Allen-Bradley 1606-XLS960EE Performance Power Supply

The Allen-Bradley 1606-XLS960EE is a high-efficiency switched-mode power supply from the XLS Performance Series, engineered to deliver 960 watts of output power. This industrial power supply converts a 200-240 VAC single-phase input to an adjustable 24-28 VDC output, capable of supplying up to 40 amperes continuous. The XLS960EE features a compact design with spring clamp terminals, 94.6% typical efficiency, and a 150% power reserve for handling motor inrush currents, charging large capacitor loads, or absorbing energy returned from regenerative drives — all while maintaining regulated output.

Technical Specifications

Key Features

• 150% Power Reserve: The ability to supply 150% of the nominal output power for up to 4 seconds makes the XLS960EE capable of starting motors, charging large capacitive loads, and supporting intermittent high-current devices without requiring an oversized power supply.

• 94.6% High Efficiency: Low internal power dissipation reduces heat load inside the control cabinet, enabling operation at higher ambient temperatures and extending the service life of neighboring heat-sensitive components.

• Spring Clamp Terminals: Screwless spring clamp connections reduce installation time, provide positive contact retention, and resist loosening under vibration. Terminals accept solid or stranded wire up to a specified AWG size.

• Compact DIN Rail Mounting: Power supply is designed for snap-on mounting to a standard 35 mm DIN rail, and the slim width saves valuable panel space compared to conventional 960W units.

• Robust Protection and Diagnostics: Automatic overload protection with hiccup mode recovery prevents damage during output short circuit; overvoltage protection (typically 30–32 V) safeguards connected loads; and an over-temperature shutdown with automatic restart prevents overheating. A green DC-OK LED and a relay output provide remote status indication.

Functional Overview

The 1606-XLS960EE is a constant-voltage, current-limited power supply. Its synchronous rectification design delivers high efficiency across the load range. A power reserve feature allows short-term output current peaks up to 150% of the rated value, helpful for starting high-inrush loads. The internal electrolytic capacitors are selected for a long service life at rated operating temperature. The supply's active inrush current limiting circuit prevents the input circuit breaker from tripping during power-up.

Integration and Compatibility

The spring clamp terminals accept ferrule-terminated or bare wires for secure connections. The output voltage is adjustable within 24–28 VDC. A margin screwdriver slot accessible through the terminal cover allows adjustment. For system architectures requiring redundancy, two 1606-XLS960EE units can be paralleled using a redundancy module. The supply also features a "parallel" mode for current sharing. The DC-OK relay output can be used to signal a PLC or to drive an indicator lamp if the output falls below ~21 V or exceeds ~30 V.

Installation and Configuration

Mount the 1606-XLS960EE on a DIN rail. First, hook the upper clip over the rail, then press downwards to snap the lower clip into place. Connect input L and N terminals to the single-phase supply, ensuring the grounding screw is connected to the panel protective earth. Connect output "+" and "-" to the load. If the output voltage must be adjusted for line drop compensation, turn the potentiometer after minimum load is applied. Output voltage is adjustable from 22 to 28 VDC. Install the supply in a vertical orientation to ensure proper convection cooling.

Maintenance and Reliability

Periodically inspect for dust accumulation on the housing end plates. Use low-pressure compressed air to clean the ventilation slots. The capacitor bank has a rated life of 10+ years at full load. No adjustment is needed during the product's service life. If the DC-OK LED flashes or the relay output indicates a fault, verify input and output voltages for short circuits or overloads. The supply offers electronic protection against reversed output connection, making it tolerant of accidental mis-wiring for short periods.

Conclusion

The Allen-Bradley 1606-XLS960EE provides a high-performance, space-saving power supply solution for industrial control cabinets requiring 24 VDC. With 960 W output, 150% power reserve, high efficiency, and spring clamp convenience, this XLS series power supply is well-suited for system integrators and panel builders responsible for reliable powering of PLCs, HMIs, and field devices.