Application Scenarios

In a high-density control cabinet powering multiple PLC racks, servo drives, and I/O modules, the available panel space is often the limiting factor in system design. When an automotive assembly line required a power supply capable of supporting the inrush demands of a dozen contactors and motor starters without voltage sag, engineers turned to the 1606-XLS960E-3. Its 150% BonusPower capability delivers up to 1440 W for short durations, providing the headroom needed to handle simultaneous load energization without tripping or causing brownouts on sensitive control electronics. The three-phase 380-480 VAC input matches the plant’s power distribution, while the stabilized 24 VDC output feeds the entire control bus with less than 100 mV of ripple.

 

Parameter

Parameter	Value/Description
Product Model	1606-XLS960E-3
Manufacturer	Allen-Bradley (Rockwell Automation)
Product Category	Switched Mode Power Supply
Input Voltage	380-480 VAC, 3-phase, 47-63 Hz
Input Current	1.65 A @ 400 VAC, 1.35 A @ 480 VAC
Output Voltage	24-28 VDC, adjustable
Output Current	40 A @ 24 VDC (continuous)
Output Power	960 W continuous, 1440 W BonusPower (4s)
Efficiency	95.3% typical @ 400 VAC full load
Ripple & Noise	<100 mVpp
Hold-up Time	20 ms typical
Operating Temperature	-25°C to +70°C (derating above +60°C)
Protection Rating	IP20
Dimensions (W×H×D)	110 × 124 × 127 mm
Weight	1.5 kg
Mounting	DIN rail, wall mount capable

 

 

Technical Principles and Innovative Values

Innovation Point 1: Synchronous Rectification for Compact Efficiency. The 1606-XLS960E-3 achieves its 95.3% efficiency through synchronous rectification and advanced switching topology, which minimizes waste heat and allows a significantly reduced unit size compared to conventional designs. This means a 960 W power supply that occupies only 110 mm of DIN rail width, freeing panel space for other components.

Innovation Point 2: BonusPower for Load Start-Up. The 1606-XLS960E-3 delivers 150% of rated power (1440 W) for up to 4 seconds, supporting loads with high inrush currents such as DC motors, capacitive loads, and multiple contactor coils energizing simultaneously. The output power manager controls this boost, ensuring it remains available repeatedly without damaging the supply.

Innovation Point 3: Active PFC and Low Inrush Current. The 1606-XLS960E-3 incorporates active power factor correction, achieving a power factor of 0.88 typical, which reduces harmonic distortion and improves compatibility with generator and UPS systems. The active inrush current limiter keeps peak input current to approximately 4.5 A, eliminating the need for oversized upstream breakers or contactors.

Innovation Point 4: Comprehensive Diagnostics and Control. The 1606-XLS960E-3 features a DC-OK relay contact synchronized with a green LED, providing remote status indication to a PLC or alarm system. A red overload LED signals output faults, while a shut-down/remote control input allows the supply to be disabled remotely or its output voltage adjusted between 14 V and 28 V.