Allen-Bradley 1606-XLE240EE Migration-Ready Power Supply

Overview

Allen-Bradley 1606-XLE240EE Migration-Ready Power Supply for Legacy Control Systems

The Allen-Bradley 1606-XLE240EE is a 240W, 24VDC DIN Rail-mount power supply engineered for demanding industrial environments. As legacy control panels age and original 1606-XLE series units reach end-of-life, the 1606-XLE240EE serves as a verified drop-in replacement that preserves existing wiring layouts, terminal assignments, and DIN rail footprints — minimizing retrofit risk and reducing planned downtime to a single maintenance window.

For facilities running aging Allen-Bradley SLC 500, MicroLogix 1500, or early ControlLogix L6x-series control cabinets, power supply obsolescence is one of the most common triggers for unplanned shutdowns. The 1606-XLE240EE addresses this directly: its 45mm DIN rail profile, screw-terminal input/output block, and 24VDC ±1% regulated output are dimensionally and electrically compatible with the original 1606-XLE240E and 1606-XLE240E-2 units it replaces. No busbar modifications, no new cable runs, and no PLC program changes are required in the vast majority of retrofit scenarios.

When planning a power supply migration, engineers should verify the following before installation: total connected load current draw across all 24VDC consumers (I/O modules, relays, solenoids, HMI panels), input voltage range at the panel feed (85–264VAC wide-range input is supported), available DIN rail space and adjacent module clearance, and terminal torque specifications to ensure reliable long-term connections. The 1606-XLE240EE’s output terminals accept up to 10 AWG conductors, consistent with the original unit’s wiring harness in most installations.

Migration Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful power supply retrofit in an active production environment requires more than a part swap. The 1606-XLE240EE is typically deployed alongside other 1606-XLE series units — such as the 1606-XLE120E (120W, 5A) for auxiliary 24VDC circuits and the 1606-XLE480E (480W, 20A) for high-demand servo and drive control panels — allowing engineers to right-size power distribution across multiple DIN rail segments without redesigning the cabinet layout.

In SLC 500 and MicroLogix-based panels, the 24VDC bus fed by the 1606-XLE240EE typically powers the 1746-IB16 or 1746-OB16 discrete I/O modules, relay output cards, and field device loops. Before replacing the power supply, document the current draw of each connected load using a clamp meter. If the existing panel also includes a 1747-L553 SLC 5/05 processor with an Ethernet communication module, confirm that the processor’s backplane power draw is within the new supply’s derating curve at the panel’s ambient temperature.

For ControlLogix L6x migration projects, the 1606-XLE240EE is commonly used to power the 24VDC field I/O segment while the chassis backplane is fed by a dedicated 1756-PA75 or 1756-PB75 chassis power supply. In these architectures, the DIN rail power supply and the chassis PSU operate on independent circuits — a critical detail when sizing the panel’s main breaker and verifying UPS runtime during a controlled switchover.

Panels undergoing a communication protocol migration — for example, from DH+ or Remote I/O to EtherNet/IP — often require the addition of a 1756-EN2T EtherNet/IP communication module or a 1747-AENTR adapter. These modules draw additional 24VDC current from the DIN rail bus, and the 1606-XLE240EE’s 10A output provides sufficient headroom for most mixed-protocol transition architectures. If the retrofit also involves adding a 2711P-T10C4D8 PanelView Plus 6 HMI, account for its 24VDC input current (typically 1.5–2.5A) in the total load budget before finalizing the power supply selection.

Installation space confirmation is essential in legacy panels where DIN rail segments are densely populated. The 1606-XLE240EE’s 45mm width and 124mm height allow it to fit in the same slot vacated by the original unit. Verify that adjacent terminal blocks, cable ducts, and grounding bars do not obstruct the unit’s ventilation slots — a minimum 50mm clearance above and below is recommended for rated output at 60°C ambient.

Downtime Control During System Migration

Minimizing production downtime during a power supply replacement is the primary concern for maintenance engineers. The 1606-XLE240EE’s direct dimensional and electrical compatibility with the legacy 1606-XLE240E means that a planned replacement can typically be completed within a single 2–4 hour maintenance window, without requiring PLC program downloads, I/O address remapping, or HMI screen modifications.

The recommended procedure is to photograph the existing terminal wiring before disconnection, label each conductor with its terminal number, and perform a controlled shutdown of the PLC system using the processor’s keyswitch or software stop command — preserving the last-known program state in battery-backed RAM. After installing the 1606-XLE240EE, perform a no-load output voltage check before reconnecting field devices, then bring loads online incrementally: first the PLC backplane, then I/O modules, then field devices and HMI panels.

For facilities that cannot tolerate a full shutdown, a parallel energization strategy is possible: mount the new 1606-XLE240EE on an adjacent DIN rail segment, bring it to rated voltage, then transfer loads one circuit at a time using the existing terminal block jumpers. This approach is particularly effective in panels where the 24VDC bus is segmented by fuse blocks or circuit breakers, allowing individual load groups to be transferred without interrupting the entire control system.

All units supplied by KNMKS undergo pre-shipment functional testing at rated load, output voltage verification, and visual inspection. Each 1606-XLE240EE is shipped with a support terms confirmed by quotation covering manufacturing defects and premature failure under rated operating conditions. Firmware is not applicable to this product class — no firmware update procedures are required during commissioning.

Retrofit Support FAQ

Q1: Is the 1606-XLE240EE a direct replacement for the 1606-XLE240E and 1606-XLE240E-2?
Yes. The 1606-XLE240EE shares the same 240W / 24VDC / 10A output rating, 45mm DIN rail width, and screw-terminal wiring interface as the 1606-XLE240E and 1606-XLE240E-2. The primary difference is the addition of a DC input range (90–375VDC) on the EE variant, which provides greater flexibility in panels with DC bus backup systems. No wiring changes or program modifications are required for a standard replacement.

Q2: What commissioning steps are required after installation?
After mounting and wiring, perform the following: (1) verify input voltage at the terminal before energizing; (2) check no-load output voltage with a calibrated multimeter — it should read 24.0–24.5VDC; (3) connect loads incrementally and verify output voltage remains within ±1% at full load; (4) re-torque all terminals to the specified value (0.5–0.6 Nm for standard screw terminals); (5) run a 30-minute burn-in at 80% rated load and confirm no thermal alarms or output deviations.

Q3: How do I verify compatibility with my existing panel wiring and I/O modules?
Confirm that the total 24VDC load current of all connected devices (I/O modules, relays, HMI, solenoids) does not exceed 10A (240W). Check that input conductor sizing matches the panel’s feed circuit. The 1606-XLE240EE accepts the same conductor sizes and terminal types as the original unit, so existing wiring harnesses are reusable in the vast majority of installations. If your panel uses a 1746 or 1756 series backplane, verify the backplane’s 24VDC input current specification in the system design guide.

Q4: What does the support terms confirmed by quotation cover, and what is KNMKS’s stock availability?
The support terms confirmed by quotation cover manufacturing defects, premature component failure, and output voltage deviation beyond rated tolerance under normal operating conditions. It does not cover damage from incorrect installation, overvoltage input, or physical impact. KNMKS maintains in-stock inventory of the 1606-XLE240EE and ships within 1–3 business days of order confirmation. For urgent retrofit projects or bulk orders, contact admin@knmks.com or call +86 18359268345 for lead time confirmation and volume pricing.

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Allen-Bradley
Allen-Bradley

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1606-XLE240EE

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Power Supplies

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