In industrial automation, power supplies rarely attract as much attention as PLCs, drives, or HMIs. However, experienced engineers know that the stability of an entire control system often depends on one overlooked component — the power supply.
A poorly selected power supply can cause unexpected downtime, controller resets, communication failures, or even premature failure of expensive equipment. This is why many system integrators and OEM manufacturers rely on proven industrial power solutions such as the Allen-Bradley 1606 series, widely used in industrial control panels worldwide.
Among this product family, the 1606-XLS and 1606-XLE series are two of the most commonly selected options. Although they share similar design principles, each series targets different application needs and performance levels.
This article provides a detailed comparison of the two series, explains their technical strengths, and helps engineers and buyers choose the right model for real-world applications.
Why Industrial Power Supplies Matter More Than You Think
In modern automation environments, controllers, sensors, communication modules, and safety systems all rely on stable 24V DC power. Even slight voltage drops can result in:
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PLC shutdowns or unexpected reboots
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Communication errors on fieldbus networks
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Sensor malfunction or inaccurate readings
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Reduced lifespan of electronic components
Unlike office electronics, industrial systems operate in harsh conditions — vibration, temperature variation, electrical noise, and continuous operation. Therefore, power supplies designed specifically for industrial environments are essential.
Many manufacturers consider the power supply the “foundation layer” of the control cabinet. If that foundation is unstable, even the most advanced PLC system will not perform reliably.
For a broader view of industrial control components, you can also explore our
PLC module collection, which shows how power systems integrate with complete automation solutions.
Overview of the Allen-Bradley 1606 Power Supply Family
The 1606 series, developed under Allen-Bradley, part of Rockwell Automation, is designed specifically for industrial control applications.
Key characteristics include:
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DIN rail mounting for easy panel integration
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High efficiency switching design
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Wide AC input range for global use
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Stable 24V DC output
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Long operational life for continuous production
These features make the series suitable for:
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PLC control panels
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Packaging machines
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Assembly lines
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Process automation
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Material handling systems
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Robotics and motion control
Within this family, the 1606-XLS and 1606-XLE series serve different performance and budget requirements.
1606-XLS Series: High-Performance Power for Demanding Applications
1. Product Positioning
The 1606-XLS series is designed for demanding industrial environments where reliability, efficiency, and long-term stability are critical.
Typical use cases include:
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High-load production lines
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24/7 continuous operation systems
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High ambient temperature environments
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Automation systems with heavy startup loads
2. Technical Advantages
High Efficiency Design
Higher efficiency means less heat generation inside control cabinets, which helps extend component life and reduce cooling requirements.
Enhanced Overload Capability
Industrial equipment often requires higher inrush current during startup. The XLS series can handle temporary overload conditions more effectively, ensuring stable startup performance.
Wide Operating Temperature Range
This makes the series suitable for factories with limited climate control or harsh operating environments.
Robust Industrial Construction
The mechanical and electrical design is optimized for long service life, reducing maintenance costs over time.
1606-XLE Series: Cost-Effective Reliability for Standard Automation
While the XLS series focuses on premium performance, the 1606-XLE series targets standard industrial applications where reliable power is needed without over-specification.
Key Characteristics
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Balanced performance and cost
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Reliable 24V DC output
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Compact footprint for panel space savings
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Easy integration into OEM equipment
Typical applications include:
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Standard manufacturing equipment
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Small to mid-size automation projects
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OEM machinery with controlled environments
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General industrial control cabinets
The XLE series is not a low-end solution — it simply provides essential industrial performance without advanced overload features that may not be necessary for every project.
1606-XLS vs 1606-XLE: Practical Comparison for Engineers
| Feature | 1606-XLS | 1606-XLE |
|---|---|---|
| Market Position | Premium industrial | Cost-efficient standard |
| Efficiency | Higher | High |
| Overload Capacity | Enhanced | Standard |
| Thermal Performance | Superior | Standard industrial |
| Recommended Use | High demand applications | General automation |
In practical terms:
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Choose XLS for critical systems and harsh environments.
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Choose XLE when cost efficiency and standard reliability are priorities.
1606-XLS Part Number
| Output | Power | nput AC | Input DC | Special Features | Catalog Number | |
| 100. …240V AC/DC Converters | ||||||
| 12V | 15A | 180W | AC 10…240V | DC T0.….150V | 一 | 1606-XLS180B |
| 24V | 3.4A | 80W | AC 10…240V | DCT10.….00V | 一 | 1606-XLS80E |
| 24V | 3.8A | 9IW | AC 10…240V | DCT10.….00V | DeviceNet/NEC Class 2 | 606-XLSDNET4 |
| 24V | 5A | 120W | AC 10…240V | DCT10.….00V | 一 | 606-XLS120E |
| 24V | 8A | 92W | AC 10…240V | DCT10.….50V | DeviceNet/NEC Class1 | 1606-XLSDNET8 |
| 24V | 10A | 240W | AC 10…240V | DC 10.….150V | 一 | 1606-XLS240E |
| 24V | 10A | 240W | AC10…240V | DC T0.….150V | 一 | 606-XLS240EC |
| 24V | 10A | 240W | AC 10…240V | DCT10.….00V | 一 | 606-XLS240E-D |
| 24V | 20A | 480W | AC200…240V | 一 | 一 | 1606-XLS480EE |
| 24V | 20A | 480W | AC 10…240V | DC T0.….150V | 一 | 606-XLS480E |
| 24V | 20A | 480W | AC 10…240V | DC T0…150V | 一 | 606-XLS480EC( |
| 24V | 40A | 960W | AC 10…240V | 一 | 一 | 1606-XLS960E |
| 24V | 40A | 960W | AC200..240V | 一 | 一 | 1606-XLS960EE |
| 30V | 8A | 240W | AC 10…240V | DC T10.….150V | 一 | 1606-XLS240K |
| 36V | 3.3A | 480W | AC 10…240V | DC T10.….150V | 一 | 1606-XLS480G |
| 48V | 5A | 240W | AC10…120V/AC20…240V | DC T10.….150V | 一 | 1606-XLS240F |
| 48V | 5A | 240W | AC 10…240V | DCT10.….00V | Extended DCinput | 1606-XLS240F-D |
| 48V | 10A | 480W | AC 10…240V | DC T0.….150V | 一 | 1606-XLS480F |
| 48V | 20A | 960W | AC 10…240V | 一 | 一 | 606-XLS960F |
| 48V | 20A | 960W | AC200…240V | 一 | 一 | 1606-XLS960FE |
| 380…480V AC/DC Converters | ||||||
| 24V | 20A | 480W | 3AC 380…480V | 一 | 一 | 1606-XLS480E-3 |
| 24V | 20A | 480W | 3AC 380…480V | 一 | 一 | 1606-XLS480E-3C |
| 24V | 40A | 960W | 3AC 380…480V | 一 | 一 | 1606-XLS960E-3 |
| 36V | 3.3A | 480W | 3AC 380…480V | 一 | 一 | 1606-XLS480G-3 |
| 48V | 10A | 480W | 3AC 380…480V | 一 | 一 | 1606-XLS480F-3 |
| 48V | 20A | 960W | 3AC 380…480V | 一 | 一 | 1606-XLS960F-3 |
| DC/DC Converter | ||||||
| 24V | 20A | 480W | 一 | DC 600V | For intermediate DC-bus | 1606-XLS480E-D |
| MOSFET Redundancy Modules | |||||||
| Output | Input DC | Special Features | Catalog Number | ||||
| DC1…28V | 40A | DC1…28V,2x 20A | Dua-input MOSFET redundancy module | 1606-XLSRED4HE | |||
| DC 12.…28V | 40A | DC 24…28V,2x20A | Dual-input MOSFET redundancy module | 1606-XLSRED40 | |||
| DC1…28V | 40A | 1x40A | Dual-input MOSFET redundancy module | 1606-XLSREDS40HE | |||
| DC1…28V | 80A | DC24…28V,2x 40A | Dual-input MOSFET redundancy module | 1606-XLSRED80 | |||
| DC1…28V | 80A | DC12…28V,2x 20A | Single input MOSFET redundancy module | 1606-XLSRED80HE | |||
| DC 24…56V | 40A | DC24…56V,2x 20A | Dual-input MOSFET redundancy module | 1606-XLSRED40HF | |||
| DC-UPS with Batteries | |||||||
| Output | Battery | Version | Catalog Number | ||||
| 24V | 10A | External,12V,3…40Ah | Batery DC-UPS | 606-XLS240-UPS | |||
| 10A | External,12V,17…30 Ah | Battery DC-UPS | 1606-XLS240-UPSE | ||||
| 10A | External,12V,3…40Ah | With aditional 12V output | 1606-XLS240-UPSD | ||||
| 10A | Built-in 12V,5Ah | DC-UPS with integrated battery | 606-XLS240-UPSC | ||||
| 20A | External,12V,3…150Ah | DC-UPS | 1606-XLS480-UPS | ||||
| Battery Modules for DC-UPS | |||||||
| Description | Dimensions | Catalog Number | |||||
| 2V,5 Ah battery replacement for 1606-XLS240-UPSC | 90x106x70mm(3.54×4.7x 2.76 in.) | 1606-XLSBAT5 | |||||
| 2V,7Ah battery replacement for 1606-XLSBATASSY1,-XLSBATASSYW,and-XLSBATASSY3 | 151x98x65mm(5.94×3.85×2.56 in.) | 1606-XLSBAT1 | |||||
| 2V,7Ah battery module for 1606-XLS2408-UPS_ | 55×124x 12 mm(6.10×4.88×441 in.) | 1606-XLSBATASSY1 | |||||
| 2V.,7Ah battery module | 158x132x98mm(6.22x 5.20×3.86in.) | 606-XLSBATASSY1W | |||||
| 2V,26 Ah battery module for 1606-XLS240-UPS_ | Z14x 179x158mm(8.42x 7.05×6.22 in.) | 606-XLSBATASSY2 | |||||
| 24V,7Ah battery module for 1606-XLS48D-UPS_ | 137x186x143mm(5.39×7.32×5.63 in.) | 1606-XLSBATASSY3 | |||||
| 24V,12Ah battery module for 1606-XLS480-UPS. | 203x186x143mm(799x 7.32×5.63in.) | 606-XLSBATASSY4 | |||||
| Same as 1606-XLSBATASSY1 battery module but without battery | 55×124×112 mm(6.10×4.88×441 in.) | 1606-XLSBATBR1 | |||||
| Same as 1606-XLSBATASSYTW battery module but without battery | 158x 132×98mm(6.22x 5.20×3.86in.) | 1606-XLSBATBRIW | |||||
| Same as 1606-XLSBATASSY2 battery module but without battery | 214x 179x158mm(8.42x 7.05×6.22 in.) | 1606-XLSBATBR2 | |||||
| Same as 1606-XLSBATASSY3 battery module but without battery | 137×186×143mm(5.39x 7.32×5.63 in.) | 1606-XLSBATBR3 | |||||
| Same as 1606-XLSBATASSY4 battery module but without battery | 203x186x143mm(5.39x 7.32×5.63 in.) | 1606-XLSBATBR4 | |||||
| Sensor board with PT1000 temperature sensor and center-tap fuse | 23×15×10.5mm(0.91x 0.59x 4.35 in.) | 1606-XLSBATSEN | |||||
| DC-UPS with Capacitor Storage | |||||||
| Output | Capacitor Storage | Catalog Number | |||||
| 24V | 20A | 6 kKWs,typical buffer time 9s at15A | 1606-XLSCAP24-6 | ||||
| 40A | 12kWs,typical buffer time 18 s at 15A | 1606-XLSCAP24-12 | |||||
| Buffer Modules with Capacitor Storage | |||||||
| Output | Capacitor Storage | Catalog Number | |||||
| DC 24V | 20A | 0.2 KWs,typical buffer time 310 ms at 20A | 16D6-XLSBUFFER24 | ||||
| 40A | 0.32 kWs,typical buffer time 250 ms at 40A | 1606-XLS960BUFFER | |||||
| DC48V | 20A | 0.2 KWs,typical buffer time 150 ms at 20A | 16D6-XLSBUFFER48 | ||||
1606-XLE Part Number
| Output | Power | Input AC | Input DC | Special Features | Catalog Number | |||
| 100…240V AC/DC Converters | ||||||||
| 12V | 10A | 120W | AC 10…240V | DC 10.….150V | 一 | 1606-XLE120B | ||
| 2V | 16A | 192W | AC 10…240V | DC 10…150V | Remote Shut-down | 1606-XLE192BM | ||
| 2V | 16A | 192W | AC 10…240V | DC T¹0…300V | 一 | 1606-XLE192BDM | ||
| 24V | 3.3A | 80W | AC 10…240V | DC 10…300V | Remote Shut-down | 1606-XLE80E | ||
| 24V | 5A | 20W | AC 10…240V | DC 10.….150V | 一 | 1606-XLE120E | ||
| 24V | 5A | 20W | AC 10…240V | DC 100..150V | Conformal Coated | 1606-XLE120EC | ||
| 24V | 5A | 20W | AC 10…240V | DC 10.…150V | Spring clamps | 1606-XLE120EL | ||
| 24V | 5A | 20W | AC 10…240V | DC 10….150V | Push-in clamps | 1606-XLE120EH | ||
| 24V | 5A | 120W | AC 10…240V | DC 10.…300V | 一 | 1606-XLE120ED | ||
| 24V | 5A | 120W | AC 10…240V | 一 | 一 | 1606-XLE120EN | ||
| 24V | 5A | 120W | AC 20…240V | 一 | 一 | 1606-XLE120EE | ||
| 24V | 10A | 240W | AC 10…240V | DC 10.….150V | 一 | 1606-XLE240E | ||
| 24V | 10A | 240W | AC100.…240V | DC10..150V | Conformal Coated | 1606-XLE240EC | ||
| 24V | 10A | 240W | AC 10…240V | DC10…150V | Spring clamps | 1606-XLE240EL | ||
| 24V | 10A | 240W | AC 10…240V | DC10…50V | Push-in clamps | 1606-XLE240EH | ||
| 24V | 10A | 240W | AC10.240V | DC 10.…300V | Extended DC input | 1606-XLE240EP | ||
| 24V | 10A | 240W | AC 10…120V | 一 | 一 | 1606-XLE240EN | ||
| 24V | 10A | 240W | AC 10…240V | 一 | 一 | 1606-XLE240EE | ||
| 24V | 20A | 480W | AC 10…240V | DC 10.…150V | Conformal Coated | 1606-XLE480EPC | ||
| 24V | 20A | 480W | AC10…240V | DC10…150V | 一 | 1606-XLE480EP | ||
| 24V | 20A | 480W | AC100…240V | DC 110.….150V | Spring clamps | 1606-XLE480EL | ||
| 24V | 20A | 480W | AC 10…240V | DC10…50V | Push-in clamps | 1606-XLE480EH | ||
| 24V | 20A | 480W | AC 10…240V | DC10…150V | Remote shutdown | 1606-XLE480EM | ||
| 48V | 2.5A | 120W | AC 10…240V | DC10…150V | 一 | 1606-XLE120F | ||
| 48V | 5.4A | 259W | AC100…240V | DC 10.….150V | 一 | 1606-XLE260F | ||
| 48V | 10A | 260 W | AC 10…240V | DC 10…150V | 一 | 1606-XLE480FP | ||
| 380…480V AC/DC Converters | ||||||||
| 2V | 8A | 96W | 2AC 380…480V | 一 | 一 | 1606-XLE96B-2 | ||
| 24V | 5A | 20W | 2AC 380…48DV | 一 | 一 | 1606-XLE120E-2 | ||
| 24V | 10A | 240W | 3AC 380…48DV | 一 | 一 | 1606-XLE240E-3 | ||
| 24V | 40A | 960W | 3AC480V | 一 | Semi-regulated | 1606-XLE960DX-3N | ||
| 48V | 5A | 240W | 3AC 380.…480V | 一 | 一 | 1606-XLE240F-3 | ||
| 48V | 20A | 960W | 3AC 400V | 一 | Semi-regulated | 1606-XLE960MX-3N | ||
| Diode Redundancy Modules | ||||||||
| Dutput | Input DC | Description | Catalog Number | |||||
| DC24…48V | 20A | DC 24..48V | Dual-input diode redundancy module | 1606-XLERED | ||||
Real Industrial Applications
Manufacturing Lines
In automotive or electronics assembly, control systems run continuously. Stable DC power prevents production interruptions and protects expensive automation hardware.
Packaging and Material Handling
Machines with frequent startup cycles benefit from power supplies capable of handling inrush currents efficiently.
Process Industries
Oil & gas, chemical, and energy sectors often operate in high-temperature environments where reliability is essential.
If you want to explore available models, visit our
Allen-Bradley 1606 product collection.
Example Model Spotlight: 1606-XLP95E Compact Power Supply 95W
A popular option in compact control systems is the 1606-XLP95E Compact Power Supply 95W.
Key advantages include:
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Space-saving design for smaller panels
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Reliable 24V output for PLC and HMI systems
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Easy DIN rail installation
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Suitable for compact OEM machines
More technical details are available here:
1606-XLP95E Compact Power Supply 95W
This model is frequently used in systems where panel size is limited but reliability remains essential.
How to Select the Right 1606 Power Supply
Engineers usually follow these steps:
Step 1 — Calculate Total Power Consumption
Include:
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PLC CPU and I/O modules
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HMI panels
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Sensors and relays
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Communication devices
Always add a 20–30% safety margin.
Step 2 — Consider Startup Current
Motors, relays, and certain loads may require higher startup current than normal operating current.
Step 3 — Evaluate Environmental Conditions
High ambient temperature or continuous operation generally favors the XLS series.
Step 4 — Check Panel Space
Compact cabinets may benefit from models like the XLP series.
Why Global OEMs Continue to Choose Allen-Bradley Power Supplies
Several reasons explain their popularity:
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Strong compatibility with ControlLogix and CompactLogix systems
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High global recognition among end users
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Long product lifecycle
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Reliable supply chain support
For exporters and trading companies, internationally recognized brands also increase customer confidence and simplify project approvals.
Future Trends in Industrial Power Supplies
Industrial automation is evolving rapidly, and power supply technology is evolving with it:
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Higher efficiency designs to reduce energy costs
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Smaller dimensions for compact equipment
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Improved diagnostic capabilities
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Longer lifecycle expectations
The continued development of the 1606 series reflects this trend toward smarter and more reliable power management in automation systems.
Conclusion
Although often overlooked, power supplies play a decisive role in system reliability. The Allen-Bradley 1606 series offers flexible solutions for different industrial needs:
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1606-XLS — best for high-performance, demanding applications
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1606-XLE — ideal for standard automation with strong cost-performance balance
Choosing the right power supply helps reduce downtime, improve system stability, and lower long-term operating costs.
