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.
www.pulspower.com Phone +49 89 9278 0 Germany
1/21
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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2/21
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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3/21
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.
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7/21
A
A
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
8. EFFICIENCY AND POWER LOSSES
Efficiency typ. 90.3% at 24V, 5A (full load)
Average efficiency*)
Power losses typ. 0.8W at 0A
typ. 7.1W at 24V, 2.5A (half load)
typ. 12.9W at 24V, 5A (full load)
*) The average efficiency is an assumption for a typical application where the power supply is loaded with 25% of the nominal load for 25%
of the time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of the time and with 100%
of the nominal load for the rest of the time.
Fig. 8-1 Efficiency vs. output current at 24V,
typ.
Efficiency
91%
90
89
88
87
86
85
84
83
0.5
Output Current
22.5 413
1.5 3.5 4.5
5
Fig. 8-3 Efficiency vs. input voltage at 24V,
Efficiency
91%
90
89
88
87
86
85
185 200
5A, typ.
Input Voltage
230 245 260Vac
215
88.7% 25% at 1.25A, 25% at 2.5A, 25% at 3.75A.
25% at 5A
Fig. 8-2 Losses vs. output current at 24V,
Power Losses
16W
Fig. 8-4 Losses vs. input voltage at 24V, 5A,
Power Losses
18W
14
12
10
8
6
4
2
0
0
16
14
12
10
185 200
typ.
Output Current
234
15
typ.
Input Voltage
230 245 260Vac
215
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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8/21
ML120.244
MiniLine-2
9. FUNCTIONAL DIAGRAM
L
N
Input Fuse
&
Input Filter
Fig. 9-1 Functional diagram
Output Over-
Protection
Input
Rectifier
&
Inrush
Limiter
10. FRONT SIDE AND USER ELEMENTS
Fig. 10-1 Front side
A
Output Terminals
Screw terminals
Dual terminals for the negative and positive pole.
Both poles are equal
+ Positive output
- Negative (return) output
Input Terminals
B
Screw terminals
L Phase (Line) input
N Neutral conductor input
C DC-on LED (green)
24V, 5A, SINGLE PHASE INPUT
Voltage
Power
Converter
Opto-
coupler
Output
Filter
Output
Voltage
Regulator
PE (Protective Earth) input
On, when the voltage on the output terminals is > 20V (±4%)
DC
ok
+
+
-
-
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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9/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
11. TERMINALS AND WIRING
All terminals are easy to access when mounted on the panel. Input and output terminals are separated from each
other (input below, output above) to help in error-free wiring.
Type
Solid wire 0.5-6mm2 0.5-6mm2
Stranded wire 0.5-4mm2 0.5-4mm2
American Wire Gauge 20-10 AWG 20-10 AWG
Max. wire diameter 2.8mm including ferrules 2.8mm including ferrules
Wire stripping length 7mm / 0.275inch 7mm / 0.275inch
Recommended tightening torque 1Nm, 9lb.in 1Nm, 9lb.in
Screw driver 3.5mm slotted or Philips No 2 3.5mm slotted or Philips No 2
Instructions:
a) Use appropriate copper cables that are designed for minimum operating temperatures of:
- 60°C for ambient up to 45°C,
- 75°C for ambient up to 60°C and
- 90°C for ambient up to 70°C minimum.
b) Follow national installation codes and installation regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Do not use the unit without PE connection.
e) Screws of unused terminal compartments should be securely tightened.
f) Ferrules are allowed.
Input Output
Screw terminals Screw terminals
12. LIFETIME EXPECTANCY AND MTBF
The power supply is extremely reliable and use only the highest quality materials. The number of critical components
such as electrolytic capacitors has been reduced.
AC 230V
Lifetime expectancy
96 000h at 24V, 2.5A and 40°C
106 000h at 24V, 5A and 25°C
**)
MTBF
T.B.D. at 24V, 5A and 25°C
MTBF
T.B.D. at 24V, 5A , 25°C; Ground Benign GB25
T.B.D. at 24V, 5A , 40°C; Ground Fixed GF40
T.B.D. at 24V, 5A , 25°C; Ground Fixed GF25
*) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime
**) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a
A MTBF figure of e.g. 1 000 000h means that statistically one device will fail every 100 hours if 10 000 devices are installed in the field.
SN 29500, IEC 61709 T.B.D. at 24V, 5A and 40°C
**)
MIL HDBK 217F T.B.D. at 24V, 5A , 40°C; Ground Benign GB40
expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours and is calculated according to the
capacitor’s manufacturer specification. The manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years
(131 400h). Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices.
device. It is the statistical representation of the likelihood of a device to fail and does not necessarily represent the life of a product.
However, it can not be determined if the failed device has been running for 50 000h or only for 100h.
*)
37 000h at 24V, 5A and 40°C
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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10/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
13. EMC
The power supply is suitable for applications in industrial environment as well as in residential, commercial and light
industry environment without any restrictions. A detailed EMC report is available on request.
EMC Immunity
Electrostatic discharge EN 61000-4-2 Contact discharge
Electromagnetic RF field EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Surge voltage on input EN 61000-4-5
Surge voltage on output EN 61000-4-5 + Æ -
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 0% of 200Vac
Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C
Input voltage swells PULS internal standard 300Vac, 500ms Criterion A
Powerful transients VDE 0160 over entire load range 750V, 1.3ms Criterion A
Criterions:
A: Power supply shows normal operation behavior within the defined limits.
B: The power supply operates continuously during and after the test. During the test minor temporary impairments may occur, which will be
corrected by the power supply itself.
C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. No damage or hazards for the power supply
will occur.
EMC Emission
Conducted emission
input lines
Conducted emission
output lines
Radiated emission EN 55011, EN 55022, CISPR 11, CISPR 22 Class B
Harmonic input current EN 61000-3-2 Class A fulfilled
Voltage fluctuations, flicker*) EN 61000-3-3 Fulfilled
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.
*) tested with constant current loads, non pulsing
**) Restrictions apply for applications in residential, commercial and light-industrial environments, where local DC power networks according
to EN 61000-6-3 are involved. No restrictions for all kinds of industrial applications.
Switching frequency
Converter frequency variable, typ. 100kHz, min. 60kHz, max. 260kHz Input voltage and output
Generic standards: EN 61000-6-1 and EN 61000-6-2
8kV
Air discharge
Output lines
DC-OK Signal (coupling clamp)
L Æ N
N Æ PE, L Æ PE
+ Æ PE, - Æ PE
40% of 200Vac
70% of 200Vac
Generic standards: EN 61000-6-3 and EN 61000-6-4
EN 55011, EN 55022, FCC Part 15,
CISPR 11, CISPR 22
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Limits for DC power port acc. EN
8kV
4kV
2kV
2kV
2kV
4kV
1kV
2kV
0Vac, 20ms
80Vac, 200ms
140Vac, 500ms
Class B
61000-6-3 not fulfilled
load dependent
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
**)
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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11/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
14. ENVIRONMENT
Operational temperature
Storage temperature -40°C to +85°C (-40°F to 185°F) for storage and transportation
Output de-rating 3W/°C 60-70°C (140°F to 158°F)
Humidity
**)
5 to 95% r.H. IEC 60068-2-30
Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
Shock 15g 6ms, 10g 11ms
Altitude 0 to 2000m (0 to 6 560ft) without any restrictions
2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature
Altitude de-rating 7.5W/ 1000m or 5°C/1000m > 2000m (6500ft), see Fig. 14-2
Over-voltage category III IEC 62103, EN 50178, altitudes up to 2000m
II altitudes from 2000m to 6000m
Degree of pollution 2 IEC 62103, EN 50178, not conductive
LABS compatibility The unit does not release any silicone or other LABS-critical substances and is suitable for
*) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit.
**) Do not energize while condensation is present
Fig. 14-1 Output power vs. ambient temp. Fig. 14-2 Output power vs. altitude
Allowed Output
Current at 24V
5A
4
3
2
1
0
-10
Ambient Temperature
02040
*)
-10°C to +70°C (14°F to 158°F) reduce output power according Fig. 14-1
IEC 60068-2-6
2 hours / axis
IEC 60068-2-27
3 bumps / direction, 18 bumps in total
see Fig. 14-2
IEC 62103, EN 50178, overvoltage category II
use in paint shops.
Allowed Output
Current at 24V
Altitude
C
B
A
6000m
60
70°C
5A
4
3
2
.
A
.
a
T
.
b
m
<
6
°
C
B
.
T
.
1
.
C
.
T
.
.
0
a
b
m
<
5
°
C
0
a
b
m
<
4
°
C
0
0
0 2000
4000
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
15. PROTECTION FEATURES
Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 31Vdc
max. 33Vdc
Output over-current protection electronically limited see Fig. 6-1
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 2.5mm in diameter e.g. screws, small parts
Over-temperature protection not included
Input transient protection MOV Metal Oxide Varistor
Internal input fuse T3.15A H.B.C. not user replaceable
*) In case of a protection event, audible noise may occur.
In case of an internal power supply fault, a redundant
circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
16. SAFETY FEATURES
Input / output separation SELV
PELV
Class of protection I PE (Protective Earth) connection required
Isolation resistance > 5MOhm Input to output, 500Vdc
Touch current (leakage current) typ. 0.56mA / 1.17mA 230Vac, 50Hz, TN-,TT-mains / IT-mains
< 0.75mA / 1.45mA 264Vac, 50Hz, TN-,TT-mains / IT-mains
*) Double or reinforced insulation
*)
IEC/EN 60950-1
*)
IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
*)
17. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to the ground. Type and factory tests are conducted by
the manufacturer. Field tests may be conducted in the field using the appropriate test equipment which applies the
voltage with a slow ramp (2s up and 2s down). Connect all phase-terminals together as well as all output poles before
conducting the test. When testing, set the cut-off current settings to the value in the table below.
Fig. 17-1 Dielectric strength
Input
L
N
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.
A
Earth, PE
B
Output
+
C
-
www.pulspower.com Phone +49 89 9278 0 Germany
Type test 60s 2500Vac 3500Vac 1000Vac
Factory test 5s 2500Vac 2500Vac 500Vac
Field test 5s 2000Vac 2000Vac 500Vac
Cut-off current setting > 10mA > 10mA > 20mA
To fulfill the PELV requirements according to EN 60204-1 § 6.4.1,
we recommend that either the + pole, the – pole or any other part
of the output circuit shall be connected to the protective earth
system. This helps to avoid situations in which a load starts
unexpectedly or can not be switched off when unnoticed earth
faults occur.
A B C
13/21
ML120.244
MiniLine-2
18. APPROVALS
EC Declaration of
Conformity
nd
IEC 60950-1 2
pending
UL 508
pending
UL 60950-1 2nd Edition
pending
Marine
pending
GOST P
pending
Edition
The CE mark indicates conformance with the
- EMC directive 2004/108/EC,
IND. CONT. EQ.
- Low-voltage directive (LVD) 2006/95/EC and the
- RoHS directive 2011/65/EC.
CB Scheme,
Information Technology Equipment
Listed for the use as Industrial Control Equipment;
E-File: E198865
Recognized for the use as Information Technology Equipment,
Level 3 in U.S.A. (UL 60950-1) and Canada (C22.2 No. 60950-1);
E-File: E137006
Marine and offshore applications environmental category: C,
EMC2
GL (Germanischer Lloyd) classified
Certificate of Conformity for Russia and other GUS countries
24V, 5A, SINGLE PHASE INPUT
19. FULFILLED STANDARDS
EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN 50178, IEC 62103 Electronic Equipment in Power Installations
EN/IEC 61131-2 Programmable Controllers
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 +49 89 9278 0 Germany
14/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
20. PHYSICAL DIMENSIONS AND WEIGHT
Weight 360g / 0.8lb
DIN-Rail Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the unit depth (103mm) to calculate the total required
installation depth.
Installation Clearances See chapter 2
Fig. 20-1 Front view Fig. 20-2 Side view
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 +49 89 9278 0 Germany
15/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
21. ACCESSORY
21.1. BUFFER MODULE UF20.241
This buffer unit is a supplementary device for DC 24V power supplies. It delivers power to bridge typical mains failures
or extends the hold-up time after turn-off of the AC power. In times when the
power supply provides sufficient voltages, the buffer module stores energy in
integrated electrolytic capacitors. In case of mains voltage fault, this energy is
released again in a regulated process. One buffer module can deliver 20A which can
also be used to support peak current demands.
The buffer unit does not require any control wiring. It can be added in parallel to
the load circuit at any given point. Buffer
units can be added in parallel to increase
the output ampacity or the hold-up time.
AC
Power
Supply
DC
Buffer
Unit(s)
Load
+
-
21.2. REDUNDANCY MODULES
The MLY10.241 is a dual redundancy module, which has two diodes with a common
cathode included. It can be used for
various purposes. The most popular
application is to configure highly
reliable and true redundant power
supply systems. Another interesting
application is the separation of sensitive
loads from non-sensitive loads. This
avoids the distortion of the power
quality for the sensitive loads w
cause controller fail
ures.
The YRM2.DIODE is a redundancy module in a DIMENSION housing
which monitors both input voltages and reports failures with an alarm
signal.
hich can
ML120.244
II
L
N
+ +
Output
Input
L N
- -
- -
+ +
Output
ML120.244
Input
L N
-
+
+
IN 2
IN 1
MLY10.241
Output
- -
+
Voltage
Monitor
-
Load
-
+
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 +49 89 9278 0 Germany
16/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
22. APPLICATION NOTES
22.1. PEAK CURRENT CAPABILITY
The power supply can deliver peak currents up to several milliseconds.
This helps to start current demanding loads. Loads such as solenoids, contactors and pneumatic modules often have a
steady state coil and a pick-up coil. The inrush current demand of the pick-up coil is several times higher than the
steady-state current and usually exceeds the nominal output current. The same situation applies when starting a
capacitive load.
The peak current capability also ensures the safe operation of subsequent circuit breakers of load circuits. The load
branches are often individually protected with circuit breakers or fuses. In case of a short or an overload in one branch
circuit, the fuse or circuit breaker need a certain amount of over-current to open in a timely manner. This avoids
voltage loss in adjacent circuits.
The extra current (peak current) is supplied by the power converter and the built-in large sized output capacitors of
the power supply. The capacitors get discharged during such an event, which causes a voltage dip on the output. The
following two examples show typical voltage dips:
Fig. 22-1 Peak loading with 2x the nominal
current for 50ms, typ.
Fig. 22-2 Peak loading with 5x the nominal
current for 5ms, typ.
24.5V
10A
0A
10ms/DIV
Peak load 10A (resistive load) for 50ms
Output voltage dips from 24V to 16V.
Output
Voltage
16V
Output
Current
24.5V
t
u
p
t
u
e
O
g
a
lt
25A
0A
1ms/DIV
Peak load 25A (resistive load) for 5ms
Output voltage dips from 24V to 10.5V.
V
10.5V
Output
Current
o
Peak current voltage dips typ. from 24V to 16V at 10A for 50ms, resistive load
typ. from 24V to 16V at 25A for 2ms, resistive load
typ. from 24V to 10.5V at 25A for 5ms, resistive load
22.2. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called
return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force).
This power supply is resistant and does not show malfunctioning when a load feeds back voltage to the power supply.
It does not matter whether the power supply is on or off.
The maximum allowed feed-back-voltage is 35Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specified in chapter 6.
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 +49 89 9278 0 Germany
17/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
22.3. CHARGING OF BATTERIES
The power supply cannot be used to charge batteries since the output voltage is not adjustable and cannot be set to
the required end-of-charge voltage.
22.4. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 20A. An external protection is only required, if the supplying
branch has an ampacity greater than this. Check also local codes and local requirements. In some countries local
regulations might apply.
If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of
the circuit breaker. A minimum value of 10A B- or 6A C-Characteristic breaker should be used.
22.5. PARALLEL USE TO INCREASE OUTPUT POWER
All MiniLine power supplies with 24V output voltage can be paralleled to
increase the output power. The ML120.244 has no feature included which
balances the load current between the power supplies. Usually the power
supply with the higher adjusted output voltage draws current until it goes into
current limitation. This means no harm to the power supply as long as the
ambient temperature stays below 45°C.
If more than three units are connected in parallel, a fuse or circuit breaker
with a rating of 8A or 10A is required on each output. Alternatively, a diode or
redundancy module can also be utilized.
Keep an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power
supplies on top of each other. Do not use power supplies in parallel in mounting orientations other than the standard
mounting orientation (input terminals on bottom and output terminals on the top of the unit) or in any other
condition where a derating of the output current is required.
Be aware that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
Unit A
AC
Unit B
AC
DC
DC
+
-
+
-
+
Load
-
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 +49 89 9278 0 Germany
18/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
22.6. PARALLEL USE FOR REDUNDANCY
Voltage
Power supplies can be paralleled for redundancy to gain higher
system availability. Redundant systems require a certain amount of
extra power to support the load in case one power supply unit fails.
+ +
Output
- -
+ +
Output
- -
+
IN 1
-
+
IN 2
The simplest way is to put two power supplies in parallel. This is called
a 1+1 redundancy. In case one power supply unit fails, the other one is
automatically able to support the load current without any
interruption. Redundant systems for a higher power demand are
usually built in a N+1 method. E.g. five power supplies, each rated for
5A are paralleled to build a 20A redundant system.
ML120.244
II
L
N
Input
L N
ML120.244
Input
L N
MLY10.241
Output
- -
+
Please note: This simple way to build a redundant system does not
cover failures such as an internal short circuit in the secondary side of the power supply. In such a case, the defect unit
becomes a load for the other power supplies and the output voltage can not be maintained any more. This can only be
avoided by utilizing decoupling diodes which are included in the redundancy module MLY10.241 or YRM2.DIODE.
Recommendations for building redundant power systems:
a) Use separate input fuses for each power supply.
b) Use separate mains systems for each power supply whenever it is possible.
c) Monitor the individual power supply units. A monitoring circuit is included in the DIMENSION redundancy
module YRM2.DIODE, which can also be used as a redundancy module for the ML120.241 units.
d) 1+1 Redundancy is allowed up to an ambient temperature of 60°C.
N+1 Redundancy is allowed up to an ambient temperature of 45°C.
e) It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting.
Monitor
-
Load
+
-
22.7. DAISY CHAINING OF OUTPUTS
Daisy chaining (jumping from one power supply output to the next) is allowed as long as the average output current
through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.
Fig. 22-3 Daisy chaining of outputs Fig. 22-4 Using distribution terminals
Power
Supply
+ +
- -
Output
Power
Supply
+ +
- -
Output
max 25A!
continuous
Load
+
Output
+ +
-
- -
Power
Supply
Input
Output
+ +
- -
Power
Supply
Input
+
Load
Distribution
Terminals
-
22.8. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any type of load, including unlimited capacitive and inductive loads.
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 +49 89 9278 0 Germany
19/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
22.9. SERIES OPERATION
Power supplies of the exact same type can be connected in series for higher
output voltages. It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed 150Vdc. Voltages
with a potential above 60Vdc are not SELV any more and can be dangerous.
Such voltages must be installed with a protection against touching.
Earthing of the output is required when the sum of the output voltage is
above 60Vdc.
Avoid return voltage (e.g. from a decelerating motor or battery) which is
applied to the output terminals.
Unit A
AC
Unit B
AC
DC
DC
+
-
+
-
Keep an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power
supplies on top of each other. Do not use power supplies in series in mounting orientations other than the standard
mounting orientation (input terminals on the bottom and output terminals on top of the unit).
Be aware that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
+
Load
-
Earth
22.10. OPERATION ON TWO PHASES
The power supply can also be used on two-phases of a three-phase-system.
A phase-to-phase connection is allowed as long as the supplying voltage is
below 240V
N input is not internally protected and is in this case connected to a hot
wire. Appropriate fuses or circuit breakers are specified in section 0
“External Input Protection”.
+10%
. Use a fuse or a circuit breaker to protect the N input. The
L3
L1
max.
+10%
240V
L2
Power Supply
L
Fuse
N
PE
AC
internal
fuse
DC
22.11. USE IN A TIGHTLY SEALED ENCLOSURE
When the power supply is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher
than outside. In such situations, the inside temperature defines the ambient temperature for the power supply.
The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure.
The power supply is placed in the middle of the box; no other heat producing items are inside the box.
Enclosure: Rittal Type IP66 Box PK 9510 100, plastic, 130x130x99mm
Input: 230Vac
Case A:
Load: 24V, 5A; load is placed outside the box
Temperature inside the box: 62.4°C (in the middle of the right side of the power supply with a distance of 1cm)
Temperature outside the box: 23.5°C
Temperature rise: 38.2K
Case B:
Load: 24V, 4A; (=80%) load is placed outside the box
Temperature inside the box: 54.8°C (in the middle of the right side of the power supply with a distance of 1cm)
Temperature outside the box: 22.8°C
Temperature rise: 32.0K
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 +49 89 9278 0 Germany
20/21
ML120.244
MiniLine-2
24V, 5A, SINGLE PHASE INPUT
22.12. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top require a reduction in
continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction
influences the lifetime expectancy of the power supply. Therefore, two different derating curves for continuous
operation can be found below:
Curve A1 Recommended output current.
Curve A2 Max allowed output current (results in approximately half the lifetime expectancy of A1).
Fig. 22-5
Mounting
Orientation A
(Standard
orientation)
Fig. 22-6
Mounting
Orientation B
(Upside down)
OUTPUT
Power
Supply
INPUT
INPUT
Supply
Power
OUTPUT
Fig. 22-7
Mounting
Orientation C
(Table-top
mounting)
Fig. 22-8
Mounting
Orientation D
(Horizontal cw)
Supply
INPUT
Power
OUTPUT
Fig. 22-9
Mounting
Orientation E
(Horizontal ccw)
OUTPUT
Power
Supply
INPUT
Output Power
5A
4A
3A
2A
1A
0
Ambient Temperature
10 20 30 40 60°C50
Output Power
5A
4A
3A
2A
1A
0
Ambient Temperature
10 20 30 40 60°C50
Output Power
5A
4A
3A
2A
1A
0
Ambient Temperature
10 20 30 40 60°C50
Output Power
5A
4A
3A
2A
1A
0
Ambient Temperature
10 20 30 40 60°C50
Output Power
5A
4A
3A
2A
1A
0
Ambient Temperature
10 20 30 40 60°C50
A
1
A
2
A
1
A
2
A
1
A
2
A
1
A
2
A
1
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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