Allen-Bradley 1606-XLS Series Modules - 1606-XLS480E

Technical Dossier

Product Details And Specifications

Allen-Bradley 1606-XLS Series: Comprehensive Module Range and Technical Overview

The Allen-Bradley (Rockwell Automation) 1606-XLS series is a standardized line of DIN-rail-mounted switched-mode power supplies (SMPS) engineered for continuous-duty industrial environments. Deployed across petrochemical refineries, nuclear auxiliary systems, offshore platforms, and large-scale discrete manufacturing facilities, the 1606-XLS range is a de facto standard for 24 VDC panel power in Logix-based control architectures. Output ratings span 20 W to 960 W, with global-input variants (85–264 VAC) enabling single-SKU deployment across multi-region plant networks. The series carries UL 508 Listed, CE, and cUL certifications, meeting baseline compliance requirements for North American and European industrial installations. Mean Time Between Failures (MTBF) figures exceed 500,000 hours at full load and 40 °C ambient, making the 1606-XLS a preferred choice for unattended remote I/O panels and safety-instrumented system (SIS) auxiliary power rails.

📩 Looking for a specific 1606-XLS model? Send your parts list to: sale@driveknms.com

The Evolution of 1606-XLS Architecture

The 1606-XLS series was introduced by Rockwell Automation as a successor to the earlier 1606-XLP and 1606-XLE families, consolidating output power classes and standardizing the form factor for 35 mm DIN rail mounting. Early variants in the XLP line offered fixed 24 VDC outputs with narrow input ranges (100–240 VAC ±10%), requiring separate SKUs for 50 Hz and 60 Hz grid environments. The XLS generation resolved this by adopting a universal PFC (Power Factor Correction) front end, accepting 85–264 VAC / 90–375 VDC across all models, eliminating input-range selection switches.

Architecturally, the XLS series uses an active PFC stage followed by an LLC resonant half-bridge topology, delivering efficiency up to 93.5% at full load and output ripple below 50 mV p-p. Output voltage is adjustable ±15% via front-panel potentiometer, accommodating 24 V bus tolerance requirements in legacy Logix I/O racks. Later production runs added enhanced diagnostic LEDs and DC-OK relay contacts (dry contact, 0.5 A / 30 VDC), enabling integration with PLC digital input cards for power-fault alarming without external monitoring relays.

The 1606-XLS series is now in a mature/sustaining lifecycle phase. Rockwell Automation continues to manufacture and support the line, but new panel designs are increasingly specified with the 1606-XLP E-series or third-party equivalents such as the Phoenix Contact QUINT 4 and PULS QS series. For existing installations, DriveKNMS maintains stock of both current-production and last-time-buy 1606-XLS units to support long-term maintenance contracts and multi-year spare parts agreements.

1606-XLS Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified production range of the Allen-Bradley 1606-XLS series, organized by output power class and function.

20–60 W Class

1606-XLS60E: 24/28 VDC, 2.5 A / 60 W, global input, DIN rail, DC-OK relay contact.
1606-XLS60EF: 24/28 VDC, 2.5 A / 60 W, global input, conformal-coated PCB for harsh environments.
1606-XLS60B: 24 VDC, 2.5 A / 60 W, 85–264 VAC input, basic diagnostic LED only — legacy variant, limited availability.

120 W Class

1606-XLS120E: 24/28 VDC, 5 A / 120 W, global input, DC-OK relay, parallel redundancy capable.
1606-XLS120EF: 24/28 VDC, 5 A / 120 W, conformal coat, extended -25 °C to +70 °C operating range.

240 W Class

1606-XLS240E: 24/28 VDC, 10 A / 240 W, global input, DC-OK relay, active current sharing for N+1 redundancy.
1606-XLS240EF: 24/28 VDC, 10 A / 240 W, conformal coat variant for marine and offshore applications.

480 W Class — Primary Listing SKU

1606-XLS480E: 24/28 VDC, 20 A / 480 W, global input (85–264 VAC), DC-OK relay, ±15% output trim, DIN rail mount — the primary SKU for this listing.
1606-XLS480EF: 24/28 VDC, 20 A / 480 W, conformal-coated, rated for IEC 60068-2 vibration and humidity cycling.

960 W Class

1606-XLS960E: 24/28 VDC, 40 A / 960 W, global input, highest output class in the XLS range, requires 35 mm DIN rail with end brackets.
1606-XLS960EF: 24/28 VDC, 40 A / 960 W, conformal coat, designed for Class I Division 2 / Zone 2 auxiliary panels.

Redundancy & Accessory Modules

1606-XLSRED4: Redundancy module, decouples two 1606-XLS outputs for true N+1 parallel operation without reverse-current flow.
1606-XLSRED8: Redundancy module, 8 A rated, for lower-power XLS pairs (60 W / 120 W class).
1606-XLSBUF24: 24 VDC buffer module, provides 40 ms holdup extension for controlled PLC shutdown during mains interruption.
1606-XLSBUF48: 48 VDC buffer module, extended holdup for 48 V bus applications.
1606-XLSEXT: DIN rail extension bracket kit for 960 W class units requiring additional mechanical support.

Sourcing Hard-to-Find & Obsolete 1606-XLS Parts

DriveKNMS maintains a dedicated inventory program for the Allen-Bradley 1606-XLS series, covering both current-production units and models that have transitioned to last-time-buy or discontinued status. For plant operators running legacy Logix 5000 or SLC 500 panels where the 1606-XLS is the installed power standard, sourcing a direct replacement is operationally preferable to a panel redesign requiring re-validation under IEC 61511 or ISA-84.

Our sourcing process for 1606-XLS units includes: verification of manufacture date codes against Rockwell Automation’s published production records; inspection of capacitor date codes on the primary PFC stage (a known wear item in units manufactured before 2018); and functional load testing at 100% rated output prior to shipment. Units sourced from decommissioned panels undergo full reconditioning including capacitor replacement on the output filter bank where date codes indicate more than 7 years of service.

For end-of-life models such as the 1606-XLS60B and early-revision 1606-XLS240E units, DriveKNMS provides cross-reference to current-production equivalents or compatible third-party alternatives, with full documentation for change-management records required under ISO 9001 and IEC 61511 management of change procedures.

Quality Control for the 1606-XLS Range

Each 1606-XLS unit processed by DriveKNMS undergoes a structured test protocol before dispatch:

Input Stage Verification: Applied input voltage swept from 85 VAC to 264 VAC at both 50 Hz and 60 Hz. Input current and power factor measured at 50%, 75%, and 100% load to confirm PFC stage integrity.

Output Load Test: Unit loaded to 100% rated output (e.g., 20 A / 480 W for the 1606-XLS480E) using a programmable DC electronic load. Output voltage stability, ripple (measured per JEITA RC-9131B), and efficiency recorded and logged against unit serial number.

DC-OK Contact Test: Relay contact continuity and dropout voltage verified. Contact must open within 200 ms of output falling below 18 VDC per Rockwell specification.

Thermal Soak: Unit operated at full load for 60 minutes in a 50 °C ambient chamber. Thermal imaging performed on primary switching transistors, output rectifiers, and output filter capacitors to identify latent thermal anomalies.

Dielectric Withstand: 1500 VAC applied between input and output for 60 seconds per IEC 62368-1 clause 5.4.

Test records are retained for 5 years and available upon request for traceability documentation in regulated industries (pharmaceutical, nuclear auxiliary, oil & gas).

📩 Contact Information

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