Puls MiniLine-2, MiniLine-2 ML120.244 Series Manual

ML120.244

MiniLine-2

GENERAL DESCRIPTION

The MiniLine-2 series covers the lower power
requirements in the range from 15W to 120W. These
units in their rugged plastic housing and large screw
terminals are highly efficient, very compact, easy to
install and are extremely reliable. Besides the standard
24V power supplies, many other output voltages are
also available as well as units rated down to -40°C.

More DIN-Rail power supplies in rugged plastic housings
can be found in the MiniLine family which is equipped
with quick-connect spring-clamp terminals. These units
come in power ranges from 25W to 100W and a variety
of output voltages.

The ML120 units are highly immune against electrical
disturbances on the mains and provides reliable output
power. This offers superior protection for equipment
which is connected to the public mains network or is
exposed to a critical industrial environment.

Besides the cost optimized ML120.244, two additional
units are available in the ML120 series. The
ML120.CLASS2 fulfills the NEC Class 2 requirements and
the ML120.241 is the standard product with an auto­select 100-120/220-240V input.

The supplementary MiniLine-2 redundancy module
MLY10.241 allows building of redundant systems or
protecting against back-feeding voltages.

ORDER NUMBERS

Power Supply ML120.244 24V Standard unit

Accessory MLY10.241 Redundancy module

YRM2.DIODE Redundancy module
with alarm contacts
UF20.241 Buffer Module

24V, 5A, SINGLE PHASE INPUT

OWER SUPPLY

P

 AC 200-240V Regional Input
 Efficiency up to 90.3%
 Compact Design, Width only 72.5mm
 Full Power between -10°C and +60°C
 Large International Approval Package
 Cost / Performance Optimized
 3 Year Warranty

SHORT-FORM DATA

Output voltage DC 24V
Adjustment range 24V
Output current 5A
Output power 120W
Output ripple < 50mVpp 20Hz to 20MHz
Input voltage AC 200-240V -15% / +10%
Mains frequency 50-60Hz ±6%
AC Input current 1.07A
Power factor 0.54
AC Inrush current typ. 31A peak value at

230Vac 40°C and

cold start
DC Input -
Efficiency 90.3%
Losses 12.9W
Temperature range -10°C to +70°C operational
Derating 3W/°C +60 to +70°C
Hold-up time typ. 35ms
Dimensions 72.5x75x103mm WxHxD
Weight 360g / 0.8lb

MARKINGS

Ind. Cont. Eq.

UL 508, pending

Class I Div 2, pend.

UL 60950-1

pending

Marine, pending

EMC, LVD, RoHS

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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ML120.244

MiniLine-2

24V, 5A, SINGLE PHASE INPUT

INDEX

Page Page

1.

Intended Use .......................................................3

2. Installation Requirements...................................3

3. AC-Input...............................................................4

4. Input Inrush Current ...........................................5

5. DC-Input...............................................................5

6. Output .................................................................6

7. Hold-up Time.......................................................7

8. Efficiency and Power Losses................................8

9. Functional Diagram.............................................9

10. Front Side and User Elements.............................9

11. Terminals and Wiring........................................10

12. Lifetime Expectancy and MTBF.........................10

13. EMC....................................................................11

14. Environment......................................................12

15. Protection Features ...........................................13

16. Safety Features ..................................................13

17. Dielectric Strength ............................................13

18. Approvals...........................................................14

19. Fulfilled Standards ............................................14

The information presented in this document is believed to be accurate and reliable and may change without notice.
The housing is patent by PULS (US patent No US D442,923S).
No part of this document may be reproduced or utilized in any form without permission in writing from the publisher.

20. Physical Dimensions and Weight..................... 15

21. Accessory........................................................... 16

21.1. Buffer module UF20.241 ..........................16

21.2. Redundancy Modules ............................... 16

22. Application Notes............................................. 17

22.1. Peak Current Capability ...........................17

22.2. Back-feeding Loads ..................................17

22.3. Charging of Batteries ...............................18

22.4. External Input Protection.........................18

22.5. Parallel Use to Increase Output Power....18

22.6. Parallel Use for Redundancy ....................19

22.7. Daisy Chaining of Outputs ....................... 19

22.8. Inductive and Capacitive Loads................19

22.9. Series Operation .......................................20

22.10. Operation on Two Phases ........................20

22.11. Use in a Tightly Sealed Enclosure ............20

22.12. Mounting Orientations ............................21

TERMINOLOGY AND ABREVIATIONS

PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol .

Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”.

T.B.D. To be defined, value or description will follow later.

AC 230V A figure displayed with the AC or DC before the value represents a nominal voltage with

standard tolerances (usually ±15%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)

230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional

tolerances included.

50Hz vs. 60Hz As long as not otherwise stated, AC 100V and AC 230V parameters are valid at 50Hz and AC

120V parameters are valid at 60Hz mains frequency.

may A key word indicating flexibility of choice with no implied preference.

shall A key word indicating a mandatory requirement.

should A key word indicating flexibility of choice with a strongly preferred implementation.

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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ML120.244

MiniLine-2

24V, 5A, SINGLE PHASE INPUT

1. INTENDED USE

This device is designed for installation in an enclosure and is intended for the general use such as in industrial control,
office, communication, and instrumentation equipment.

Do not use this power supply in equipment, where malfunction may cause severe personal injury or threaten human
life.

2. INSTALLATION REQUIREMENTS

This device may only be installed and put into operation by qualified personnel.
This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to

the factory for inspection.
Mount the unit on a DIN-rail so that the output terminals are located on top and input terminal on the bottom. For

other mounting orientations see de-rating requirements in this document.
This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do

not cover ventilation grid (e.g. cable conduits) by more than 15%!
Keep the following installation clearances:

- on top 40mm

- on the bottom 20mm

- Left and right: 0mm (or 15mm in case the adjacent device is a heat source; in example another power supply, …).

WARNING

- Do not use the power supply without proper grounding (Protective Earth). Use the terminal on the input block for
earth connection.

- Turn power off before working on the device. Protect against inadvertent re-powering.

- Make sure that the wiring is correct by following all local and national codes.

- Do not modify or repair the unit.

- Do not open the unit as high voltages are present inside.

- Use caution to prevent any foreign objects from entering into the housing.

- Do not use in wet locations or in areas where moisture or condensation can be expected.

- Do not touch during power-on, and immediately after power-off. Hot surface may cause burns.

Notes for use in hazardous location areas:

The power supply is suitable for use in Class I Division 2 Groups A, B, C, D locations.

WARNING EXPLOSION HAZARDS!

Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the
voltage adjustment unless power has been switched off or the area is known to be non-hazardous.

A suitable enclosure must be provided for the end product which has a minimum protection of IP54 and fulfils the
requirements of the EN 60079-15:2010.

Risk of electrical shock, fire, personal injury or death.

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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ML120.244

MiniLine-2

24V, 5A, SINGLE PHASE INPUT

3. AC-INPUT

AC input nom. AC 200-240V -15% / +10%
Allowed mains networks TN/ TT/ IT-mains
AC input range 170-264Vac continuously allowed
0-170Vac no damage to the unit
264–300Vac < 0.5s
Allowed voltage L or N to earth max. 300Vac continuously allowed, IEC 62103
Input frequency nom. 50–60Hz ±6%
Input current (rms) typ. 1.07A at 24V, 5A see Fig. 3-3
Power factor*) typ. 0.54 at 24V, 5A see Fig. 3-4
Crest factor
Start-up delay typ. 80ms see Fig. 3-2
Rise time typ. 65ms at 24V, 5A const. current load, 0mF load

175ms at 24V, 5A const. current load, 5mF load

Turn-on overshoot max. 200mV see Fig. 3-2
Turn-on voltage typ. 158Vac steady-state value, see Fig. 3-1
Shut-down voltage typ. 134Vac steady-state value, see Fig. 3-1

*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
**) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.

Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, definitions

**)

typ. 4.0 at 24V, 5A

capacitance, Fig. 3-2

capacitance

P

OUT

Rated input range

Input
Voltage

Turn-on

Shut-down

V

IN

170V

264Vac

Output
Voltage

- 5%

Start-up

delay

Rise

Time

Overshoot

Fig. 3-3 Input current vs. output load at 24V Fig. 3-4 Power factor vs. output load at 24V

Input Current, typ.

1.4A

1.2

1.0

0.8

0.6

0.4

0.2

0

0.5 1 1.5 2 2.5 3 3.5 4 4.5

Output Current

5A

Power Factor, typ.

0.65

0.60

0.55

0.50

0.45

0.40

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5A

Output Current

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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ML120.244

MiniLine-2

24V, 5A, SINGLE PHASE INPUT

4. INPUT INRUSH CURRENT

A NTC limits the input inrush current after turn-on of the input voltage. The inrush current is input voltage and
ambient temperature dependent.

The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.

Inrush current max. 37A
typ. 28A
typ. 23A
Inrush energy typ. 1A

Fig. 4-1 Input inrush current, typical behavior

230Vac input, 24V 5A output, 25°C ambient

Input
Current

10A/DIV

Input Voltage

- 500V/DIV

Fig. 4-2 Input inrush current, zoom into first peak
230Vac input, 24V 5A output, 25°C ambient

40°C ambient, cold start

peak

40°C ambient, cold start

peak

25°C ambient, cold start

peak

2

s 40°C ambient, cold start

Ipeak = 23A

Output
Voltage

20V/DIV

40ms/DIV

Input Current

1ms/DIV

- 5A/DIV

5. DC-INPUT

Do not operate this power supply with DC-input voltage. Use the ML120.241 unit instead.

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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ML120.244

MiniLine-2

24V, 5A, SINGLE PHASE INPUT

6. OUTPUT

Output voltage nom. 24V
Adjustment range min. fixed no adjustment included
Factory setting 24.5V ±3%, at full load, cold unit
Line regulation max. 10mV 85-264Vac
Load regulation max. 100mV static value, 0A Æ 5A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 3 000μF
Output current nom. 5A at 24V, see Fig. 6-1
nom. 4.3A at 28V, see Fig. 6-1
peak 25A The full output voltage cannot be maintained and the

output voltage will drip to lower values. Detailed

curves can be found in chapter22.1.
Output power nom. 120W
Short-circuit current min. 7.8A load impedance 200mOhm, see Fig. 6-1
max. 9.2A load impedance 200mOhm, see Fig. 6-1
max. 8.5A load impedance <10mOhm, see Fig. 6-1

Fig. 6-1 Output voltage vs. output current,

Output Voltage

28V

24

20

16

12

8

4
0

024

typ.

Output Current

8A531 67

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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6/21

ML120.244

MiniLine-2

24V, 5A, SINGLE PHASE INPUT

7. HOLD-UP TIME

Hold-up Time typ. 71ms at 24V, 2.5A, see Fig. 7-1
min. 60ms at 24V, 2.5A, see Fig. 7-1
typ. 35ms at 24V, 5A, see Fig. 7-1
min. 30ms at 24V, 5A, see Fig. 7-1

Note: At no load, the hold-up time can be up to several seconds. The green DC-on LED is also on during this time

Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, definitions

Hold-up Time

90ms

75

60

45

30

15

0

200 210 230 240 260Vac

Input Voltage

220

a

a) 24V 2.5A typ.
b) 24V 2.5Amin.
c) 24V 5A typ.
d) 24V 5A min.

250

b

c
d

Input
Voltage

Output
Voltage

Zero Transition

Hold-up Time

- 5%

Apr. 2013 / Rev. 1.1 DS-ML120.244-EN
All parameters are specified at 24V, 5A, 230Vac input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

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