Product Overview

The Allen-Bradley 1606-XL120DR is a compact industrial switching power supply manufactured by Rockwell Automation. Part of the Allen-Bradley Bulletin 1606 Power Supply XL family, this module converts an appropriate AC or DC input into a regulated 24 V DC output for industrial control systems, automation equipment, and electrical control panels.

With a rated output of 120 W and a nominal output current of 5 A, the 1606-XL120DR is designed to provide reliable DC power for compatible control devices. Typical loads include programmable logic controllers (PLCs), remote I/O modules, industrial sensors, control relays, communication equipment, and other 24 V DC devices.

The module supports a manually selectable 115 V or 230 V AC input configuration and also accepts DC input within its specified operating range. This flexibility can be useful when designing control panels for different power environments. Correct input selection and compliance with the manufacturer’s wiring instructions are essential before energizing the unit.

One of the important characteristics of the 1606-XL120DR is its suitability for N+1 redundant power arrangements. In an appropriately designed system, multiple power supplies can be configured so that the remaining supply capacity supports the required load if one supply fails. Redundancy performance depends on the system design, load distribution, wiring, and the operating condition of the installed modules.

The compact enclosure and DIN rail mounting arrangement make the unit suitable for industrial cabinets where efficient use of space is important. Its front-accessible connections also support convenient wiring and maintenance.

The 1606-XL120DR has been discontinued by the manufacturer. Nevertheless, the model remains relevant to legacy automation systems that require maintenance or replacement of existing power supply equipment. When sourcing this product, buyers should verify the full catalog number, condition, output performance, and suitability for the existing installation.

Technical Specifications

Specifications are based on available product documentation and the supplied product data. Confirm the individual unit’s nameplate, input selector position, and wiring requirements before installation.

Function and Working Principle

The primary function of the Allen-Bradley 1606-XL120DR is to provide a regulated 24 V DC supply from an appropriate AC or DC input. Many industrial automation devices require stable DC power to operate reliably, making the power supply an essential component of the control system.

1. AC/DC Input Conversion

The module accepts AC input at the specified voltage range or DC input within the permitted range. Its internal switching circuitry converts the incoming energy into a regulated DC output.

Before applying power, the input voltage selector must be set correctly for the incoming AC supply. The unit must also be wired according to the designated input terminals and the applicable electrical requirements.

2. Regulated 24 V DC Output

The power supply provides a nominal 24 V DC output rated at 5 A, corresponding to a maximum nominal output power of 120 W.

This output can supply compatible automation devices such as PLCs, sensors, interface relays, and communication equipment. The total connected load must remain within the unit’s electrical ratings, with appropriate allowance for startup currents and load variations.

A regulated DC supply helps reduce the effects of normal input-voltage variations on connected equipment. However, the power supply should be used within its specified environmental and electrical operating limits.

3. Overload Capability

Industrial control loads may draw additional current during startup or under transient operating conditions. The 1606-XL120DR documentation describes a power-boost capability, with output current above the nominal 5 A rating available under specified conditions.

This capability should not be treated as a continuous operating rating. Engineers must consult the applicable load curves and technical instructions when evaluating startup demand or short-term overload requirements.

4. N+1 Redundant Power Arrangements

The 1606-XL120DR is intended for use in N+1 redundant power supply arrangements. In a suitable configuration, multiple power supplies share the responsibility of supporting a load, with additional capacity available to maintain operation if one unit fails.

For example, an industrial control cabinet may use two compatible supplies to provide redundancy for a critical 24 V DC load. The system must be designed so that the remaining power supply can support the required load following a failure.

Redundancy depends on proper system sizing, compatible wiring, load sharing, and appropriate protective arrangements. Simply connecting two power supplies together does not automatically create a safe or correctly functioning redundant system.

5. Power Status and Diagnostics

The power supply includes status-related features intended to help personnel assess its operating condition. The exact monitoring and signal arrangements should be confirmed against the unit’s technical documentation.

During maintenance, technicians should verify output voltage under load, inspect terminal connections, and investigate abnormal heating or unstable output. A power supply that appears normal without a load may still require testing under representative operating conditions.

Role in Industrial Automation Systems

The Allen-Bradley 1606-XL120DR provides the DC power required by many industrial control components. Although it does not execute control logic itself, the reliability of the power supply can directly affect the availability of PLCs, sensors, communication devices, and other connected equipment.

PLC Power Supply

A programmable logic controller requires a compatible power source to execute its control program and communicate with other automation devices. The 1606-XL120DR can be considered as a 24 V DC source for compatible PLC-related loads, provided the total current demand and electrical requirements are within its ratings.

When planning a control cabinet, engineers should calculate the combined consumption of the controller, I/O devices, communication modules, and associated field equipment rather than sizing the power supply based on the PLC alone.

Remote I/O and Sensor Circuits

Remote I/O modules and field sensors often rely on a stable 24 V DC supply. A correctly sized power supply can support these circuits and help maintain reliable signal acquisition and control.

Where different groups of devices have different electrical requirements, separate protected branches may be appropriate. This helps simplify troubleshooting and limits the impact of certain wiring faults.

Industrial Communication Equipment

Communication devices such as network switches, gateways, and interface modules may need continuous DC power to maintain data exchange between controllers and supervisory equipment.

The 1606-XL120DR can be used for compatible communication loads when the required voltage, current, and power quality are satisfied. Critical communication equipment may benefit from a properly engineered redundant power arrangement.

Control Panel Power Distribution

In an industrial control cabinet, the power supply commonly forms part of a larger DC distribution arrangement that includes protective devices, terminal blocks, relays, and field wiring.

The power supply should be selected according to the total load, operating environment, and required level of availability. Clear labeling and documented wiring arrangements can improve maintenance efficiency.

Industrial Applications

The 1606-XL120DR can be considered for a range of industrial applications that require regulated 24 V DC power. Its suitability depends on load demand, input availability, environmental conditions, and the intended redundancy arrangement.

1. PLC and Automation Cabinets

PLC cabinets commonly contain controllers, I/O modules, interface relays, sensors, and communication devices. The 1606-XL120DR can provide a suitable DC source for compatible devices within its rated output capacity.

For larger cabinets, engineers should divide loads into suitable branches and confirm that the power supply can handle both normal operating demand and expected startup currents.

2. Manufacturing Equipment

Automated manufacturing machinery often uses 24 V DC for control circuits, sensors, switches, and interface devices. A stable supply helps these components operate within their designed electrical limits.

The 1606-XL120DR can be used in suitable machine-control applications where its output power and installation requirements meet the equipment specifications.

3. Remote I/O Stations

Remote I/O stations collect signals from field devices and exchange information with a controller. A compatible 24 V DC supply can support the station’s electronics and associated field circuits.

The power demand of output devices, transmitters, and other connected loads must be considered separately when determining whether one supply can support the complete station.

4. Process Control Equipment

Process control systems may use sensors, interface relays, communication devices, and auxiliary control equipment that operate from 24 V DC.

A suitable supply can support these devices in applications such as water treatment, material processing, and general manufacturing. Critical applications should evaluate whether redundant power supplies or additional monitoring are required.

5. Industrial Control and Distribution Panels

The compact DIN rail design makes the 1606-XL120DR appropriate for consideration in space-conscious electrical panels.

Panel designers must account for ventilation, electrical clearance, wiring access, and the heat generated by the complete installation. The listed dimensions should be checked against the available mounting space before replacement.

Installation and System Integration

Correct installation is important for safe and reliable operation. Qualified personnel should follow the manufacturer’s instructions, applicable electrical codes, and the site’s maintenance procedures.

1. Confirm the Input Voltage

The 1606-XL120DR supports manually selectable 115 V or 230 V AC input configurations. Verify the incoming supply and position the selector correctly before energizing the unit.

The power supply also supports a specified DC input range. DC input wiring must follow the manufacturer’s requirements, including the appropriate selector position and terminal identification.

Never assume that the unit is configured for the correct input voltage based solely on its physical appearance.

2. Calculate the Connected Load

The rated output is 24 V DC at 5 A, equivalent to 120 W. Calculate the expected current consumption of all connected devices before installation.

Allow for transient loads, device startup current, and possible future additions to the control system. If the total load exceeds the rated capacity, select a suitably rated supply or redesign the distribution arrangement.

3. Install on the DIN Rail

Mount the module securely on a compatible DIN rail in accordance with the manufacturer’s installation instructions. Ensure that the mounting arrangement is stable and that terminal connections remain accessible for inspection and maintenance.

The enclosure dimensions are 64 × 124 × 102 mm. The overall panel layout should also allow sufficient space for wiring, ventilation, and safe service access.

4. Provide Adequate Ventilation

The power supply relies on suitable thermal conditions to operate reliably. Follow the recommended clearances around the module and avoid obstructing the ventilation path.

High ambient temperatures, restricted airflow, and excessive electrical loading can increase component temperatures and affect service life.

5. Design Redundant Power Correctly

Where N+1 redundancy is required, verify that the selected supplies, wiring, and load distribution are suitable for the intended arrangement.

Confirm the total load, the capacity available following a single-supply failure, and the method used to prevent a fault in one supply from affecting the remaining supply. Follow the manufacturer’s recommended redundant configuration rather than improvising connections.

6. Verify Output Voltage

After wiring and before connecting sensitive equipment, verify that the output voltage is within the specified range. After connecting the load, check the output under representative operating conditions.

If the voltage drops unexpectedly, inspect the load demand, wiring, terminal tightness, and operating temperature before concluding that the power supply itself is defective.

7. Document the Installation

Record the input configuration, output connections, branch protection, connected loads, and any redundant power arrangement. This information can reduce troubleshooting time and help prevent wiring errors during future maintenance.

Compatible System Components

The following components are examples of equipment commonly used alongside a 24 V DC industrial power supply. Actual compatibility depends on the voltage and current requirements of each device.

These are general integration examples rather than a list of components included with the 1606-XL120DR.

Alternative Models and Replacement Considerations

The 1606-XL120DR has been discontinued, and the manufacturer does not list a planned direct replacement for this exact model. Any alternative should be selected according to the electrical requirements of the application.

The models above are comparison references, not automatic replacements. In particular, a standard power supply should not be assumed to provide the same redundancy functions as the 1606-XL120DR.

Before choosing an alternative, confirm:

• Input voltage and frequency.
• Output voltage and continuous current.
• Total load and transient demand.
• Redundancy requirements.
• DIN rail mounting and physical dimensions.
• Terminal arrangement and wiring requirements.
• Operating temperature and ventilation requirements.
• Available status monitoring and diagnostics.
• Manufacturer documentation and product condition.

For existing automation cabinets, record the current wiring and load distribution before replacing the power supply. A replacement with a different form factor or terminal arrangement may require panel modifications.

Key Advantages of the 1606-XL120DR

1. Regulated 24 V DC Output

The power supply provides a nominal 24 V DC output suitable for a broad range of compatible industrial control devices.

2. 120 W Output Capacity

Its 5 A output rating supports small to medium DC loads when the total demand remains within the specified limits.

3. Flexible Input Configuration

The selectable AC input configuration and supported DC input range provide flexibility for appropriately designed industrial power systems.

4. Redundancy-Oriented Design

The model is designed for N+1 redundant power arrangements. When properly engineered, this approach can improve power availability for critical control loads.

5. Compact DIN Rail Installation

The compact enclosure supports installation in industrial cabinets where mounting space and convenient access are important.

6. Industrial Control Applications

The module can support compatible PLC-related equipment, field sensors, interface relays, remote I/O, and communication devices requiring 24 V DC power.

Technical FAQs

1. What is the Allen-Bradley 1606-XL120DR?

The 1606-XL120DR is an industrial switching power supply from the Allen-Bradley Bulletin 1606 Power Supply XL series. It provides a regulated 24 V DC output with a rated capacity of 120 W.

2. What is the rated output current?

The rated output current is 5 A at 24 V DC, corresponding to a nominal output power of 120 W.

3. What input voltage does the unit support?

It supports manually selectable 100–120 V AC or 200–240 V AC input configurations, with an AC frequency of 47–63 Hz. It also supports a specified DC input range of 210–375 V DC.

4. Can the 1606-XL120DR be used in a redundant power system?

Yes. It is designed for N+1 redundant power arrangements. The actual redundancy configuration must follow the manufacturer’s requirements and account for total load, wiring, and fault isolation.

5. What are the dimensions and weight?

The supplied product information lists dimensions of 64 × 124 × 102 mm and a weight of 0.61 kg. The specified enclosure dimensions do not include all possible external wiring or panel clearance requirements.

6. Is the unit DIN rail mounted?

Yes. It is designed for DIN rail mounting in an appropriately designed electrical control cabinet.

7. Is the 1606-XL120DR still manufactured?

No. Rockwell Automation lists this model as discontinued, effective December 31, 2020. Availability may depend on remaining inventory or the industrial surplus market.

8. Is there a direct manufacturer replacement?

The manufacturer does not list a planned direct replacement for this exact model. A suitable alternative should be selected by comparing input range, output capacity, redundancy functions, dimensions, and system requirements.

9. What should be checked before purchasing a used module?

Verify the complete catalog number, physical condition, terminal condition, output voltage, operation under load, and any signs of overheating or damage. For critical applications, request appropriate functional testing and confirm the product’s condition with the supplier.

10. Can it power all devices in a control cabinet?

Only if the combined load remains within its ratings and each connected device is compatible with its output. Calculate the total load rather than assuming that a 120 W supply can support every device in a cabinet.

Procurement and Maintenance Recommendations

When sourcing the Allen-Bradley 1606-XL120DR, verify the full catalog number and inspect the unit’s condition. Because this model is discontinued, it is particularly important to confirm whether the offered product is new old stock, used, or refurbished.

For replacement projects, record the existing input selector position, output voltage, connected loads, and redundancy arrangement. Confirm that any alternative provides the required 24 V DC output and the necessary current capacity.

During maintenance, inspect the module for loose terminals, damaged wiring, excessive heat, or other signs of deterioration. Measure the output voltage under representative load conditions and investigate any abnormal fluctuations.

Before working on the unit, isolate the supply and follow the site’s electrical safety procedures. Verify that the equipment is de-energized before disconnecting wiring or removing the module from its mounting rail.

For international procurement, confirm the exact product condition, packaging, included accessories, and shipping dimensions with the supplier. If the module is intended for an existing machine, provide the original model number and the connected load requirements to help assess suitability.

Conclusion

The Allen-Bradley 1606-XL120DR Power Supply Module is a compact 24 V DC industrial power supply rated at 120 W and 5 A. Its selectable AC input configuration, supported DC input range, DIN rail mounting, and suitability for N+1 redundant arrangements make it relevant to a range of industrial control applications.

Although the model has been discontinued, it remains important for legacy system maintenance and replacement planning. Confirming the input configuration, load requirements, redundancy design, and product condition helps ensure that the selected power supply is appropriate for the intended industrial application.