Application Scenarios
In the central control cabinet of a large material handling system, dozens of PLC racks, I/O modules, safety relays, and field transmitters shared a single 24V DC power bus. The original single-phase power supply frequently triggered thermal derating during high-temperature summer conditions, causing intermittent resets of certain I/O modules and loss of conveyor speed references. After calculation, the maintenance team found that single-phase supply at the 960W level generated far more heat per ampere than a three-phase solution, and the high input current caused frequent nuisance tripping of upstream breakers. After replacing with the 1606-XLS960E-3, the three-phase input dramatically reduced current draw, and active inrush current limiting kept startup surge below 4.5A, significantly lowering the thermal load inside the control cabinet. More critically, the power supply’s 150% power reserve (60A for 4 seconds) provided ample transient margin when multiple contactors energized simultaneously or motor starting surges occurred, completely eliminating I/O resets caused by voltage sags. For this conveyor line, the 1606-XLS960E-3 transformed a fragile system limited by power supply transient capability into a robust architecture capable of handling simultaneous multi-load starting.
Parameter
| Main Parameters | Value/Description |
|---|---|
| Product Model | 1606-XLS960E-3 |
| Manufacturer | Allen-Bradley (Rockwell Automation) |
| Product Category | Switched Mode Power Supply / Performance Series |
| Input Voltage | Three-phase 380–480V AC, 47–63 Hz |
| Output Voltage | 24–28V DC adjustable |
| Rated Output Power | 960 W |
| Rated Output Current | 40A @ 24V DC |
| Power Reserve | 60A @ 24V DC (typical 4 seconds) |
| Efficiency | 95.3% typical |
| Hold-Up Time | 20 ms |
| Input Inrush Current | 4.5A peak (actively limited) |
| DC-OK Signal | Relay contact + LED indication |
| Protection Class | IP20 |
| Operating Temperature | -25°C to +60°C (derating above +60°C) |
| Mounting Method | DIN rail / wall mount |
| Dimensions (W×H×D) | 110 × 124 × 127 mm |
| Weight | Approximately 1.5 kg |
Technical Principles and Innovative Values
- Innovation Point 1: Three-Phase Input Architecture for Lower Current and Reduced Heat. The 1606-XLS960E-3 employs a three-phase 380–480V AC input, reducing per-phase current by approximately two-thirds compared to an equivalent single-phase supply. Rated input current is only 1.65A, meaning upstream protection devices, incoming cables, and terminal blocks can all be significantly downsized. Lower input current translates directly into less I²R loss, with the power supply’s own power dissipation at only 47.3W—far lower temperature rise in sealed control cabinets than single-phase alternatives.
- Innovation Point 2: 150% Power Reserve for Heavy-Duty Starting. The 1606-XLS960E-3 provides 60A of 4-second power reserve capability, 150% of rated output current. This feature allows the supply to comfortably handle capacitive load charging, DC motor starting, or simultaneous energization of multiple inductive loads without over-sizing to a higher power class for occasional surges. For retrofit scenarios with limited cabinet space, this means a more compact power supply can cover a wider range of load transients.
- Innovation Point 3: Active Power Factor Correction and Wide-Range Adaptability. The supply incorporates active PFC circuitry with a typical power factor of 0.88, effectively reducing grid-side harmonic pollution. Meanwhile, the 380–480V AC wide input range and 47–63 Hz frequency adaptability allow direct application across major global industrial power systems, including remote plants with significant voltage fluctuation or marine/offshore platform scenarios (certified to ABS/GL/RINA).
- Innovation Point 4: Comprehensive Diagnostics and Parallel Operation Capability. The 1606-XLS960E-3 features DC-OK relay contacts and dual-color LED indication, enabling maintenance personnel to quickly determine output status without a multimeter. The module supports parallel operation for redundancy or capacity expansion. When combined with 1606 series buffer modules, it maintains load current during brief main power failures or switching events, providing true “ride-through” capability for PLCs and control systems.