The Allen-Bradley 1606-XLS480E power supply solves the problem of unstable power delivery that causes equipment malfunctions and unplanned downtime in industrial automation. As part of Rockwell Automation’s XLS series, the 1606-XLS480E delivers consistent 24VDC power with high efficiency and short-term power boost capability, ensuring critical components like PLCs, I/O modules, and actuators operate reliably. In manufacturing, process control, and machine building—including oil and gas, food and beverage, and automotive production—the 1606-XLS480E provides robust power delivery, supports high-inrush loads, and reduces energy consumption. Its compact design, quick-connect terminals, and wide environmental tolerance make it ideal for both new installations and upgrades of legacy power supply systems, while global certifications ensure compliance in diverse industrial settings.
Technical Insights
Power Output Specifications (480W / 20A / 24VDC)
The 1606-XLS480E delivers 480W of continuous output power and 20A of continuous current at 24VDC, perfectly matching the power needs of industrial control systems and heavy-duty I/O racks. It features a power boost capability, providing 150% of rated power (720W, 30A) for up to 4 seconds, which helps start motors, charge capacitors, and absorb reverse energy in dynamic applications. The 24VDC output voltage has an adjustment range of 24-28VDC, allowing fine-tuning to match specific equipment requirements. This power specification eliminates the need for oversized power supplies, lowering upfront costs while ensuring enough reserve power to handle peak loads without voltage drops. The output ripple is less than 100mVpp (20Hz to 20MHz), protecting sensitive electronics from interference and ensuring stable performance.
Efficiency & Energy-Saving Features
With a typical efficiency of 94.5% at 230VAC input, the 1606-XLS480E reduces energy waste and operational costs compared to standard power supplies. Its synchronous rectification design and novel engineering details contribute to both high efficiency and a compact form factor, making it a sustainable choice for industrial facilities. The power supply also features active inrush current limiting circuitry, which restricts peak inrush current to a typical 40A at 230VAC, preventing damage to the power supply and upstream electrical systems. By minimizing energy losses (typically 28.3W at 230VAC), the 1606-XLS480E reduces heat generation, extending its service life and reducing the need for additional cooling in control panels.
Environmental & Physical Design
The 1606-XLS480E features an IP20 protection rating, designed for DIN rail mounting in control panels and industrial enclosures. It operates reliably in temperatures ranging from -25°C to +70°C, with a derating of 12W/°C between +60°C and +70°C to maintain performance in extreme conditions. Its compact dimensions (70x124x127mm WxHxD) save valuable panel space, while its rugged construction withstands typical industrial vibration and electromagnetic interference. The power supply weighs approximately 870g and includes quick-connect spring-clamp terminals for safe, fast installation, reducing wiring time and minimizing connection errors. It also meets global certifications including UL 60950-1, UL 508, CE, and ATEX Class I Div 2, ensuring compliance in international industrial environments.
Protection & Diagnostic Features
The 1606-XLS480E includes comprehensive protection features to safeguard both the power supply and connected equipment, including overvoltage, overcurrent, and short-circuit protection. It features a DC-OK relay and status LEDs—a green DC-OK light and a red overload light—for easy diagnostics, allowing operators to quickly identify power supply status and potential issues. The power supply also has a typical hold-up time of 46ms at 230VAC, ensuring uninterrupted power delivery during brief input voltage dips. Its active inrush current limiter (NTC and fixed resistor bypassed by an IGBT) prevents excessive current spikes during startup, protecting the power supply and upstream circuitry. These features reduce downtime by enabling proactive fault detection and preventing damage from electrical anomalies.
Installation & Maintenance
DIN Rail Mounting & Wiring Best Practices
Mount the 1606-XLS480E on a standard DIN rail in a clean, well-ventilated control panel, ensuring proper alignment to avoid strain on terminals. Leave at least 30mm of clearance around the power supply for adequate heat dissipation, as overheating can reduce efficiency and service life—this is especially critical when operating above +60°C. Use the quick-connect spring-clamp terminals to secure power and signal wires, ensuring tight connections to prevent voltage drops or intermittent faults. Connect the AC input (200-240VAC ±15%, 50-60Hz ±6%) to the designated terminals and the 24VDC output to connected equipment, following Allen-Bradley’s wiring diagrams. Separate AC input and DC output wiring to minimize EMI interference, and use shielded cables for sensitive connections. Ensure proper grounding to protect against electrical shock and noise.
Configuration & Startup Steps
Configure the 1606-XLS480E by adjusting the output voltage (24-28VDC) to match the requirements of your connected equipment, using the built-in adjustment potentiometer. Verify the AC input voltage matches the power supply’s specifications (200-240VAC) to prevent damage. Before startup, check all wiring connections for correctness and tightness, ensuring no loose wires or incorrect polarity. Turn on the AC input power and verify the green DC-OK LED illuminates, indicating stable 24VDC output. Test the power supply by connecting a small load first, checking for unusual heat, noise, or voltage fluctuations. For critical applications, configure the DC-OK relay to trigger alarms or shutdowns in the event of power loss, ensuring timely response to power anomalies. Document all configuration settings for future reference and troubleshooting.
Routine Maintenance & Troubleshooting
Inspect the 1606-XLS480E monthly to remove dust and debris from cooling vents, which can block airflow and cause overheating. Check terminal connections quarterly for loose wires or corrosion, especially in humid environments, as these can lead to intermittent faults. Monitor the power supply’s operating temperature and output voltage regularly to detect potential issues early. If the red overload LED illuminates, check for excessive load or short circuits in downstream equipment—most power supply faults are caused by downstream components, not the power supply itself. If a fault occurs, disconnect the AC input power, wait 5 minutes for internal capacitors to discharge, and troubleshoot the load or wiring before restarting. Update any associated firmware or software per Rockwell’s recommendations to maintain optimal performance. Calibrate the output voltage annually to ensure it remains within the 24-28VDC range.
Safety Precautions During Service
Always disconnect AC input power to the 1606-XLS480E before performing installation, maintenance, or troubleshooting. Wait at least 5 minutes after powering off to allow internal capacitors to discharge, reducing the risk of electrical shock. Use insulated tools and wear appropriate personal protective equipment (PPE) when working with the power supply, as hot surfaces can cause burns during operation. Never modify or open the power supply, as it contains no serviceable parts and high voltages are present inside. Ensure all wiring complies with local electrical codes and Allen-Bradley’s guidelines, and do not bypass built-in protection features. For hazardous location installations (Class I Div 2), ensure the power supply is mounted in an approved enclosure and avoid disconnecting equipment unless power is fully switched off.
Buyer's Guide FAQ
What applications are best suited for the 1606-XLS480E?
The 1606-XLS480E is ideal for industrial automation applications requiring stable, high-efficiency power delivery, including control systems, process automation, machine building, and robotics. It suits critical applications in oil and gas, food and beverage processing, automotive component manufacturing, and water/wastewater treatment, where reliable power is essential to prevent downtime. Its power boost capability makes it perfect for applications with high-inrush loads, such as motor starters and capacitor charging. It also works well in compact control panels where space is limited, thanks to its small form factor and DIN rail mounting design.
Is the 1606-XLS480E compatible with existing Allen-Bradley systems?
Yes, the 1606-XLS480E integrates seamlessly with Allen-Bradley PLCs (including MicroLogix, CompactLogix, and ControlLogix), I/O modules, HMIs, and other automation components. Its 24VDC output is compatible with standard industrial control equipment, and its quick-connect terminals simplify integration into existing control panels. The power supply supports parallel operation for increased power capacity, making it easy to scale power delivery as system needs grow. It also works with third-party industrial equipment that requires 24VDC power, ensuring flexibility in multi-vendor systems. The DC-OK relay integrates with PLCs and HMIs to provide real-time power status monitoring, enhancing system visibility.
How does the 1606-XLS480E compare to other 1606 XLS series models?
The 1606-XLS480E is a high-power model in the 1606 XLS series, offering 480W output—other models range from 80W to 720W to cater to different power needs. Unlike smaller XLS models (e.g., 1606-XLS120E), the 1606-XLS480E provides enough power to support large I/O racks and multiple control components. It shares the same core features as other XLS models, including high efficiency, power boost capability, quick-connect terminals, and global certifications, ensuring consistency in installation and maintenance. The 1606-XLS480E differs from the 1606-XLS480E-3 model primarily in input voltage range, with the 1606-XLS480E designed for 200-240VAC single-phase input, making it suitable for regional applications with specific power grids.
What are the key considerations when selecting the 1606-XLS480E?
When selecting the 1606-XLS480E, confirm that its 480W power rating and 20A current match the total load of your connected equipment, including peak inrush loads. Ensure the 200-240VAC single-phase input aligns with your facility’s power supply. Consider the environmental conditions—its -25°C to +70°C operating range suits most industrial settings, but derating is required above +60°C. Check that the IP20 rating is sufficient for your installation (indoor, clean environments); use an approved enclosure for harsh or dusty locations. Verify compatibility with your control system and ensure the power supply’s certifications (UL, CE, ATEX) meet local regulatory requirements. Finally, consider future scalability—parallel operation support allows adding additional units if power needs increase.
