ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine POWER SUPPLY ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ AC 100-240V Wide Range Input NEC Class 2 Compliant Adjustable Output Voltage Efficiency up to 89% Compact Design, Width only 45mm Full Output Power Between -10°C and +60°C DC-OK Signal Included Large International Approval Package DIN-Rail Bracket for Wall or Panel Mount Included 3 Year Warranty 1. GENERAL DESCRIPTION 2. SHORT-FORM DATA A compact size, light weight, simple mounting on the DIN-rail and the quick connect spring-clamp terminals are what makes the MiniLine power supplies so easy to use and installs in seconds. Output voltage Adjustment range Output current DC 24V 24-28V 2.1–1.8A 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. Output power 50W Output ripple Input voltage Mains frequency AC Input current Power factor AC Inrush current < 50mVpp AC 100-240V 50-60Hz typ. 0.77 / 0.44A typ. 0.56 / 0.52 17 / 35A DC Input Efficiency Losses Temperature range Derating Hold-up time Dimensions 85-375Vdc typ. 88.4 / 89.0% typ. 6.6 / 6.2W -10°C to +70°C 1.3W/°C typ. 35 / 190ms 45x75x91mm The MiniLine series offers output voltages from 5 to 56Vdc and a power rating of up to 100W. A DC-OK signal allows remote diagnostics. The supplementary MiniLine decoupling diode module MLY02.100 allows building of redundant systems or to protect against back-feed voltages. Screw terminals 24V MiniLine Related products ML30.100 Less ML50.100 power For other output voltages or output power see catalog ML50.111 Conformal ML50.109 coating Parallel use ML50.101 option More ML100.100 power 380-480V ML100.200 input 3. ORDER NUMBERS Power Supply Accessory ML50.100 ML50.109 MLY02.100 24-28V 20Hz to 20MHz Wide Range Input ±6% at 120 / 230Vac at 120 / 230Vac typ. peak value at 120 / 230Vac 40°C and cold start at 120 / 230Vac at 120 / 230Vac operational +60 to +70°C at 120 / 230Vac WxHxD 4. MARKINGS Standard unit Conformal coated unit Decoupling / Redundancy module IND. CONT. EQ. UL 60950-1 UL 508 NEC Class 2 & Medical approval GL Marine Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Class I Div 2 Germany EMC, LVD 1/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine INDEX 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. PAGE General Description ............................................1 Short-form Data ..................................................1 Order Numbers....................................................1 Markings ..............................................................1 AC-Input...............................................................3 Input Inrush Current Surge .................................4 DC-Input...............................................................4 Hold-up Time.......................................................5 DC-OK Output .....................................................5 Output .................................................................6 Efficiency and Power Losses................................7 Functional Diagram.............................................8 Reliability .............................................................8 Front Side and User Elements.............................9 Terminals and Wiring..........................................9 EMC....................................................................10 Environment ......................................................11 Protection Features ...........................................11 Safety .................................................................12 Dielectric Strength ............................................12 INDEX 21. 22. 23. 24. 25. 26. 27. PAGE Approvals.......................................................... 13 Fulfilled Standards............................................ 13 Used Substances ............................................... 13 Physical Dimensions and Weight ..................... 14 Installation and Operation Instructions .......... 14 Accessory........................................................... 15 Application Notes............................................. 16 27.1. Peak Current Capability ......................... 16 27.2. Back-feeding Loads ................................ 16 27.3. Series Operation..................................... 17 27.4. Parallel Use to Increase Output Power . 17 27.5. Parallel Use for Redundancy.................. 17 27.6. Daisy Chaining of Outputs..................... 18 27.7. Charging of Batteries ............................. 18 27.8. External Input Protection....................... 19 27.9. Inductive and Capacitive Loads ............. 19 27.10. Operation on Two Phases ...................... 19 27.11. Use in a Tightly Sealed Enclosure .......... 19 27.12. Mounting Orientations .......................... 20 INTENDED USE The power supply shall only be installed and put into operation by qualified personnel. This power supply 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 device in aircraft, trains and nuclear equipment, where malfunctioning of the power supply may cause severe personal injury or threaten human life. 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 regardless whether it is charged (13.7V) or discharged (10V). 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. 230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included. DISCLAIMER 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. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 2/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 5. AC-INPUT AC input AC input range nom. Input frequency Turn-on voltage Shut-down voltage nom. typ. typ. AC 100-240V 85-264Vac 60-85Vac 264-300Vac 50 – 60Hz 65Vac 55Vac typ. typ. typ. typ. typ. typ. max. AC 100V 0.91A 0.58 3.05 32ms 33ms 45ms 400mV Input current Power factor *) Crest factor **) Start-up delay Rise time Turn-on overshoot Wide-range input, TN-, TT-, IT-Mains, see Fig. 5-1 Continuous operation Full power for 200ms, no damage between 0 and 85Vac < 0.5s ±6% Steady-state value, see Fig. 5-1 Steady-state value, see Fig. 5-1 AC 120V 0.77A 0.56 3.26 32ms 33ms 45ms 400mV AC 230V 0.47A 0.52 3.91 32ms 48ms 60ms 400mV at 24V, 2.1A see Fig. 5-3 at 24V, 2.1A see Fig. 5-1 at 24V, 2.1A See Fig. 5-2 0mF, 24V, 2.1A, see Fig. 5-2 2mF, 24V, 2.1A, see Fig. 5-2 See Fig. 5-2 *) 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. Fig. 5-1 Input voltage range Turn-on Shut-down full power for 200ms Intput Voltage max. 500ms VIN 60V 85V Start-up delay Fig. 5-3 Input current vs. output load 0.8 Rise Time 264V 300Vac Fig. 5-4 Power Factor vs. output load Power Factor, typ. Input Current, typ. 1.0A - 5% Output Voltage Overshoot Rated input range POUT Fig. 5-2 Turn-on behavior, definitions a b a) 100Vac b) 120Vac c) 230Vac 0.6 c 0.4 0.65 0.6 a) 100Vac b) 120Vac c) 230Vac a b 0.55 c 0.5 0.2 0.45 Output Current 0 0.1 0.5 0.9 1.3 1.7 2.1A 0.4 0.1 Output Current 0.5 0.9 1.3 1.7 2.1A Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 3/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 6. INPUT INRUSH CURRENT SURGE A NTC limits the input inrush current after turn-on of the input voltage. The inrush current is input voltage and ambient temperature dependent. max. typ. typ. Inrush current Inrush energy AC 100V 18Apeak 14Apeak 0.3A2s Fig. 6-1 Input inrush current, typical behavior AC 120V 23Apeak 17Apeak 0.4A2s AC 230V 48Apeak 35Apeak 1.5A2s 40°C ambient, cold start 40°C ambient, cold start 40°C ambient, cold start Fig. 6-2 Input inrush current, zoom into the first peak Input Current Input Voltage Output Voltage Input Current Input: Output: Ambient: Upper curve: Middle curve: Lower curve: Time scale: 230Vac 24V, 2.1A 40°C Input current 20A / DIV Input voltage 1000V / DIV Output voltage 20V / DIV 20ms / DIV Input: 230Vac Output: 24V, 2.1A Ambient: 40°C Input current curve: 10A / DIV, 1ms / DIV Ipeak 32.4A The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on. 7. DC-INPUT DC input DC input range DC input current Turn-on voltage Shut-down voltage nom. min. typ. typ. typ. DC 110-290V -25%/+30% 85-375Vdc Continuous operation 0.50A / 0.19A 110Vdc / 300Vdc at 24V and 2.1A 81Vdc Steady state value 58Vdc Steady state value Fig. 7-1 Wiring for DC Input Battery + AC L internal fused + Fuse a) Use a battery or similar DC source. b) Connect +pole to L and – pole to N. c) Connect the PE terminal to a earth wire or to the machine ground. d) In case the – pole of the battery is not connected to earth, use an appropriate fuse to protect the N terminal. Load N - Instructions for DC use: Power Supply - PE DC Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 4/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 8. HOLD-UP TIME Hold-up Time typ. typ. AC 100V 54ms 26ms AC 120V 82ms 40ms Fig. 8-1 Hold-up time vs. input voltage AC 230V 360ms 180ms 1.05A, 24V, see Fig. 8-1 2.1A, 24V, see Fig. 8-1 Fig. 8-2 Shut-down behavior, definitions Hold-up Time a 120ms b c Zero Transition d Intput Voltage 100 80 a) 24V 1.05A typ. b) 24V 1.05Amin. c) 24V 2.1A typ. d) 24V 2.1A min. 60 40 - 5% Output Voltage 20 Hold-up Time Input Voltage 0 85 120 155 190 230Vac 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. 9. DC-OK OUTPUT This feature monitors the output voltage, which is present on the output terminals. The signal is a source output which can feed loads up to 30mA. Loads can be a 24V relay (Rcoil < 700Ohm), a LED or the input of a PLC system. The relays operates or the LED is on if output voltage exceeds the threshold level. A freewheeling diode (necessary when the load is a relay) is already included in the power supply. Threshold value Output current Output voltage 20V +/-4% 30mA Vout – 1V at 30mA min. min For typical values see Fig. 9-2 The open collector is internally linked to the positive output pole. The DC-OK voltage is approximately the output voltage if the output voltage is higher than the threshold level. Fig. 9-2 Output characteristic DC-OK signal Fig. 9-1 DC-ok wiring diagram DC-OK Voltage Test Setup ML50 Relay ++- DC-ok DC ok 24-28V + 28V + 24 20 - 16 LED 12 MiniLine DC OK V Load 8 A 4 0 N L DC-OK Current 0 5 10 15 20 Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 25 30 35 40mA 5/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 10. OUTPUT Output voltage Adjustment range Factory setting Line regulation Load regulation Ripple and noise voltage Output capacitance Output current Output power Short-circuit current nom. min. max. 24V 24-28V 30V max. max. max. typ. nom. nom. nom. min. max. 24.5V 10mV 100mV 50mVpp 1600µF 2.1A 1.8A 50W 3.1A 5A Guaranteed At clockwise end position of potentiometer ±0.2%, at full load, cold unit 85 to 264Vac Static value, 0A Æ 2.1A Æ 0A 20Hz to 20MHz, 50Ohm At 24V, see Fig. 10-1 At 28V, see Fig. 10-1 Load impedance 400mOhm, see Fig. 10-1 Load impedance 400mOhm, see Fig. 10-1 Fig. 10-1 Output voltage vs. output current, 230Vac, typ. Output Voltage Adjustment Range 28V 24 20 16 12 8 4 0 Output Current 0 0.5 1 1.5 2 2.5 3 3.5 4A Peak current capability (up to several ms) 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 cause a voltage dip on the output. Detailed curves can be found in chapter 27.1. Peak current voltage dips typ. typ. typ. from 24V to 16V from 24V to 15V from 24V to 10.5V at 4.2A for 50ms, resistive load at 10.5A for 2ms, resistive load at 10.5A for 5ms, resistive load Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 6/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 11. EFFICIENCY AND POWER LOSSES Efficiency Power losses typ. typ. typ. typ. AC 100V 87.5% 0.6W 4.0W 7.2W Fig. 11-1 Efficiency vs. output current at 24V Efficiency 90% 88 86 84 82 80 78 76 74 0.3 AC 120V 88.4% 0.7W 4.1W 6.6W AC 230V 89.0% 1.3W 4.4W 6.2W 2.1A, 24V 0A 1.05A, 24V 2.1A, 24V Fig. 11-2 Losses vs. output current at 24V Power Losses b a c a) 100Vac b) 120Vac c) 230Vac Output Current 0.6 0.9 1.2 1.5 8W 7 6 5 4 3 2 1 0 a) 100Vac b) 120Vac c) 230Vac c b a Output Current 0 1.8 2.1A Fig. 11-3 Efficiency vs. input voltage, 24V, 2.1A Efficiency a b c 0.3 0.6 0.9 1.2 1.5 1.8 2.1A Fig. 11-4 Losses vs. input voltage, 24V, 2.1A Power Losses 9W 91% 90 8 89 88 7 87 6 86 Input Voltage 85 85 120 155 190 Input Voltage 5 225 260Vac 85 120 155 190 225 260Vac Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 7/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 12. FUNCTIONAL DIAGRAM Fig. 12-1 Functional diagram DC ok L N Input Fuse & Input Filter Input Rectifier & Inrush Limiter Power Converter Output OverVoltage Protection Output Filter + + - DC-OK Transistor Signal DC-ok Signal Output Voltage Regulator VOUT 13. RELIABILITY These units are extremely reliable and use only the highest quality materials. The number of critical components such as electrolytic capacitors has been reduced. Lifetime expectancy MTBF SN 29500, IEC 61709 MTBF MIL HDBK 217F min. min. min. AC 100V AC 120V AC 230V 34 000h 112 000h 96 000h 2 383 000h 3 977 000h 1 021 000h 1 370 000h 44 000h 117 000h 125 000h 2 456 000h 4 100 000h 1 053 000h 1 413 000h 54 000h 111 000h 152 000h 2 613 000h 4 362 000h 1 120 000h 1 503 000h 40°C, 24V, 2.1A 40°C, 24V, 1.05A 25°C, 24V, 2.1A 40°C, 24V, 2.1A 25°C, 24V, 2.1A 40°C, 24V, 2.1A, Ground Benign GB40 25°C, 24V, 2.1A, Ground Benign GB25 The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s manufacturer specification. The prediction model allows a calculation of up to 15 years from date of shipment. MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 8/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 14. FRONT SIDE AND USER ELEMENTS Fig. 14-1 Front side DC-OK LED (green) On when the voltage at the output terminals is > 20 V Output & Signal Terminals Spring-clamp terminals Dual terminals per pole DC-OK LED and DC-OK signal functions are synchronized + - Positive output Negative (return) output Dual pins per pole DC-OK Open collector output Indicates an output voltage higher than 20Vdc Output Voltage Potentiometer Turn to set the output voltage. Factory set: 24.5V Input Terminals Spring-clamp terminals N … Neutral input L … Line (hot) input ... PE (Protective Earth) input 15. 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. Mounting and wiring do not require any screwdriver. Type Solid wire Stranded wire American wire gauge Ferrules Wire stripping length Pull-out force Quick-connect spring-clamp terminals 0.3-4mm2 0.3-2.5mm2 26-12 AWG Allowed, but not required 6mm / 0.25inch 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E) Fig. 15-1 Connecting a wire Instructions: a) Use appropriate copper cables b) Follow local and national installation codes and regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Do not use the unit without PE connection. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 9/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 16. EMC The CE mark indicates conformance with EMC guideline 89/336/EEC, 93/68/EEC and the low-voltage directive (LVD) 73/23/EWG. A detailed EMC Report is available on request. EMC Immunity Electrostatic discharge EN 61000-6-2, EN 61000-6-1 EN 61000-4-2 Electromagnetic RF field Fast transients (Burst) EN 61000-4-3 EN 61000-4-4 Surge voltage on input EN 61000-4-5 Surge voltage on output EN 61000-4-5 Conducted disturbance Mains voltage dips EN 61000-4-6 EN 61000-4-11 Voltage interruptions Input voltage swells Powerful transients EN 61000-4-11 PULS internal standard VDE 0160 Contact discharge Air discharge 80MHz-1GHz Input lines Output lines LÆN N / L Æ PE +Æ+ / - Æ PE 0,15-80MHz 0% of 100Vac 40% of 100Vac 70% of 100Vac 0% of 200Vac 40% of 200Vac 70% of 200Vac over entire load range Generic standards 8kV 8kV 10V/m 4kV 2kV 2kV 4kV 500V 500V 10V 0Vac, 20ms 40Vac, 200ms 70Vac, 500ms 0Vac, 20ms 80Vac, 200ms 140Vac, 500ms 0Vac, 5000ms 300Vac, 500ms Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion C Criterion A Criterion A Criterion A Criterion A Criterion C Criterion A 750V, 1.3ms Criterion A Criterions: A: Power supply shows normal operation behavior within the defined limits. C: Temporary loss of function is possible. Power supply might shut-down and restarts by itself. No damages or hazards to the power supply will occur. EN 61000-6-3, EN 61000-6-4 Generic standards EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B, input lines EN 55022 Class B, output lines Radiated emission EN 55011, EN 55022 Class B Harmonic input current EN 61000-3-2 Fulfilled Voltage fluctuations, flicker EN 61000-3-3 Fulfilled This device complies with FCC Part 15 rules. Operation is subjected to the 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. EMC Emission Conducted emission Switching frequency variable, typ. 100kHz, (60-275kHz) Input voltage and output load dependent Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 10/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 17. ENVIRONMENT Operational temperature Output de-rating Storage temperature Humidity -10°C to +70°C (14°F to 158°F) 1.3W/°C -40 to +85°C (-40°F to 185°F) 5 to 95% r.H. Reduce output power according to Fig. 17-1 60-70°C (140°F to 158°F), see Fig. 17-1 Storage and transportation IEC 60068-2-30 Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g 2 hours / axis 20g 6ms, 10g 11ms 3 bumps / direction, 18 bumps in total 0 to 6000m (0 to 20000ft) IEC 60068-2-6 Do not energize while condensation is present Shock Altitude Output de-rating (for altitude) Over-voltage category Degree of pollution 3W/1000m or 5°C/1000m III II 2 Fig. 17-1 Output current vs. ambient temp. Fig. 17-2 Output current vs. altitude, 24V 2.4A 2.4A 2.0 2.0 1.6 1.6 1.2 1.2 0.8 0.8 0.4 0.4 Ambient Temperature -10 0 Reduce output power or ambient temperature above 2000m sea level. Above 2000m (6500ft), see Fig. 17-2 EN 50178, IEC 62103 altitudes < 2000m Altitudes from 2000m to 6000m EN 50178, IEC 62103, non conductive Allowable Output Current at 24V Allowable Output Current at 24V 0 IEC 60068-2-27 20 40 A A... Tamb < 60°C B... Tamb < 50°C C... Tamb < 40°C 0 2000 C Altitude 0 60 70°C B 4000 6000m The ambient temperature is defined 2cm below the unit. 18. PROTECTION FEATURES Output protection Output over-voltage protection Output over-current protection Degree of protection Penetration protection Over-temperature protection Input transient protection Internal input fuse Electronically protected against overload, no-load and short-circuits typ. 36V In case of an internal power supply fault, a redundant max. 39V circuit limits the maximum output voltage. The output shuts down and automatically attempts to restart. electronically limited see Fig. 10-1 IP 20 EN/IEC 60529 > 2.5mm in diameter E.g. screws, small parts not included MOV Metal Oxide Varistor T3.15A H.B.C. Not user replaceable Note: In case of a over-voltage, overload, no-load or short-circuit event, an audible noise may be heard. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 11/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 19. SAFETY Input / output separation SELV IEC/EN 60950-1 PELV EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41 double or reinforced insulation I PE (Protective Earth) connection required > 5MOhm input to output, 500Vdc typ. 0.12mA 100Vac, 50Hz, TN mains typ. 0.17mA 120Vac, 60Hz, TN mains typ. 0.29mA 230Vac, 50Hz, TN mains < 0.16mA 110Vac, 50Hz, TN mains < 0.23mA 132Vac, 60Hz, TN mains < 0.40mA 264Vac, 50Hz, TN mains Class of protection Isolation resistance Touch current (leakage current) 20. DIELECTRIC STRENGTH Fig. 20-1 Dielectric strength Input L N B + A Earth, PE Output C DCOk Type test 60s A 2500Vac B 3000Vac C 500Vac Factory test 5s 2500Vac 2500Vac 500Vac Field test 5s 2000Vac 2000Vac 500Vac Type tests and factory tests: Conducted by the manufacturer. Do not repeat test in field! Rules for field test: Use appropriate test equipment which applies the voltage with a slow ramp! Connect L and N together as well as all output poles. The output voltage is floating and has no ohmic connection to ground. To fulfill the PELV requirements according to EN60204-1 § 6.4.1, it is recommended that either the + pole, the – pole or any other part of the output circuit should 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 an unnoticed earth faults occur. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 12/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 21. APPROVALS IEC 60950-1 IECEE CB Scheme, Information Technology Equipment CB SCHEME IEC 60601-1 IECEE CB Scheme, Medical, Basic Insulation CB SCHEME UL 508 LISTED as Industrial Control Equipment E198865 IND. CONT. EQ. UL2601 LISTED as Medical UL 60950-1 RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-1) and Canada (C22.2 No. 60950). Information Technology Equipment, Level 3 NEC Class 2 Listed as Limited Power Source (LPS) in the UL 60950-1 UL report. UL 1604 RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and Canada (C22.2 No. 213-M1987) Hazardous Location Class I Div 2 T4 Groups A,B,C,D and Class I Zone 2 Groups IIA, IIB and IIC The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations as well as for Class I Zone 2 Groups IIA, IIB and IIC locations. Substitution of components may impair suitability for Class I Division 2 environment. Do not disconnect equipment unless power has been switched off. Wiring must be in accordance with Class I, Division 2 wiring methods of the National Electrical Code, NFPA 70, and in accordance with other local or national codes. Marine GL ABS GL (Germanischer Lloyd) classified and ABS (American Bureau for Shipping) PDA for marine and offshore applications. Environmental category: C, EMC2 SEMI F47 SEMI F47-0200 Power Quality Star Ride-through compliance for semiconductor industry. Full SEMI range compliance (Input: 120Vac or 208Vac) 22. FULFILLED STANDARDS EN 61558-2-17 Safety of Power Transformers EN/IEC 60204-1 Safety of Electrical Equipment of Machines EN/IEC 61131-2 Programmable Controllers EN 50178, IEC 62103 Electronic Equipment in Power Installations 23. USED SUBSTANCES Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems. Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated. The unit conforms to the RoHS directive 2002/96/EC The materials used in our production process do not include the following toxic chemicals: Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 13/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 24. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN-Rail 240g / 0.53lb 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 depth (91mm) to calculate the total required installation depth. Electronic files with mechanical data can be downloaded at www.pulspower.com Fig. 24-1 Front view Fig. 24-2 Side view 25. INSTALLATION AND OPERATION INSTRUCTIONS Mounting: Output terminal must be located on top and input terminal on the bottom. For other orientations see chapter 27.12. An appropriate electrical and fire end-product enclosure should be considered in the end use application. Cooling: Convection cooled, no forced cooling required. Do not cover ventilation grill (e.g. cable conduits) by more than 30%! Installation clearances: 25mm on top and bottom. Risk of electrical shock, fire, personal injury or death! Do not use the unit without proper earth connection (Protective Earth). Turn power off before working on the power supply. Protect against inadvertent re-powering. Make sure the wiring is correct by following all local and national codes. Do not open, modify or repair the unit. 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. Service parts: The unit does not contain any service parts. The tripping of an internal fuse is caused by an internal fault. If damage or malfunctioning should occur during operation, immediately turn power off and send unit to the factory for inspection! Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 14/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 26. ACCESSORY DIN-Rail bracket for wall or panel mount A DIN-rail bracket is included in each shipping box. Fig. 26-1 DIN-Rail Bracket Fig. 26-2 DIN-Rail Bracket Dimensions Hole diameter: 4.2mm MLY02.100 Dual decoupling module 2x5A Fig. 26-4 Redundant System with Two ML50.100 and One MLY02.100 PS1 ok PS2 ok + + - - DC ok + + - - DC ok adj. ML50.100 + - VIN 2 ML50.100 N L N MLY02 Load VOUT ++ -- - I L + - VIN 1 adj. + Fig. 26-3 MLY02.100 Dual Decoupling Module I L N Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 15/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 27. APPLICATION NOTES 27.1. PEAK CURRENT CAPABILITY Solenoids, contactors and pneumatic modules often have a steady state (sealed) 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. Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit, the protective device (fuse, circuit breaker) needs a certain amount of over-current to trip or to blow. The peak current capability ensures the safe operation of subsequent circuit breakers. Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the power supply can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The following two examples show typical voltage dips: Fig. 27-1 Peak load 4.2A for 50ms, typ. Output Voltage 24.0V Fig. 27-2 Peak load 10.5A for 5ms, typ. 24.0V t t pu Ou ltage o V 16V 10.5A 4.2A Output Current 0A 10.5V Output Current 0A 1ms/DIV 10ms/DIV Peak load 4.2A (resistive) for 50ms Output voltage dips from 24V to 16V. Peak load 10.5A (resistive) for 5ms Output voltage dips from 24V to 10.5V. 27.2. 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 10. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 16/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 27.3. SERIES OPERATION The power supply can be put in series to increase the output voltage. Fig. 27-3 Schematic for series operation Unit A AC DC + + Unit B AC DC Load + - Earth Instructions for use in series: a) It is possible to connect as many units in series as needed, providing the sum of the output voltage does not exceed 150Vdc. b) 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. c) For serial operation use power supplies of the same type. d) Earthing of the output is required when the sum of the output voltage is above 60Vdc. Note: Avoid return voltage (e.g. from a decelerating motor or battery) which is applied to the output terminals. 27.4. PARALLEL USE TO INCREASE OUTPUT POWER Several power supplies can be paralleled to increase the output power. The ML50.100 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 this power supply as long as the ambient temperature stays below 50°C. If a current sharing feature is required, choose the ML50.101 or ML50.111. Fig. 27-4 Schematic for parallel operation Unit A AC DC + + Unit B AC DC Load + - - Instructions for parallel use: a) Use only power supplies from the same series (ML-Series). b) Adjust the output voltages of all power supplies to approximately the same value (±200mV). c) A fuse (or diode) on the output is only required if more than three units are connected in parallel. d) Do not load terminals with more than 13A. Follow wiring instructions according to chapter 27.6 e) Ensure that the ambient temperature of the power supply does not exceed 50°C. 27.5. PARALLEL USE FOR REDUNDANCY Power supplies can be paralleled for redundancy to gain a higher system reliability. Redundant systems require a certain amount of extra power to support the load in case one power supply unit fails. The simplest way is to put two MiniLine 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 2.1A are paralleled to build a 8A redundant system. If one unit fails, the 8A can still be drawn. Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 17/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine Please note: This simple way to build a redundant system has two major disadvantages: - The faulty power supply can not be recognized. The green LED will still be on since it is reverse-powered from the other power supply. - It does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a situation the defective unit becomes a load for the other power supplies and the output voltage can not be maintained any more. This above conditions can be avoided by utilizing decoupling diodes which are included in the decoupling module MLY02.100. Other recommendations for building redundant power systems: a) Use separate input fuses for each power supply. b) Monitor the individual power supply units. A DC-ok output is included in the ML50.100, ML50.101 and ML50.111. In all other cases, use the redundancy module YRM2.DIODE which has a monitoring circuit for each input included. c) When possible, connect each power supply to different phases of the mains network. 27.6. DAISY CHAINING OF OUTPUTS Daisy chaining (jumping from one power supply output to the next) is allowed as long as the maximum current through one terminal pin does not exceed 13A. If the current is higher, use a separate distribution terminal block. Fig. 27-5 Daisy chaining of outputs Fig. 27-6 Using distribution terminals max 13A! + + - Output + + - Output + - + + - Output + + - Output + Load Power Supply Power Supply Power Supply Power Supply Input Input Input Input - Load Distribution Terminals 27.7. CHARGING OF BATTERIES The power supply can be used for float-charging of lead-acid or maintenance free 24V VRLA batteries. Instructions for charging batteries: a) Ensure that the ambient temperature of the power supply does not exceed 50°C. b) Set the output voltage on a disconnected load, very precisely to the end-of-charge voltage according to the expected battery temperature. End-of-charge voltage Battery temperature c) d) e) f) 27.8V 10°C 27.5V 20°C 27.15V 30°C 26.8V 40°C Use a 4A or 6A circuit breaker (or blocking diode ) between the power supply and the battery. Ensure that the output current of the power supply is below the allowed charging current of the battery. Use only matched batteries when putting 12V types in series. The return current to the power supply is typ. 10.7mA at 25Vdc when the power supply is switched off (except in case a blocking diode is utilized). Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 18/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 27.8. EXTERNAL INPUT PROTECTION The unit is tested and approved for branch circuits up to 15A (UL) or 16A (IEC). External protection is only required if the supplying branch has an ampacity greater than this. In some countries local regulations might apply so check local codes and requirements. If an external protective device is utilized, a minimum value is required to avoid undesired tripping of the fuse. B-Characteristic max. 15A (UL), 16A (IEC) min. 10A Ampacity C-Characteristic 15A (UL), 16A (IEC) 6A 27.9. INDUCTIVE AND CAPACITIVE LOADS The unit is designed to supply any type of load, including unlimited capacitive and inductive loads. 27.10. OPERATION ON TWO PHASES Fig. 27-7 Schematic for two phase operation Power Supply AC +10% max. L1 Fuse 240V L3 L internal fuse N PE L2 DC Instructions for two phase operation: a) A phase to phase connection is allowed as long as the supplying voltage is below 240V+10%. b) Use a fuse or a circuit breaker to protect the N input. The N input is internally not protected and is in this case connected to a hot wire. Appropriate fuses or circuit breakers are specified in section 27.6 “External Input Protection”. 27.11. 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 the outside. The inside temperature defines the ambient temperature for the power supply. Results from such an installation: Power supply is placed in the middle of the box, no other heat producing equipment inside the box Enclosure: Input: Rittal Type IP66 Box PK 9510 100, plastic, 130x130x75mm 230Vac Load: Temperature inside the box: Temperature outside the box: Temperature rise: 24V, 2.1A; load is placed outside the box 40.8°C (in the middle of the right side of the power supply with a distance of 1cm) 21.9°C 18.9K Load: Temperature inside the box: Temperature outside the box: Temperature rise: 24V, 1.7A; (=80%) load is placed outside the box 38.7°C (in the middle of the right side of the power supply with a distance of 1cm) 21.7°C 17.0K Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 19/20 ML50.100, ML50.109 24V, 2.1A, SINGLE PHASE INPUT MiniLine 27.12. MOUNTING ORIENTATIONS Mounting orientations other than input terminals on the bottom and output on the top requires 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 Curve A2 Recommended output power. Max allowed output power (results approx. in half the lifetime expectancy of A1). Fig. 27-8 Mounting Orientation A Standard Orientation Output Power OUTPUT 50W 40 30 20 10 0 10 Power Supply INPUT Fig. 27-9 Mounting Orientation B (Upside down) 20 30 40 50 60°C INPUT 50W 40 30 20 10 0 10 A2 A1 Ambient Temperature 20 30 40 50 60°C Power Supply OUTPUT Output Power 50W 40 30 20 10 0 10 A2 A1 Ambient Temperature 20 30 40 50 60°C Output Power OUTPUT Power Supply INPUT 50W 40 30 20 10 0 10 A2 A1 Ambient Temperature 20 30 40 50 60°C INPUT Power Supply Output Power OUTPUT Fig. 27-12 Mounting Orientation E (Horizontal ccw) Ambient Temperature Output Power Fig. 27-10 Mounting Orientation C (Table-top mounting) Fig. 27-11 Mounting Orientation D (Horizontal cw) A1 50W 40 30 20 10 0 10 A2 A1 Ambient Temperature 20 30 40 50 60°C Mar. 2007 / Rev. 1.0 DS-ML50.100-EN All parameters are specified at 24V, 2.1A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 20/20