bradley 1606-XLE120E is a 120-watt, 24 VDC switch-mode power supply designed for continuous-duty industrial automation service. Manufactured by Rockwell Automation under the 1606-XLE product family, this unit occupies a 55 mm wide DIN rail footprint and delivers a regulated 24 VDC output at up to 5 A continuous current. Its universal AC input stage accepts 85–264 VAC at 47–63 Hz, eliminating the need for input voltage selection switches and enabling direct deployment across North American 120 VAC, European 230 VAC, and Asian 220 VAC grid infrastructures without hardware modification.

Within a control panel, the 1606-XLE120E functions as the primary DC bus source for PLC racks, distributed I/O nodes, field sensors, and 24 VDC actuator circuits. Its DC OK relay contact — a dry-contact output that closes when output voltage is within the ±5% regulation window — provides a hardware-level health signal that can be wired directly into a ControlLogix or CompactLogix digital input card, enabling the PLC program to monitor PSU status without polling or software overhead. This deterministic fault-signaling architecture is a key differentiator from generic switch-mode supplies that rely solely on LED indicators.

The output voltage is field-adjustable from 24 V to 28 V via a front-panel potentiometer, accommodating voltage-drop compensation on long cable runs to remote I/O panels. At 91% typical conversion efficiency, heat dissipation at full 120 W load is approximately 13 W — low enough to permit convection cooling in sealed enclosures rated IP54 or higher without forced-air augmentation, provided ambient temperature remains below +60°C.

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Technical Parameters

Hardware Logical Analysis

The 1606-XLE120E employs an active power factor correction (PFC) front-end stage operating at a switching frequency of approximately 65 kHz. This PFC stage maintains input current waveform in phase with the AC supply voltage, achieving a power factor of ≥ 0.95 at full load — a requirement in facilities subject to IEC 61000-3-2 Class A harmonic current limits. The PFC stage also pre-regulates the internal DC bus to a stable 400 VDC rail, which decouples the downstream LLC resonant converter from input voltage transients up to ±15% of nominal.

The LLC resonant DC-DC stage operates in zero-voltage switching (ZVS) mode across its full load range. ZVS topology eliminates switching losses at turn-on transitions, which is the primary mechanism behind the ≥ 91% efficiency figure. At the secondary side, synchronous rectification replaces conventional Schottky diodes, reducing conduction losses by approximately 40% compared to earlier XLE-generation designs. The combined effect is a thermal dissipation of ≤ 13 W at 120 W output — a figure that permits convection-only cooling in most panel configurations.

EMC performance is addressed at three levels. At the input, a two-stage common-mode and differential-mode filter network attenuates conducted emissions to CISPR 11 Class A limits. The transformer core uses a gapped ferrite structure with interleaved primary-secondary winding geometry to minimize interwinding capacitance, suppressing common-mode noise coupling to the output. The PCB layout routes high-frequency switching nodes away from the DC OK signal conditioning circuit, preventing false relay trips during load transients. The result is a conducted emission profile that passes EN 55011 Class A without external line filters in most panel installations.

The DC OK relay circuit monitors output voltage through a precision voltage divider referenced to an internal 2.5 V bandgap reference. The relay closes when output voltage exceeds 22.5 V (93.75% of nominal) and opens with a 20 ms delay when voltage drops below 21.6 V (90% of nominal). This hysteresis band prevents relay chatter during load step transients. The relay contact rating is 30 VDC / 1 A, suitable for direct wiring to PLC digital input modules without interposing relays.

Parallel current sharing is implemented via a resistive droop method: the output voltage is programmed to droop by approximately 0.5% per ampere of load current. When two units are paralleled, the unit with the higher no-load voltage supplies more current, which increases its droop, until both units reach equilibrium at equal current contributions. This passive sharing mechanism requires no communication bus between units and is inherently fault-tolerant — a failed unit simply drops out of the parallel pair without disrupting the surviving unit.

System Integration Benefits

• Deterministic fault signaling: The DC OK dry-contact relay provides a hardware interrupt path to the PLC digital input, enabling sub-10 ms fault detection latency independent of scan cycle timing.
• Redundancy without additional modules: Native parallel current sharing allows N+1 redundant configurations using two 1606-XLE120E units and a standard diode OR-ing module, reducing BOM complexity versus systems requiring dedicated redundancy controllers.
• Universal input eliminates site-specific SKUs: A single part number covers 100–240 VAC global installations, simplifying spare parts inventory management for multi-site operations.
• Output voltage trim for cable drop compensation: The 24–28 VDC adjustment range allows field engineers to compensate for resistive voltage drop on cable runs up to 30 meters at 5 A without adding intermediate power distribution points.
• ATEX Zone 2 / Class I Div 2 certification: The unit can be installed in control panels located in hazardous areas classified for flammable gas or vapor presence, without requiring an additional purge-and-pressurization system for the PSU itself.
• Wide operating temperature range: The -25°C to +70°C specification covers outdoor enclosures in northern climates without panel heaters, and high-ambient industrial environments such as foundries and glass manufacturing lines.
• Low output ripple for sensor accuracy: The ≤ 150 mVpp output ripple specification ensures that 4–20 mA analog transmitters and precision RTD transmitters powered from the 24 VDC bus do not experience measurement errors attributable to PSU noise.
• High MTBF reduces unplanned downtime: The > 500,000-hour MTBF figure at 25°C full load translates to a predicted failure rate of less than 0.2% per year in a 24/7 production environment, supporting maintenance interval planning aligned with annual scheduled shutdowns.
• Compact 55 mm DIN rail width: The narrow footprint allows higher PSU density in space-constrained panels, freeing rail space for additional I/O terminal blocks or safety relays.
• Peak current capability for inrush-heavy loads: The 6 A / 5-second peak rating accommodates the inrush current of solenoid valves and contactor coils without triggering overload protection during machine startup sequences.

Quality Assurance & Global Logistics

Every Allen-Bradley 1606-XLE120E unit supplied by siemensplc.com is sourced as genuine Rockwell Automation product. Prior to dispatch, each unit undergoes a multi-point inspection protocol: output voltage accuracy is verified at 25%, 50%, and 100% load; DC OK relay operation is confirmed at the 22.5 V threshold; and physical condition — including label integrity, terminal block condition, and DIN rail clip function — is documented. Units that do not pass inspection are quarantined and not shipped.

Our warehouse is located in Xiamen, China, a major international logistics hub served by direct air freight connections to Hong Kong, Singapore, Frankfurt, Los Angeles, and Dubai. Standard export shipments are dispatched via DHL Express, FedEx International Priority, or UPS Worldwide Express, with typical transit times of 3–5 business days to Europe, 4–6 business days to North America, and 2–3 business days to Southeast Asia. For time-critical plant shutdowns, same-day dispatch is available for orders confirmed before 14:00 CST.

All shipments are accompanied by a commercial invoice, packing list, and certificate of origin. For customers requiring import duty optimization, HS code 8504.40 documentation is provided. Export compliance screening is performed on every order in accordance with applicable Chinese export regulations and destination-country import requirements.

A 12-month warranty from the date of shipment covers manufacturing defects and premature failure under normal operating conditions. Warranty claims are processed within 5 business days of receipt of the returned unit. Replacement units are dispatched from Xiamen stock; no advance replacement deposit is required for established accounts.

Contact Information

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