Puls MiniLine-2 ML60.241, MiniLine-2 Series User Manual
ML60.241
MiniLine-2
24V, 2.5A, SINGLE PHASE INPUT
P
OWER SUPPLY
100-240V Wide Range Input
NEC Class 2 Compliant
Adjustable Output Voltage
Efficiency up to 89.7%
Low No-load Losses and Excellent Partial-load Efficiency
Compact Design, Width only 45mm
Full Power between -10°C and +60°C
Large International Approval Package
3 Year Warranty
1/23
GENERAL DESCRIPTION
A compact size, light weight, simple mounting onto the
DIN-rail and the utilization of only quality components
are what makes the MiniLine power supplies so easy to
use and install within seconds.
A rugged electrical and mechanical design as well as a
high immunity against electrical disturbances on the
mains 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.
The MiniLine series offers output voltages from 5 to
56Vdc and a power rating from 15W to 120W.
The supplementary MiniLine decoupling diode module
MLY10.241 allows building of redundant systems or to
protect against back-feeding voltages.
SHORT-FORM DATA
Output voltage DC 24V
Adjustment range 24 - 28V
Output current 2.5A at 24V
2.1A at 28V
Output power 60W
Output ripple < 50mVpp 20Hz to 20MHz
Input voltage AC 100-240V -15% / +10%
Mains frequency 50-60Hz ±6%
AC Input current 0.98 / 0.58A at 120 / 230Vac
Power factor 0.58 / 0.5 at 120 / 230Vac
AC Inrush current typ. 16 / 32A peak value at 120
/ 230Vac 40°C
and cold start
DC Input 88-375Vdc below 110Vdc
derating required
Efficiency 87.8 / 89.7% at 120 / 230Vac
Losses 8.3 / 6.7W at 120 / 230Vac
Temperature range -10°C to +70°C operational
Derating 1.5W/°C +60 to +70°C
Hold-up time typ. 24 / 107ms at 120 / 230Vac
Dimensions 45x75x91mm WxHxD
Weight 250g / 0.55lb
ORDER NUMBERS
Power Supply ML60.241 24-28V Standard unit
Accessory MLY10.241 Redundancy Module
UF20.241 Buffer Module
ZM3.WALL Wall mount bracket
MARKINGS
Ind. Cont. Eq. UL 508
UL 60950-1
Marine
Class I Div 2
NEC
Class 2
EMC, LVD
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
ML60.241
MiniLine-2
24V, 2.5A, SINGLE PHASE INPUT
INDEX
Page Page
1.
Intended Use .......................................................3
2. Installation Requirements...................................3
3. AC-Input...............................................................4
4. Input Inrush Current ...........................................5
5. Output .................................................................6
6. Hold-up Time.......................................................7
7. DC-Input...............................................................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 ............................................14
18. Approvals...........................................................15
19. RoHS, REACH and Other Fulfilled Standards ...15
20. Physical Dimensions and Weight......................16
21. Accessory........................................................... 17
21.1. ZM3.WALL – Wall Mount Bracket............17
21.2. MLY10.241 - Redundancy Module........... 17
21.3. UF20.241 - Buffer Module........................17
22. Application Notes............................................. 18
22.1. Peak Current Capability ...........................18
22.2. Back-feeding Loads ..................................18
22.3. Charging of Batteries ...............................19
22.4. External Input Protection.........................19
22.5. Parallel Use to Increase Output Power....19
22.6. Parallel Use for Redundancy .................... 20
22.7. Daisy Chaining of Outputs ....................... 20
22.8. Inductive and Capacitive Loads................20
22.9. Series Operation .......................................21
22.10. Operation on Two Phases ........................21
22.11. Use Without PE on the Input ...................21
22.12. Use in a Tightly Sealed Enclosure ............22
22.13. Mounting Orientations ............................23
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.
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.
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
2/23
ML60.241
MiniLine-2
24V, 2.5A, 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 30%!
Keep the following installation clearances:
40mm on top, 20mm on the bottom
Left / right: 0mm (or 15mm in case the adjacent device is a heat source; in example another power supply….).
WARNING
Risk of electrical shock, fire, personal injury or death.
- 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.
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
3/23
ML60.241
MiniLine-2
24V, 2.5A, SINGLE PHASE INPUT
3. AC-INPUT
AC input nom. AC 100-240V -15% / +10%, TN/TT/IT-mains
AC input range
85-264Vac continuous operation, reduce output power linearly
to 50W between 90Vac and 85Vac at ambient
temperatures above +45°C, see Fig. 3-5
264–300Vac < 0.5s
Allowed voltage L or N to earth max. 264Vac or 375Vdc
Input frequency nom. 50–60Hz ±6%
Turn-on voltage typ. 65Vac
Shut-down voltage typ. see Fig. 3-1
AC 100V AC 120V AC 230V
Input current (rms) typ. 1.14A 0.98A 0.58A at 24V, 2.5A see Fig. 3-3
Power factor *) typ. 0.61 0.58 0.50 at 24V, 2.5A see Fig. 3-4
Crest factor **) typ. 3.2 3.3 3.7 at 24V, 2.5A
Start-up delay typ. 170ms ***) 110ms ***) 90ms see Fig. 3-2
Rise time typ. 50ms 50ms 60ms at 24V, 2.5A, 0mF, see Fig. 3-2
120ms 110ms 140ms at 24V, 2.5A, 2.5mF
Turn-on overshoot max. 200mV 200mV 200mV see Fig. 3-2
*) 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.
***) At low temperatures, start-up attempts may occur which extends the start-up delay
Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, definitions
4/23
85
Rated
input range
max.
500ms
V
IN
V
OUT
300Vac26465
Start-up
delay
Rise
Time
Overshoot
- 5%
Output
Voltage
Input
Voltage
Fig. 3-3 Input current vs. output load at 24V Fig. 3-4 Power factor vs. output load at 24V
2.5A
0.5 1.50
0
0.4
1.2A
Input Current, typ.
2.0
Power Factor, typ.
0.8
1.0
1.0
0.6
0.2
b
c
a
0.50
0.55
0.60
0.65
a) 100Vac
b) 120Vac
c) 230Vac
Output Current
2.5A
0 0.5 1.0 2.0
a) 100Vac
b) 120Vac
c) 230Vac
0.40
0.45
b
a
c
Output Current
1.5
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
ML60.241
MiniLine-2
24V, 2.5A, SINGLE PHASE INPUT
Fig. 3-5 De-rating requirements for
low input voltages
0
85Vac
10
20
30
40
50
60W
Input Voltage
A
.
.
.
<
+
4
5
°
C
B
.
.
.
<
+
6
0
°
C
A
B
90Vac
Allowable
Output Power
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.
AC 100V AC 120V AC 230V
Inrush current max. 17A
peak
21A
peak
40A
peak
40°C ambient, cold start
typ. 14A
peak
16A
peak
32A
peak
40°C ambient, cold start
Inrush energy typ. 0.15A
2
s 0.2A2s 1.0A2s 40°C ambient, cold start
Fig. 4-1 Input inrush current, typical behavior
Fig. 4-2 Input inrush current, zoom into first peak
Input Current
Input Voltage
Input Current
Output Voltage
Input: 230Vac
Output: 24V, 2.5A
Ambient: 25°C
Input current 2A/DIV
Time basis: 0.5ms / DIV
Input: 230Vac
Output: 24V, 2.5A
Ambient: 25°C
Upper curve: Input current 5A/DIV
Middle curve: Input voltage 100V/DIV
Lower curve: Output voltage 5V/DIV
Time basis: 20ms / DIV
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
5/23
ML60.241
MiniLine-2
24V, 2.5A, SINGLE PHASE INPUT
5. OUTPUT
Output voltage nom. 24V
Adjustment range min. 24-28V guaranteed
max. 30V *) at clockwise end position of potentiometer
Factory setting 24.5V ±0.2%, at full load, cold unit
Line regulation max. 10mV 85-264Vac
Load regulation max. 100mV static value, 0A Æ 2.5A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 1 600μF
Output current nom. 2.5A at 24V, see Fig. 5-1
nom. 2.1A at 28V, see Fig. 5-1
Output power nom. 60W
Short-circuit current min. 3.6A load impedance 400mOhm, see Fig. 5-1
max. 6.2A load impedance 400mOhm, see Fig. 5-1
*) This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. It is not
guaranteed value which can be achieved. The typical value is about 28.6V.
Fig. 5-1 Output voltage vs. output current,
typ.
Output Voltage
0
0
4
8
12
28V
16
20
24
321 5 6A4
Adjustment
Range
Output Current
a) 100Vac
b) 120Vac
c) 230Vac
b
c
a
Peak current capability (up to several milliseconds)
The power supply can deliver a peak current which is higher than the specified short term current. This helps to start
current demanding loads or to safely operate subsequent circuit breakers.
The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be
discharged and causes a voltage dip on the output. Detailed curves can be found in chapter 22.1.
Peak current voltage dips typ. from 24V to 16V at 5A for 50ms, resistive load
typ. from 24V to 15V at 12.5A for 2ms, resistive load
typ. from 24V to 10.5V at 12.5A for 5ms, resistive load
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
6/23
ML60.241
MiniLine-2
24V, 2.5A, SINGLE PHASE INPUT
6. HOLD-UP TIME
AC 100V AC 120V AC 230V
Hold-up Time typ. 36ms 54ms 218ms at 24V, 1.25A, see Fig. 6-1
typ. 15ms 24ms 107ms at 24V, 2.5A, see Fig. 6-1
Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on during this time
Fig. 6-1 Hold-up time vs. input voltage Fig. 6-2 Shut-down behavior, definitions
0
20
40
100
120ms
85 120 155 190 230Vac
Input Voltage
Hold-up Time
60
80
a) 24V 1.25A typ.
b) 24V 1.25Amin.
c) 24V 2.5A typ.
d) 24V 2.5A min.
a b c
d
- 5%
Hold-up Time
Zero Transition
Output
Voltage
Input
Voltage
7. DC-INPUT
The power supply can also be supplied from a DC source. Use a battery or similar DC source. For other sources contact
PULS. Connect the + pole to L and the – pole to N. Connect the PE terminal to an earth wire or to the machine ground.
DC input nom. DC 110-300V -20%/+25%
DC input range min. 88-375Vdc continuous operation, reduce output power according
Fig. 7-2 at voltages below 110Vdc
Allowed Voltage L/N to Earth max. 375Vdc IEC 62103
DC input current typ. 0.62A / 0.22A 110Vdc / 300Vdc, at 24V, 2.5A
Turn-on voltage typ. 80Vdc steady state value
Shut-down voltage typ. 30-70Vdc depending on output load
Fig. 7-1 Wiring for DC Input
Fig. 7-2 Allowable output current below
110Vdc input voltage
7/23
+
-
Load
L
N
PE
+
-
Power Supply
AC
DC
Battery
internal
fused
0
10
80 90 100 110 130Vdc
20
30
40
60W
Output Power
50
(
b
)
(
a
)
(a) Continuous
Input Voltage Vdc
120
(b) Short-term
Nov. 2015 / Rev. 1.4 DS-ML60.241-EN
All parameters are specified at 24V, 2.5A, 230Vac 50Hz input, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0 Germany
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