1606-XLS960E Allen-Bradley Switched-Mode Power Supply 40A

1606-XLS960E Allen-Bradley 24V DC Industrial Power Supply

The Allen-Bradley 1606-XLS960E is a high-performance switched-mode power supply from the Bulletin 1606-XL series. It converts single-phase AC input power into a regulated 24 V DC output for industrial control panels, automation equipment, and distributed control loads.

With a rated output of 960 W at 24 V DC and a nominal output current of 40 A, this DIN rail-mounted supply is suited to control systems that require substantial DC power from a compact panel-mounted unit. Its output voltage can be adjusted from 24 to 28 V DC, allowing engineers to account for application-specific voltage requirements within the manufacturer's limits.

The unit also features a DC OK relay contact for status monitoring and a stated 50% power reserve capability. Before applying this reserve in a load design, verify its operating conditions, duration, and permitted output limits in the applicable technical manual.

Power Architecture at a Glance

Power stage	Specification	Engineering purpose
AC input	100–240 V AC, single phase	Connects the supply to a compatible industrial AC source.
Conversion stage	Switched-mode power supply	Converts incoming AC power into regulated DC power.
DC output	24 V nominal, adjustable from 24–28 V DC	Supplies compatible control devices and DC loads.
Rated output	960 W, 40 A nominal	Supports higher-current 24 V DC distribution within the specified operating limits.
Status monitoring	DC OK relay contact	Provides a status signal that can be incorporated into a compatible monitoring circuit.
Panel installation	DIN rail mounting, screw terminals	Supports installation in industrial electrical enclosures.

Electrical Specifications

Parameter	Value
Manufacturer	Allen-Bradley
Product series	Bulletin 1606-XL
Catalog number	1606-XLS960E
Product type	Switched-mode power supply
Input phase	Single phase
Input voltage	100–240 V AC
Nominal output voltage	24 V DC
Output adjustment range	24–28 V DC
Nominal output current	40 A
Output current range	40–34.3 A, as supplied in the product data; confirm the applicable voltage and derating conditions in the technical manual.
Rated output power	960 W
Typical efficiency	94.6%
Typical power losses	54.8 W
Maximum ripple and noise	100 mV peak-to-peak
Typical power factor	0.99
Power reserve feature	50% reserve, subject to manufacturer-defined conditions
DC OK monitoring	Relay contact
Communication interface	None specified
Communication protocols	None

Load Planning: What 24 V DC at 40 A Means

At its nominal output rating, the 1606-XLS960E provides up to 960 W of DC power. Engineers should calculate the combined load of connected devices rather than selecting a supply based only on the number of components in the panel.

• Steady-state load: Add the rated current of PLCs, remote I/O, sensors, relays, communication equipment, and other connected 24 V DC devices.
• Startup demand: Account for inrush current from capacitive loads, electronic devices, and equipment that starts simultaneously.
• Voltage adjustment: Use the 24–28 V adjustment range only where connected devices permit the selected voltage. A higher setting does not automatically increase the supply's rated power.
• Power reserve: Do not treat the stated 50% reserve as a continuous 50% increase in rated output. Check the manufacturer's conditions and time limits before including it in calculations.
• Ambient derating: Apply the specified thermal derating when designing for elevated enclosure temperatures.

Example: A control cabinet with a combined steady-state load of 28 A at 24 V DC draws approximately 672 W. This is below the nominal 960 W rating, but final sizing must also account for startup demand, load transients, ambient temperature, and the supply's documented operating limits.

Thermal Performance and Installation Envelope

Parameter	Specification	Design consideration
Operating temperature	−25°C to +70°C	Confirm the permitted output load at the actual ambient temperature.
Thermal derating	24 W/°C from +60°C to +70°C	Apply the manufacturer's derating curve when operating above +60°C.
Storage temperature	−40°C to +85°C, non-operating	Use the stated range for storage planning, not energized operation.
Protection rating	IP20	Install inside a suitable enclosure that protects against environmental exposure and accidental contact.
Relative humidity	No percentage value supplied	Consult the applicable technical documentation for humidity and condensation limits.
Mounting	DIN rail	Follow the manufacturer's orientation, spacing, ventilation, and mounting instructions.

The listed thermal derating is particularly important in densely packed control cabinets. At higher ambient temperatures, do not assume the full 960 W output remains available. Use the product-specific derating curve and maintain the required airflow and clearance around the power supply.

Mechanical Details and Panel Integration

Item	Specification
Dimensions (H × W × D)	124 × 125 × 127 mm
Weight	1.90 kg
Mounting method	DIN rail
Electrical connections	Screw terminals
Status connection	DC OK relay contact
Communication ports	None
Printed circuit board or enclosure protection details	Refer to the exact product documentation for additional construction details.

Allow sufficient cabinet space for wiring, ventilation, and maintenance access. Verify terminal conductor sizes, tightening torque, protective earthing arrangements, and required clearances using the applicable installation manual before energizing the equipment.

Control Cabinet Applications

The 1606-XLS960E is a power conversion component rather than a PLC, network interface, or standalone controller. Its role is to provide the DC supply required by compatible automation hardware.

• PLC and remote I/O cabinets: Supply compatible 24 V DC controllers, I/O modules, and field interface equipment within the calculated load budget.
• Industrial Ethernet infrastructure: Power compatible network switches and communication devices that require 24 V DC.
• Machine automation: Provide DC power for sensors, relays, interface modules, and other control-panel components.
• Process control systems: Support suitable auxiliary DC loads in industrial process and instrumentation cabinets.
• Control system upgrades: Replace an existing supply when the required output rating, input conditions, mounting arrangement, and protection requirements match.
• Centralized DC distribution: Supply a properly designed distribution system with branch protection selected for each downstream circuit.

For safety-related or high-availability systems, evaluate power-supply redundancy, branch protection, load segregation, and failure behavior at the system level. Do not assume that a single 1606-XLS960E automatically provides redundant power or uninterrupted operation.

Commissioning and Fault-Finding Guide

Symptom	Potential cause	Engineering checks
No DC output	Missing AC input, incorrect wiring, protection activation, or equipment fault	Verify the AC source, input connections, protective devices, and manufacturer-defined status indications.
DC voltage is below the expected value	Excessive load, wiring voltage drop, loose terminals, or thermal derating	Measure voltage at the supply and the load under operating conditions. Inspect connections after isolating power safely.
Output voltage falls during startup	Load inrush or simultaneous startup demand exceeds the available transient capability	Review startup current, stagger equipment startup if appropriate, and verify the permitted boost or reserve behavior in the manual.
DC OK signal indicates an abnormal condition	Output status outside the relay's defined operating criteria, wiring error, or monitoring-circuit issue	Check the relay contact wiring and compare the measured DC output with the manufacturer's DC OK definition.
Supply becomes unusually hot	High cabinet temperature, restricted airflow, excessive load, or incorrect installation clearance	Measure ambient temperature, review load current, and verify mounting orientation and ventilation requirements.
PLC or field devices reset intermittently	DC voltage dips, poor terminal connections, transient loads, or insufficient power capacity	Record voltage during the event, inspect connection integrity, and compare total and transient load demand against the supply specifications.

Diagnostic note: The supplied specifications identify a DC OK relay contact but no built-in communication interface. System diagnostics should therefore use the relay status, electrical measurements, PLC event records, and appropriate test equipment. Do not expect Ethernet diagnostics, protocol status data, or remote parameter access from this power supply itself.

Global PLC Spare HUB's Insight

When specifying a 24 V DC power supply for an automation cabinet, the nominal current rating is only one part of the design. Experienced engineers also review load inrush, cable voltage drop, branch protection, cabinet temperature, and the impact of a supply failure on the controlled process.

The 1606-XLS960E's 960 W rating and stated 50% power reserve make it important to distinguish continuous capacity from temporary overload capability. Treat the reserve feature as a documented operating function, not as a blanket increase in the continuous output rating. Confirm the permissible duration, thermal conditions, and output limits in the correct technical manual.

During troubleshooting, measure the DC voltage both at the supply terminals and at the affected load. If the supply voltage remains stable while the downstream voltage drops, investigate cable resistance, terminal integrity, and branch loading before replacing the supply. If voltage falls at the supply itself, assess total demand, transient current, ambient temperature, and the unit's operating status.

Global PLC Spare HUB Review

The Allen-Bradley 1606-XLS960E is a high-power DIN rail supply for industrial systems that need 24 V DC distribution at up to its specified 40 A nominal output. Its adjustable output, DC OK relay contact, and compact mounting format support integration into properly designed control cabinets.

Its lack of a communication interface is an important selection detail. Applications that require remote power telemetry or network-based configuration will need a separate monitoring solution. Before ordering a replacement, verify the complete catalog number, AC input conditions, DC load requirements, thermal derating, and panel installation constraints.

Warranty, Packaging, and Shipping

• Warranty: 12-month warranty, subject to the seller's applicable warranty terms and conditions.
• Shipping options: FedEx, UPS, or DHL, subject to destination, carrier service availability, and shipment requirements.
• Product identification: Confirm the catalog number 1606-XLS960E and compare the required electrical ratings before purchase.
• Compatibility support: Provide the existing power supply label, input voltage, required DC load, and cabinet conditions when requesting a replacement.

Frequently Asked Questions

Q1: Can I use the 1606-XLS960E to replace a 24 V DC supply with a lower current rating?

Potentially, but compare the input requirements, output voltage, continuous current, transient performance, dimensions, terminal arrangement, thermal limits, and protection requirements. A higher current rating does not force the connected equipment to draw more current, but branch protection and wiring must still be suitable for the installation.

Q2: Does the adjustable 24–28 V output allow me to compensate for voltage drop across long cables?

It may provide limited adjustment where the downstream devices permit the selected voltage. First calculate cable voltage drop and inspect the wiring and terminal connections. Ensure that the voltage at every connected device remains within its permitted range; do not increase the supply setting without checking all loads on the same DC bus.

Q3: How should I determine whether 960 W is enough for my cabinet?

Calculate the combined steady-state wattage and current of all connected loads, then assess startup inrush, transient demand, ambient-temperature derating, and the manufacturer's output limits. Include future expansion where appropriate. Do not count the stated 50% reserve as continuous capacity unless the product documentation explicitly permits that operating condition.

Q4: Can the DC OK relay replace a dedicated voltage monitoring device?

The relay can provide a useful status signal, but its exact switching thresholds, contact ratings, and behavior must be checked in the technical manual. If the application requires detailed voltage measurement, historical trending, or network-based diagnostics, use an appropriate external monitoring device or PLC measurement arrangement.

Q5: What should I investigate if the supply works normally at low load but fails when equipment starts?

Record the DC voltage during startup and identify which loads energize at the same time. Compare the transient demand with the supply's documented overload capability, then inspect cable sizing, terminal tightness, and branch protection. Where appropriate, sequence load startup or distribute loads across correctly designed power supplies after verifying the system architecture.

Request a Quote for 1606-XLS960E

Need the Allen-Bradley 1606-XLS960E Bulletin 1606-XL power supply for a control cabinet, maintenance project, or replacement requirement? Contact Global PLC Spare HUB with your application details to request pricing and technical selection support.

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