MLY02.100

MLY02.100 MiniLine MLY-Series DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE REDUNDANCY MODULE          Cost Effective Solution to Build Redundant Systems Dual Input with Single Output Two Diodes (Common Cathode) DC12-48V (120Vdc) ±25% Wide-range Input Full Power Between -40°C and +60°C Compact Design, Width only 45mm Quick-connect Spring-clamp Terminals Easy Wiring: Distribution Terminal for Negative Pole Included 3 Year Warranty PRODUCT DESCRIPTION SHORT-FORM DATA The MLY02.100 is a simple is a redundancy module, which can be used to build 1+1 and N+1 redundant system. It is equipped with two input channels, which can be connected to power supplies with up to 5A output current and one output, which can carry nominal currents up to 10A. The module is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior. Input voltage Unique quick-connect spring-clamp terminals allow a safe and fast installation and a large international approval package for a variety of applications makes this unit suitable for nearly every situation. ORDER NUMBERS Input voltage range Input current Output current DC 12-48V ±25% DC 12-120V ±25% 9-60Vdc 9-150Vdc 2x 0-5A 2x 0-8A 0-10A 10-16A 60V) Power Supply AC AC + DC (>60V) - Diode Module + - + - + - + + Load - >60V DC (>60V) Power Supply AC + - DC (>60V) Diode Module + - + - + - + Load - >60V Diode Module + - + - + - Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 5/18 MLY02.100 DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series MiniLine Fig. 3-2 Input to output voltage drop when both inputs draw current (typical 1+1 redundant case, when the output voltages of the two units are equal or set into “parallel use” mode) Voltage Drop, typ. QS5.241 1000mV I1 A 24V,5A + 800mV A 600mV B - A... 25°C B... 60°C 400mV V U1 QS5.241 + Input, Output Current 0mV Output: 0A Input: 0A 2A 4A 6A 8A 2x1A 2x2A 2x3A 2x4A 10A 2x5A - Input 1 Output V U2 Variable Load, 0-10A UOUT V Input 2 Voltage Drop = U1 - UOUT U1 = U2 I1 = I2 IOUT A I2 A 24V,5A 200mV Output MLY02.100 Fig. 3-3 Input to output voltage drop when only one input draws current QS10.241 Voltage Drop, typ. I1 A 24V,10A 1000mV + A 800mV B - 600mV V U1 Output MLY02.100 Input 1 IOUT A Output Variable Load, 0-10A UOUT V A... 25°C B... 60°C 400mV 200mV Not used or power supply with lower voltage Output Current 0mV 0A 2A 4A 6A 8A Input 2 10A Voltage Drop = U1 - UOUT 4. POWER LOSSES Power losses DC 24V 4.0W 4.5W 9.0W 0W typ. typ. typ. typ. Standby power losses input: 2x2.5A input: 1x5A input: 2x5A at no output current Fig. 4-1 Power losses Power Losses, typ. 10W 8W A B A... 25°C B... 60°C 6W 4W 2W Input, Output Current 0 Output: 0A Input: 0A 2A 4A 6A 8A 2x1A 2x2A 2x3A 2x4A 10A 2x5A Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 6/18 MLY02.100 MiniLine DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series 5. LIFETIME EXPECTANCY AND MTBF The redundancy module has two input channels which are completely independent from each other. Each control circuit, auxiliary voltage source, or other circuitry in the module are designed separately for each input. The dual input redundancy module can be considered as two single redundancy modules combined together in one housing. The only common point is the circuit trace that ties the two separate circuits together at the output. The MTBF figures below are for the entire dual input module. If the MTBF number of only one path is needed, simply double the value from the table. The redundancy module does not have electrolytic capacitors included. Therefore, the lifetime expectancy is extremely high. Input / output current conditions Lifetime expectancy *) MTBF **) SN 29500, IEC 61709 MTBF **) MIL HDBK 217F min. min. Input: 2x5A Output: 10A 25 years 25 years 84 868 000h 125 266 000h 71 454 000h 81 453 000h at 24V and 40°C at 24V and 25°C at 24V 40°C at 24V 25°C at 24Vand 40°C (Ground Benign GB40) at 24Vand 25°C (Ground Benign GB25) *) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life). **) 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. Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 7/18 MLY02.100 MiniLine MLY-Series DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE 6. TERMINALS AND WIRING Type Solid wire Stranded wire American Wire Gauge Max. wire diameter Wire stripping length Pull-out force Input and output Bi-stable, quick-connect spring clamp terminals. IP20 Finger safe construction. Suitable for field- and factory installation. 0.3-4mm2 0.3-2.5mm2 26-12 AWG 2.8mm (including ferrule) 6mm / 0.25inch 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E) Instructions: a) Use appropriate copper cables that are designed for minimum operating temperatures of: 60°C for ambient up to 45°C and 75°C for ambient up to 60°C and 90°C for ambient up to 70°C minimum. b) Follow national installation codes and installation regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Ferrules are allowed, but not required. e) Do not connect or disconnect the wires from the terminals below -25°C (-13°F). Terminals shipped in open position. Fig. 6-1 Connecting a wire Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 8/18 MLY02.100 MiniLine DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series 7. FUNCTIONAL DIAGRAM Fig. 7-1 Functional diagram + - + + + Input 2 - - Input 1 Output 8. FRONT SIDE AND USER ELEMENTS Fig. 8-1 Front side A Output terminal B Input terminals for input 1 C Input terminals for input 2 Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 9/18 MLY02.100 MiniLine MLY-Series DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE 9. EMC The redundancy module 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 lines Surge voltage on output line Conducted disturbance Power-frequency magnetic field *) According generic standards: EN 61000-6-1 and EN 61000-6-2 Contact discharge 8kV EN 61000-4-2 Air discharge 15kV EN 61000-4-3 80MHz-2.7GHz 10V/m Input lines 2kV EN 61000-4-4 Output lines 2kV EN 61000-4-5 + / -  DIN rail 1kV EN 61000-4-5 + / -  DIN rail 1kV EN 61000-4-6 0.15-80MHz 10V EN 61000-4-8 50Hz 30A/m Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterions: A: Redundancy module shows normal operation behavior within the defined limits. Notes: *) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic fields, e.g. hall elements, electrodynamic microphones, etc. According generic standards: EN 61000-6-3 and EN 61000-6-4 IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, input lines *) IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, output lines *) Radiated emission EN 55011, EN 55032 Class B 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. EMC Emission Conducted emission *) Provided, that power sources connected on the inputs fulfill the class B requirements too. Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 10/18 MLY02.100 DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series MiniLine 10. ENVIRONMENT Operational temperature *) Output de-rating Storage temperature Humidity **) Vibration sinusoidal ***) Shock ***) Altitude -40°C to +70°C (-40°F to 158°F) 0.25A/°C -40 to +85°C (-40°F to 185°F) 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 6560ft) 2000 to 6000m (6560 to 20000ft) Altitude derating Over-voltage category 0.7A/1000m or 5°C/1000m not applicable Degree of pollution 2 Reduce output power above +60°C 60-70°C (140°F to 158°F), see for storage and transportation IEC 60068-2-30 IEC 60068-2-6 IEC 60068-2-27 without any restrictions reduce output power or ambient temperature, see Fig. 10-2 > 2000m (6500ft), see Fig. 10-2 The concept of the overvoltage category is used for equipment energized directly from the low voltage mains (IEC 60664-1 §4.3.3.2.1). IEC 62103, EN 50178, not conductive *) 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 ***) Tested in combination with DIN rails according to EN 60715 with a height of 15mm and a thickness of 1.3mm and standard mounting orientation. Fig. 10-1 Output current vs. ambient temp. Allowed Output Current 17.5A 15.0 Allowed Output Current 17.5A at overload / short circuit 12.5 10.0 Fig. 10-2 Output current vs. altitude 12.5 normal mode 7.5 5.0 5.0 2.5 2.5 Ambient Temperature 0 20 normal mode 10.0 7.5 0 -40 -25 overload / short circuit 15.0 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 Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 11/18 MLY02.100 MiniLine MLY-Series DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE 11. PROTECTION FEATURES Output over-current protection Reverse input polarity protection Degree of protection Penetration protection Over-temperature protection Input transient protection Output transient protection Internal input fuse not included included IP 20 > 2.5mm not included not included not included not included unit does not start when input voltage is reversed EN/IEC 60529 e.g. screws, small parts 12. SAFETY FEATURES Input / output separation Safety level of output voltage Class of protection no galvanic separation 200V epitaxial diode between input and output The output voltage is regarded to be SELV (EN 60950-1) or PELV (EN 60204-1, EN 50178, IEC 60364-4-41) if the input voltage fulfils the requirements for a SELV source or PELV source. III plastic housing, PE connection not required Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 12/18 MLY02.100 MiniLine MLY-Series DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE 13. APPROVED, FULFILLED OR TESTED STANDARDS UL 508 IEC 60950-1 UL 60950-1 ATEX IECEx Class I Div 2 Marine (DNV) Marine (ABS) IEC 60068-2-60 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 Agency Certificate (Bureau Veritas) EN 60079-0 Explosive atmospheres - General requirements EN 60079-7 Equipment protection by type of protection "e" Certificate: EPS 11 ATEX 1 312 X Temperature Code: T4 Type of Protection: ec IECEx Certificate IEC 60079-0 Explosive atmospheres - General requirements IEC 60079-7 Equipment protection by type of protection "e” Certificate: IECEx EPS 12.0032X Temperature Code: T4 Type of Protection: ec 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 Certificate DNV Type approved product Certificate: TAA00002JT 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-PDA 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 10 years. Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 13/18 MLY02.100 MiniLine ISA-71.04 G3 VDMA 24364 MLY-Series DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE 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 10 years Paint Wetting Impairment Substances Test (or LABS-Test) Tested for Zone 2 and test class C1 according to VDMA 24364-C1L/W for solvents and water-based paints 14. REGULATORY PRODUCT COMPLIANCE EU Declaration of Conformity REACH Directive WEEE Directive EAC TR Registration The CE mark indicates conformance with the - EMC directive - ATEX directive - RoHS directive Manufacturer's Statement EU-Directive regarding the Registration, Evaluation, Authorization and Restriction of Chemicals Manufacturer's Statement EU-Regulation on Waste Electrical and Electronic Equipment Registered in Germany as business to business (B2B) products. EAC Certificate EAC EurAsian Conformity - Registration Russia, Kazakhstan and Belarus 8504408200, 8504409000 Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 14/18 MLY02.100 MLY-Series MiniLine DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE 15. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN rail Installation clearances 140g / 0.31lb Use 35mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm. The DIN rail depth must be added to the unit depth (91mm) to calculate the total required installation depth. See chapter 2 Fig. 15-1 Front view Fig. 15-2 Side view 16. ACCESSORIES DIN rail bracket for wall or panel mount: A suitable DIN rail bracket is available on request. The picture of the power supply is for representation only Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 15/18 MLY02.100 MiniLine DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series 17. APPLICATION NOTES 17.1. RECOMMENDATIONS FOR REDUNDANCY Recommendations for the configuration of redundant power systems: • Use separate input fuses for each power supply. • Use three-phase power supplies to gain functional safety if one phase fails. • When single-phase power supplies are utilized connect them to different phases or mains circuits if possible. • Set the power supply in “Parallel-Use” mode if this feature is available • It is desirable to set the output voltages of all power supplies to the same value. 17.2. INDUCTIVE AND CAPACITIVE LOADS The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads. 17.3. EXAMPLE: 1+1 REDUNDANCY 1+1 Redundancy up to 2.1A requires two ML50.100 power supplies (each 2.1A output current) and one MLY02.100 redundancy module. Fig. 17-1 Wiring diagram, 1+1 Redundancy, 2.1A output current Alarm Monitor + + - - DC OK + + - - Output ML50.100 Power Supply ML50.100 Power Supply Input Input L L N + - + IN 1 IN 2 DC OK Output MLY02.100 Load Output + + - - + - N I I L N Note: Use separate mains systems for each power supply whenever it is possible Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 16/18 MLY02.100 MiniLine DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series 17.4. EXAMPLE: N+1 REDUNDANCY N+1 Redundancy up to 6.3A requires four ML50.100 power supplies (each 2.1A output current) and two MLY02.100 redundancy modules. Fig. 17-2 Wiring diagram, N+1 Redundancy, 6.3A output current Alarm Monitor ML50.100 Power Supply Input L N + - + IN 1 IN 2 MLY02.100 + + - - DC OK + + - - DC OK Output Output ML50.100 Power Supply ML50.100 Power Supply Input Input L L Output + + - - N N + + - - + - + IN 1 IN 2 DC OK Output ML50.100 Power Supply MLY02.100 Output + + - - Input L I DC OK Output N Load + - I + + - - I I L N Note: Use separate mains systems for each power supply whenever it is possible 17.5. EXAMPLE: BATTERY BACK-UP A battery back-up requires one power supply and one MLY02.100 redundancy module. Please note: Set output voltage of power supply to 26.5Vdc minimum to ensure, that the load current is delivered from the power supply and not from charger (battery). Use a fuse between battery and MLY02.100! Fig. 17-3 Wiring diagram, 10A Battery back-up Failure Monitor 24V Battery + I - + + - - DC OK Output ML50.100 Power Supply Battery Charger Input L N + - + IN 1 IN 2 MLY02.100 Output + + - - L N PE Load Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 17/18 MLY02.100 MiniLine DC12-48V (120V), 10A, DUAL REDUNDANCY MODULE MLY-Series 17.6. 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. Fig. 17-4 Mounting Orientation A (Standard orientation) Output Current INPUT 10A 8 6 4 2 0 10 Redundancy Module OUTPUT Fig. 17-5 Mounting Orientation B (Upside down) 20 30 40 50 60°C Output Current OUTPUT 10A 8 6 4 2 0 10 Redundancy Module INPUT Fig. 17-6 Mounting Orientation C (Table-top mounting) Ambient Temperature 20 30 40 50 60°C Output Current 10A 8 6 4 2 0 10 Ambient Temperature 20 30 40 50 60°C Output Current INPUT Fig. 17-8 Mounting Orientation E (Horizontal ccw) Redundancy Module OUTPUT 10A 8 6 4 2 0 10 Ambient Temperature 20 30 40 50 60°C OUTPUT INPUT Output Current Redundancy Module Fig. 17-7 Mounting Orientation D (Horizontal cw) Ambient Temperature 10A 8 6 4 2 0 10 Ambient Temperature 20 30 40 50 60°C Jul. 2021 / Rev. 1.5 DS-MLY02.100-EN All parameters are specified at 24V, 10A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 18/18