ML60.121

ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 POWER SUPPLY          100-240V Wide Range Input NEC Class 2 Compliant Adjustable Output Voltage Efficiency up to 87.2% 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 GENERAL DESCRIPTION SHORT-FORM DATA 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. Output voltage Adjustment range Output current 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 Output ripple Input voltage DC 12V 12 - 15V 4.5A at 12V 3.6A at 15V 54W < 50mVpp AC 100-240V Mains frequency AC Input current Power factor AC Inrush current 50-60Hz 0.91 / 0.54A 0.58 / 0.5 typ. 16 / 32A DC Input 88-375Vdc Efficiency Losses Temperature range Derating Hold-up time Dimensions Weight 85.3 / 87.2% 9.3 / 7.9W -10°C to +70°C 1.4W/°C typ. 25 / 113ms 45x75x91mm 250g / 0.55lb 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. ORDER NUMBERS 20Hz to 20MHz -15% / +10% AC 100V mains requires derating ±6% at 120 / 230Vac at 120 / 230Vac peak value at 120 / 230Vac 40°C and cold start below 130Vdc derating required at 120 / 230Vac at 120 / 230Vac operational +60 to +70°C at 120 / 230Vac WxHxD MARKINGS Power Supply ML60.121 12-15V Standard unit Accessory MLY10.241 ZM3.WALL Redundancy Module Wall mount bracket UL 508 UL 60950-1 Marine Class I Div 2 Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 1/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 INDEX Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Intended Use .......................................................3 Installation Instructions ......................................3 AC-Input...............................................................5 Input Inrush Current ...........................................6 Output .................................................................7 Hold-up Time .......................................................8 DC-Input...............................................................8 Efficiency and Power Losses................................9 Functional Diagram...........................................10 Front Side and User Elements ...........................10 Terminals and Wiring ........................................11 Lifetime Expectancy and MTBF.........................11 EMC ....................................................................12 Environment ......................................................13 Protection Features ...........................................14 Safety Features ..................................................14 Dielectric Strength ............................................15 Approvals and Fulfilled Standards ...................16 Regulatory Compliance .....................................17 Page 20. Physical Dimensions and Weight ..................... 18 21. Accessory ........................................................... 19 21.1. ZM3.WALL – Wall Mount Bracket............ 19 21.2. MLY10.241 - Redundancy Module ........... 19 22. Application Notes ............................................. 20 22.1. Peak Current Capability ........................... 20 22.2. Back-feeding Loads .................................. 20 22.3. Charging of Batteries ............................... 21 22.4. External Input Protection ......................... 21 22.5. Parallel Use to Increase Output Power .... 21 22.6. Parallel Use for Redundancy .................... 22 22.7. Daisy Chaining of Outputs ....................... 22 22.8. Inductive and Capacitive Loads................ 22 22.9. Series Operation ....................................... 23 22.10. Operation on Two Phases ........................ 23 22.11. Use Without PE on the Input ................... 23 22.12. Use in a Tightly Sealed Enclosure ............ 24 22.13. Mounting Orientations ............................ 25 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 Earth, Ground PE is the abbreviation for Protective Earth and has the same meaning as the symbol . 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. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 2/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 1. INTENDED USE This device is designed for installation in an enclosure and is intended for commercial use, such as in industrial control, process control, monitoring and measurement equipment or the like. Do not use this device in equipment, where malfunctioning may cause severe personal injury or threaten human life without additional appropriate safety devices, that are suited for the end application. If this device is used in a manner outside of its specification, the protection provided by the device may be impaired. 2. INSTALLATION INSTRUCTIONS Install device in an enclosure providing protection against electrical, mechanical and fire hazards. Install the device onto a DIN-rail according to EN 60715 with the input terminals on the bottom of the device. Other mounting orientations require a reduction in output current. Make sure that the wiring is correct by following all local and national codes. Use appropriate copper cables that are designed for a minimum operating temperature of 60°C for ambient temperatures up to +45°C, 75°C for ambient temperatures up to +60°C and 90°C for ambient temperatures up to +70°C. Ensure that all strands of a stranded wire enter the terminal connection. Unused screw terminals should be securely tightened. The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed. The housing of the device provides a degree of protection of IP20. The housing does not provide protection against spilled liquids. The isolation of the device is designed to withstand impulse voltages of overvoltage category III according to IEC 60664-1. The device is designed as “Class of Protection” I equipment according to IEC 61140. Do not use without a proper PE (Protective Earth) connection. The device is suitable to be supplied from TN, TT or IT mains networks. The continuous voltage between the input terminal and the PE potential must not exceed 300Vac. The input can also be powered from batteries or similar DC sources. The continuous voltage between the supply voltage and the PE/ground potential must not exceed 375Vdc. Connect the +pole to L and the -pole to the N terminal. A disconnecting means shall be provided for the input of the device. The device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid! The device is designed for altitudes up to 5000m (16400ft). Above 2000m (6560ft) a reduction in output current and over voltage category is required. Keep the following minimum installation clearances: 40mm on top, 20mm on the bottom, 0mm left and right side. Increase the 0mm to 15mm in case the adjacent device is a heat source. The device is designed, tested and approved for branch circuits up to 20A without additional protection device. If an external fuse is utilized, do not use circuit breakers smaller than 10A B- or 6A C-Characteristic to avoid a nuisance tripping of the circuit breaker. The maximum surrounding air temperature is +70°C (+158°F). The operational temperature is the same as the ambient or surrounding air temperature and is defined 2cm below the device. The device is designed to operate in areas between 5% and 95% relative humidity. 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. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 3/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 Notes for use in hazardous location areas: The device 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. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 4/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 3. AC-INPUT AC input AC input range nom. Allowed voltage L or N to earth Input frequency Turn-on voltage Shut-down voltage max. nom. typ. typ. Input current (rms) Power factor *) Crest factor **) Start-up delay Rise time typ. typ. typ. typ. typ. Turn-on overshoot max. AC 100-240V 85-264Vac 264–300Vac 264Vac or 375Vdc 50–60Hz 65Vac see Fig. 3-1 AC 100V 1.06A 0.61 3.2 120ms ***) 40ms 100ms 200mV -15% / +10%, TN/TT/IT-mains continuous operation, see Fig. 3-3 for de-rating requirements for AC 100V mains. < 0.5s ±6% AC 120V 0.91A 0.58 3.3 100ms ***) 40ms 90ms 200mV AC 230V 0.54A 0.50 3.7 90ms 50ms 110ms 200mV at 12V, 4.5A see Fig. 3-3 at 12V, 4.5A see Fig. 3-4 at 12V, 4.5A see Fig. 3-2 at 12V, 4.5A, 0mF, see Fig. 3-2 at 12V, 4.5A, 4.5mF 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 time. Rated input range VOUT Fig. 3-2 Turn-on behavior, definitions max. 500ms Input Voltage - 5% Output Voltage VIN 65 85 264 Input Current, typ. a b a) 100Vac b) 120Vac c) 230Vac 0.6 c 0.4 0.2 0 Fig. 3-4 Power factor vs. output load at 12V Power Factor, typ. 1.2A 0.8 Rise Time 300Vac Fig. 3-3 Input current vs. output load at 12V 1.0 Start-up delay Overshoot Fig. 3-1 Input voltage range 0.65 0.60 a) 100Vac b) 120Vac c) 230Vac 0.55 0.50 c 0.45 Output Current 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5A a b Output Current 0.40 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5A Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 5/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 Fig. 3-5 De-rating requirements for low input voltages Allowable Output Power 60W 50 40 A B 30 20 10 0 85Vac A... < +45°C B... < +60°C Input Voltage 90Vac 108Vac 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 Inrush energy max. typ. typ. Fig. 4-1 Input inrush current, typical behavior AC 100V 17Apeak 14Apeak 0.15A2s AC 120V 21Apeak 16Apeak 0.2A2s 40°C ambient, cold start 40°C ambient, cold start 40°C ambient, cold start Fig. 4-2 Input inrush current, zoom into first peak Input: Output: Ambient: Input current Time basis: Input: Output: Ambient: Upper curve: Middle curve: Lower curve: Time basis: AC 230V 40Apeak 32Apeak 1.0A2s 230Vac 12V, 4.5A 25°C 2A/DIV 0.5ms / DIV 230Vac 12V, 4.5A 25°C Input current 5A/DIV Input voltage 100V/DIV Output voltage 2.5V/DIV 20ms / DIV Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 6/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 5. OUTPUT Output voltage Adjustment range nom. 12V 12-15V 16.2V *) 12.0V 10mV 100mV 50mVpp 3 000µF 4.5A 3.6A 54W 6.0A 8.0A max. Factory setting Line regulation Load regulation Ripple and noise voltage Output capacitance Output current max. max. max. typ. nom. nom. nom. min. max. Output power Short-circuit current *) guaranteed at clockwise end position of potentiometer ±0.2%, at full load, cold unit 85-264Vac static value, 0A  4.5A 20Hz to 20MHz, 50Ohm at 12V, see Fig. 5-1 at 15V, see Fig. 5-1 load impedance 250mOhm, see Fig. 5-1 load impedance 250mOhm, 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 15.8V. Fig. 5-1 Output voltage vs. output current, typ. Output Voltage 16V 14 12 10 8 6 4 2 0 Adjustment Range a) 100Vac b) 120Vac c) 230Vac c ba Output Current 0 1 2 3 4 5 6 7 8 9A 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. typ. typ. from 12V to 7V from 12V to 5V from 12V to 3.2V at 9A for 50ms, resistive load at 22.5A for 2ms, resistive load at 22.5A for 5ms, resistive load Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 7/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 6. HOLD-UP TIME Hold-up Time AC 100V 37ms 16ms typ. typ. AC 120V 56ms 25ms AC 230V 229ms 113ms at 12V, 2.25A, see Fig. 6-1 at 12V, 4.5A, 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 Hold-up Time b a 120ms Fig. 6-2 Shut-down behavior, definitions c d 100 Zero Transition Input Voltage 80 60 a) 12V 2.25A typ. b) 12V 2.25Amin. c) 12V 4.5A typ. d) 12V 4.5A min. 40 20 - 5% Output Voltage Hold-up Time Input Voltage 0 85 120 155 190 230Vac 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 DC input range nom. min. DC 110-300V 88-375Vdc Allowed Voltage L/N to Earth DC input current Turn-on voltage Shut-down voltage max. typ. typ. typ. 375Vdc 0.57A / 0.2A 80Vdc 30-70Vdc Fig. 7-2 Allowable output current below 110Vdc input voltage Fig. 7-1 Wiring for DC Input Battery Output Power Power Supply + L 60W AC 50 internal fused 40 + N - PE - -20%/+25% continuous operation, reduce output power according Fig. 7-2 at voltages below 130Vdc IEC 62103 110Vdc / 300Vdc, at 12V, 4.5A steady state value depending on output load DC Load (b) (a) 30 (a) Continuous (b) Short-term 20 10 Input Voltage Vdc 0 80 90 100 110 120 130Vdc Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 8/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 8. EFFICIENCY AND POWER LOSSES Efficiency Power losses AC 100V 83.5% 0.45W 4.2W 10.6W typ. typ. typ. typ. Efficiency vs. output current at 12V, typ. Fig. 8-1 AC 120V 85.3% 0.5W 3.9W 9.3W AC 230V 87.2% 0.85W 4.2W 7.9W Losses vs. output current at 12V, typ. Fig. 8-2 Efficiency Power Losses 90% 12W a) 230Vac b) 120Vac c) 100Vac 88 a 86 b 84 c at 12V, 4.5A (full load) at 0A at 12V, 2.25A (half load) at 12V, 4.5A (full load) a) 230Vac b) 120Vac c) 100Vac 10 8 c b a 6 4 82 80 Output Current 78 2 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5A Fig. 8-3 Efficiency vs. input voltage at 12V, 4.5A, typ. Output Current 0 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5A Fig. 8-4 Losses vs. input voltage at 12V, 4.5A, typ. Efficiency Power Losses 89% 12W 88 10 87 8 86 6 85 4 84 83 85 2 Input Voltage 120 155 190 Input Voltage 0 225 260Vac 85 120 155 190 225 260Vac Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 9/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 9. FUNCTIONAL DIAGRAM Fig. 9-1 Functional diagram DC on L N Input Rectifier & NTC Inrush Limiter Input Fuse & Input Filter PE Power Converter Output OverVoltage Protection + + - Output Filter Output Voltage Regulator VOUT 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 B Input Terminals Screw terminals L Phase (Line) input N Neutral conductor input PE (Protective Earth) input C DC-on LED (green) On, when the voltage on the output terminals is > 9V D Output voltage potentiometer (single turn potentiometer) Turn to set the output voltage. Factory set: 12.0V Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 10/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 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 Stranded wire American Wire Gauge Wire stripping length Screwdriver Recommended tightening torque Input screw terminals max. 6mm2 max. 4mm2 max. AWG10 7mm / 0.275inch 3.5mm slotted or Pozidrive No 2 1Nm, 9lb.in Output screw terminals max. 6mm2 max. 4mm2 max. AWG10 7mm / 0.275inch 3.5mm slotted or Pozidrive No 2 1Nm, 9lb.in Instructions: a) Use appropriate copper cables that are designed for an operating temperature of: 60°C for ambient up to 45°C and 75°C for ambient up to 60°C minimum. b) Follow national installation codes and installation regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Up to two stranded wires with the same cross section are permitted in one connection point (except PE wire). e) Do not use the unit without PE connection. f) Screws of unused terminal compartments should be securely tightened. g) Ferrules are allowed. 12. LIFETIME EXPECTANCY AND MTBF 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 AC 100V 34 000h 180 000h *) 95 000h *) 1 327 000h 2 437 000h 1 085 000h 1 464 000h AC 120V 41 000h 181 000h *) 115 000h *) 1 458 000h AC 230V 56 000h 128 000h *) 158 000h *) 1 690 000h 2 639 000h 1 126 000h 1 520 000h 3 007 000h 1 067 000h 1 445 000h at 12V, 4.5A and 40°C at 12V, 2.25A and 40°C at 12V, 4.5A and 25°C at 12V, 4.5A and 40°C at 12V, 4.5A and 25°C at 12V, 4.5A and 40°C; Ground Benign GB40 at 12V, 4.5A and 25°C; Ground Benign GB25 The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime 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. **) 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. The MTBF figure is a statistical representation of the likelihood of a device to fail. A MTBF figure of e.g. 1 000 000h means that statistically one unit will fail every 100 hours if 10 000 units are installed in the field. However, it can not be determined if the failed unit has been running for 50 000h or only for 100h. *) Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 11/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 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 Electromagnetic RF field Fast transients (Burst) Surge voltage on input Generic standards: EN 61000-6-1 and EN 61000-6-2 Contact discharge EN 61000-4-2 Air discharge EN 61000-4-3 80MHz-2.7GHz Input lines EN 61000-4-4 Output lines EN 61000-4-5 LN N  PE, L  PE ++  PE, -  PE 0.15-80MHz 0% of 100Vac 40% of 100Vac 70% of 100Vac 0% of 200Vac 40% of 200Vac 70% of 200Vac 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 over entire load range 8kV 8kV 20V/m 4kV 2kV 2kV 4kV Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A 1kV 2kV 20V 0Vac, 20ms 40Vac, 200ms 70Vac, 500ms 0Vac, 20ms 80Vac, 200ms 140Vac, 500ms 0Vac, 5000ms 300Vac, 500ms 750V, 1.3ms Criterion A Criterion A Criterion A Criterion A *) Criterion C Criterion A Criterion A Criterion A Criterion A Criterion C Criterion A 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. *) Up to 3A output current criterion A, above 3A output current criterion B EMC Emission Conducted emission Radiated emission Harmonic input current Generic standards: EN 61000-6-3 and EN 61000-6-4 EN 55011, EN 55032, FCC Part 15, CISPR 11, CISPR 32 EN 55011, EN 55032, CISPR 11, CISPR 32 EN 61000-3-2 Class B, input lines Class B Not applicable below 75W input power Class A limits acc. to EN 61000-3-2 fulfilled. Fulfilled Voltage fluctuations, EN 61000-3-3 flicker *) 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 Switching frequency Converter frequency variable, typ. 100kHz, min. 45kHz, max. 160kHz Input voltage and output load dependent Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 12/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 14. ENVIRONMENT Operational temperature *) Storage temperature Output de-rating Humidity **) Vibration sinusoidal Shock Altitude Altitude de-rating Over-voltage category -10°C to +70°C (14°F to 158°F) -40°C to +85°C (-40°F to 185°F) 1.4W/°C 5 to 95% r.H. 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g 2 hours / axis 15g 6ms, 10g 11ms 3 bumps / direction, 18 bumps in total 0 to 2000m (0 to 6 560ft) 2000 to 6000m (6 560 to 20 000ft) reduce output power according Fig. 14-1 for storage and transportation 60-70°C (140°F to 158°F) IEC 60068-2-30 IEC 60068-2-6 IEC 60068-2-27 without any restrictions reduce output power or ambient temperature see Fig. 14-2 IEC 62103, EN 50178, overvoltage category II > 2000m (6500ft), see Fig. 14-2 IEC 62103, EN 50178, altitudes up to 2000m altitudes from 2000m to 6000m IEC 62103, EN 50178, not conductive 4W/1000m or 5°C/1000m III II 2 Degree of pollution *) 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 Allowable Output Power Allowable Output Power 60W 60W 50 50 40 40 30 30 20 20 10 0 -10 20 40 A... Tamb < 60°C B... Tamb < 50°C C... Tamb < 40°C 10 Ambient Temperature 0 A 0 2000 C Altitude 0 60 70°C B 4000 6000m Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 13/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 15. 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. 18Vdc In case of an internal power supply fault, a redundant max. 19Vdc circuit limits the maximum output voltage. In such a case, the output shuts down and stays down until the input voltage is turned off and on again. electronically limited see Fig. 5-1 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 In case of a protection event, audible noise may occur. 16. SAFETY FEATURES Input / output separation *) Class of protection Isolation resistance Touch current (leakage current) *) SELV PELV I II (with restrictions) > 5MOhm typ. 0.13mA / 0.29mA typ. 0.19mA / 0.40mA typ. 0.30mA / 0.63mA < 0.17mA / 0.38mA < 0.25mA / 0.53mA < 0.41mA / 0.85mA IEC/EN 60950-1 IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41 PE (Protective Earth) connection required for use without PE connection contact PULS Input to output, 500Vdc 100Vac, 50Hz, TN-,TT-mains / IT-mains 120Vac, 60Hz, TN-,TT-mains / IT-mains 230Vac, 50Hz, TN-,TT-mains / IT-mains 110Vac, 50Hz, TN-,TT-mains / IT-mains 132Vac, 60Hz, TN-,TT-mains / IT-mains 264Vac, 50Hz, TN-,TT-mains / IT-mains Double or reinforced insulation Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 14/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 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. Type test 60s A 2500Vac B 4000Vac C 2000Vac Factory test 5s 2500Vac 2500Vac 500Vac Field test 5s 2000Vac 2000Vac > 4mA > 4mA 500Vac > 1mA at 500V > 4mA at 2000V Fig. 17-1 Dielectric strength Input L N B Output A Earth, PE Cut-off current setting + C - 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. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 15/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 18. APPROVALS AND FULFILLED STANDARDS UL 508 IEC 60950-1 UL 60950-1 Class I Div 2 Marine (DNV GL) Marine (ABS) NEC Class 2 IEC 60068-2-60 ISA-71.04-1985 VDMA 24364 UL Certificate Listed equipment for category NMTR - Industrial Control Equipment Applicable for US and Canada E-File: E198865 CB Scheme Certificate General safety requirements for Information Technology Equipment (ITE) UL Certificate Recognized component for category QQGQ - Information Technology Equipment (ITE) Applicable for US and Canada E-File: E137006 CSA Certificate Power Supplies for Hazardous Location Applicable for Canada and US CSA Class: 5318-01 (Canada), 5318-81 (USA) Temperature Code: T4 Groups: A, B, C and D DNV-GL Certificate DNV-GL Type approved product Certificate: 12508-10HH Temperature: Class B Humidity: Class B Vibration: Class C EMC: Class A Enclosure: Class A ABS Design Assessment Certificate ABS (American Bureau of Shipment) assessed product Certificate: 17-HG1599236-PD Manufacturer's Declaration NEC CLASS 2 – Limited Power Source Listed device according to NEC Handbook chapter 725-121 Manufacturer's Declaration (Online Document) Environmental Tests, Flowing Mixed Gas Corrosion Test Test Ke - Method 4 H2S: 10ppb NO2: 200ppb Cl2: 10ppb SO2: 200ppb Test Duration: 3 weeks, which simulates a service life of at least 10 years. Manufacturer's Declaration (Online Document) Airborne Contaminants Corrosion Test Severity Level: G3 Harsh H2S: 100ppb NOx: 1250ppb Cl2: 20ppb SO2: 300ppb Test Duration: 3 weeks, which simulates a service life of at least 10 years Paint Wetting Impairment Substances Test (or LABS-Test) Tested for Zone 2 and test class C1 according to VDMA 24364-C1-L/W for solvents and water-based paints Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 16/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 19. REGULATORY COMPLIANCE EU Declaration of Conformity REACH Directive EAC TR Registration The CE mark indicates conformance with the - EMC directive - Low-voltage directive - RoHS directive Manufacturer's Statement EU-Directive regarding the Registration, Evaluation, Authorisation and Restriction of Chemicals EAC Certificate EAC EurAsian Conformity - Registration Russia, Kazakhstan and Belarus 8504408200, 8504409000 Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 17/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 20. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN-Rail Installation Clearances 250g / 0.55lb 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 (91mm) to calculate the total required installation depth. See chapter 2 Fig. 20-1 Front view Fig. 20-2 Side view Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 18/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 21. ACCESSORY 21.1. ZM3.WALL – WALL MOUNT BRACKET DIN-Rail bracket for wall or panel mount: The picture of the power supply is for representation only Hole diameter: 4.2mm 21.2. MLY10.241 - REDUNDANCY MODULE 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 which can cause controller failures. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 19/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 22. APPLICATION NOTES 22.1. PEAK CURRENT CAPABILITY 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 motor or switching-on a capacitive load. In many cases, the peak current capability also ensures a safe operation of subsequent circuit breakers. Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in a branch circuit, the fuse needs a certain amount of over-current to trip or to blow. 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. 22-1 Peak loading with 2x the nominal current for 50ms, typ. Peak load 9A (resistive load) for 50ms Output voltage dips from 12V to 7V. Fig. 22-2 Peak loading with 5x the nominal current for 5ms, typ. Peak load 22.5A (resistive load) for 5ms Output voltage dips from 12V to 3.2V. 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 25Vdc. The absorbing energy can be calculated according to the built-in large sized output capacitor which is specified in chapter 5. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 20/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 22.3. CHARGING OF BATTERIES The power supply can be used to charge 12V lead-acid or maintenance free batteries. Instructions for charging batteries (float charging): a) Ensure that the ambient temperature of the power supply is below 45°C b) Set output voltage (measured at no load and at the battery end of the cable) very precisely to the end-of-charge voltage. End-of-charge voltage 13.9V 13.75V 13.6V 13.4V Battery temperature 10°C 20°C 30°C 40°C c) Use a 6A circuit breaker (or blocking diode) between the power supply and the battery. d) Ensure that the output current of the power supply is below the allowed charging current of the battery. e) The return current to the power supply (battery discharge current) is typical 6mA when the power supply is switched off (except in case a blocking diode is utilized). 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. Unit A 22.5. PARALLEL USE TO INCREASE OUTPUT POWER AC + ML60.121 power supplies can be paralleled to increase the output power. This power supply has no feature included which balances the load current DC + between the power supplies. Usually the power supply with the higher Unit B adjusted output voltage draws current until it goes into current limitation. This Load AC means no harm to this power supply as long as the ambient temperature stays + below 45°C. The ML60.121 can also be paralleled with other power supplies from MiniLine series with 12V output voltage. The output voltages of all DC power supplies shall be adjusted to the same value (±100mV). A fuse or diode on the output of each unit is only required if more than three units are connected in parallel. If a fuse (or circuit breaker) is used, choose one with approximately 150% of the rated output current of one power supply. 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 the bottom and output terminals on top of the unit). Be aware that leakage current, EMI, inrush current and harmonics will increase when using multiple power supplies in parallel. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 21/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 22.6. PARALLEL USE FOR REDUNDANCY Voltage Monitor 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. 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 4.5A are paralleled to build a 18A redundant system. + + - Output + + - Output ML60.121 ML60.121 Input Input L N L + - + IN 1 IN 2 N MLY10 Load Output + - - + - I I L Please note: This simple way to build a redundant system does not cover N 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. 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. 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. 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 max 25A! Output + + - - Output + + - - + - Load Output + + - - Output + + - - Power Supply Power Supply Power Supply Power Supply Input Input Input 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. Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 22/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 22.9. SERIES OPERATION Unit A Power supplies of the exact same type can be connected in series for higher AC + 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 DC 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 Unit B Load the output is required when the sum of the output voltage is above 60Vdc. AC Avoid return voltage (e.g. from a decelerating motor or battery) which is + applied to the output terminals. Keep an installation clearance of 15mm (left / Earth right) between two power supplies and avoid installing the power supplies on DC 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 ware that leakage current, EMI, inrush current and harmonics will increase when using multiple power supplies series. 22.10. OPERATION ON TWO PHASES Power Supply L1 AC 240V +10% max. 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+10%. Use a fuse or a circuit breaker to protect the N input. The 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 22.4 “External Input Protection”. L3 L Fuse internal fuse N PE DC L2 22.11. USE WITHOUT PE ON THE INPUT From a safety standpoint, the unit is internally designed according to the requirements for Protection Class 1 and 2. Please contact PULS if you do not plan to use the PE terminal. A different marking of the front foil is then required. Grounding of the input is beneficial for a high EMI immunity: Symmetrical spikes or fast transients on the input side can be conducted directly to earth by the built-in filter capacitors. The magnitude of such spikes or fast transients on the output side caused by the input is much smaller compared to not connecting this terminal to ground. Fig. 22-5 Earthed input Fig. 22-6 Not earthed input Surge Spike Surge 24V L Power Supply + L - N X N Power Supply + X - Y Ground Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 23/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 22.12. 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: Input: Rittal Type IP66 Box PK 9510 100, plastic, 130x130x75mm 230Vac Case A: Load: Temperature inside the box: Temperature outside the box: Temperature rise: 12V, 4.5A; load is placed outside the box 42.8°C (in the middle of the right side of the power supply with a distance of 1cm) 21.7°C 21.1K Case B: Load: Temperature inside the box: Temperature outside the box: Temperature rise: 12V, 3.6A; (=80%) load is placed outside the box 41.1°C (in the middle of the right side of the power supply with a distance of 1cm) 21.9°C 19.2K Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 24/25 ML60.121 12V, 4.5A, SINGLE PHASE INPUT MiniLine-2 22.13. 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 Curve A2 Recommended output current. Max allowed output current (results in approximately half the lifetime expectancy of A1). Fig. 22-7 Mounting Orientation A (Standard orientation) Output Power OUTPUT 60W 48 36 24 12 0 10 Power Supply INPUT Fig. 22-8 Mounting Orientation B (Upside down) 20 30 40 50 60°C INPUT 60W 48 36 24 12 0 10 A2 A1 Ambient Temperature 20 30 40 60°C 50 Power Supply OUTPUT Output Power 60W 48 36 24 12 0 10 A2 A1 Ambient Temperature 20 30 40 60°C 50 Output Power OUTPUT Power Supply INPUT 60W 48 36 24 12 0 10 A2 A1 Ambient Temperature 20 30 40 60°C 50 INPUT Power Supply Output Power OUTPUT Fig. 22-11 Mounting Orientation E (Horizontal ccw) Ambient Temperature Output Power Fig. 22-9 Mounting Orientation C (Table-top mounting) Fig. 22-10 Mounting Orientation D (Horizontal cw) A1 60W 48 36 24 12 0 10 A2 A1 Ambient Temperature 20 30 40 50 60°C Nov. 2020 / Rev. 1.5 DS--ML60.121-EN All parameters are specified at 12V, 4.5A, 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 25/25