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- Honeywell
- 2MLR-DC42
- Redundant Power Supply Module
- USA
- 110 × 55 × 95 mm
- 0.417 kg
- Xiamen, China
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Product Overview
The Honeywell 2MLR-DC42 is a 24 V DC redundant power supply module for the MasterLogic-200R PLC system. It converts an external DC supply into the regulated 5 V DC power required by the controller and associated system hardware. With a rated output current of 7.5 A, it serves as one of the power supply options for redundant MasterLogic installations.
In a PLC control cabinet, the power supply is responsible for maintaining the electrical conditions required by the CPU, communication modules, and other rack-mounted components. An unstable supply can affect controller operation, interrupt communication, or cause connected modules to stop functioning. The 2MLR-DC42 addresses the power requirements of the MasterLogic-200R platform by accepting a 24 V DC input and supplying a regulated 5 V DC output.
The redundant power configuration is particularly relevant in continuous industrial processes. For example, in an oil and gas processing facility, a PLC may continuously monitor pressure, temperature, flow, and equipment operating status. A power interruption affecting the controller can have consequences beyond the control cabinet itself. The redundant power architecture helps reduce the risk associated with a single power supply failure.
The 2MLR-DC42 also includes a RUN status relay output. This contact can be incorporated into the system’s monitoring arrangement so that the power supply operating condition can be checked by the controller or associated monitoring circuit. A voltage status LED provides a local indication when the output voltage is normal.
Unlike the AC-input power supply variants in the same family, the 2MLR-DC42 accepts a 24 V DC input. This makes it appropriate for installations where a DC power distribution system is already available. When selecting a replacement, the input voltage, output current requirement, mounting position, and redundant power configuration should all be checked.
Technical Specifications
| Parameter | Specification |
|---|---|
| Manufacturer | Honeywell |
| Model | 2MLR-DC42 |
| Product Series | MasterLogic-200 |
| System Type | MasterLogic-200R |
| Product Type | Redundant Power Supply Module |
| Power Supply Type | DC Input Power Module |
| Rated Input Voltage | 24 V DC |
| Input Voltage Range | 19.2–28.8 V DC |
| Output Voltage | 5 V DC |
| Output Voltage Accuracy | ±2% |
| Rated Output Current | 7.5 A |
| Rated Output Power | 37.5 W |
| Efficiency | 65% or higher |
| Inrush Current | 80 A peak or lower |
| Input Fuse | Built-in, non-user-replaceable |
| DC Input Fuse Rating | 125 V / 10 A, Time-Lag Type |
| Allowable Instantaneous Interruption | Within 20 ms |
| RUN Relay Output | 24 V DC, 0.5 A |
| Minimum Relay Switching Load | 5 V DC, 1 mA |
| Relay Response Time | OFF to ON: ≤10 ms; ON to OFF: ≤12 ms |
| Voltage Status Indicator | LED |
| Applied Installation Position | Power section of basic/expansion base |
| Dimensions | 110 × 55 × 95 mm |
| Weight | 0.417 kg |
Product Features
- 24 V DC Input: Accepts an industrial DC supply within the specified 19.2–28.8 V input range.
- Regulated 5 V DC Output: Supplies the operating voltage required by compatible MasterLogic-200R hardware.
- 7.5 A Output Capacity: Provides the rated current required by the configured controller and associated modules.
- Redundant Power Architecture: Belongs to the dedicated redundant power supply family for MasterLogic-200R installations.
- Built-In Input Fuse: Includes an internal fuse for input-side protection. The fuse is not intended for user replacement.
- Overcurrent Protection: Helps protect the power supply and connected circuits when excessive current is detected.
- RUN Relay Contact: Provides a relay output for power supply operating-status monitoring.
- Voltage Status LED: Allows maintenance personnel to check the normal output voltage condition locally.
- DC Power Distribution: Fits installations using a 24 V DC control power distribution arrangement.
- Industrial PLC Integration: Installs in the designated power supply position of the MasterLogic-200R basic or expansion base.
Product Working Principle
The 2MLR-DC42 operates as a DC-to-DC power conversion module within the MasterLogic-200R PLC system.
Its input stage receives 24 V DC from the cabinet power distribution system. The internal power conversion circuit then regulates this input to produce a 5 V DC output, which supplies the electronic components installed in the PLC base.
The basic power conversion process is:
24 V DC Power Source → 2MLR-DC42 Input Circuit → Internal Power Conversion → Regulated 5 V DC Output → PLC System Modules
During normal operation, the module maintains its regulated output within the specified voltage tolerance. The available output current is rated at 7.5 A, so the total current consumption of the installed modules must be considered when selecting the power supply.
The module also incorporates protection functions. If an overcurrent condition occurs in the DC output circuit, the protection mechanism can interrupt the affected supply to prevent continued operation under an abnormal load condition. A short circuit or insufficient power capacity can therefore result in the power supply shutting down its output.
The RUN relay output provides another useful function. It supplies a status contact that can be incorporated into the controller’s monitoring arrangement. This allows the system to detect or monitor the power supply operating condition rather than relying exclusively on a visual inspection of the module.
The voltage status LED provides a local indication when the output voltage is normal. During maintenance, this indicator can help technicians distinguish between an input power problem, an output condition, and a fault elsewhere in the PLC system.
In a redundant installation, the power supply status is also relevant to the controller’s monitoring logic. The MasterLogic-200R architecture includes dedicated redundant power supply arrangements, allowing the system to monitor power supply failure conditions.
Role in Honeywell MasterLogic-200R Control System Architecture
The 2MLR-DC42 forms part of the power distribution architecture of the MasterLogic-200R controller. It supplies regulated 5 V DC power to the electronic modules installed in the basic or expansion base.
Unlike CPU and I/O modules, the power supply does not execute control logic or process field signals. Its responsibility is to maintain the electrical supply required for those components to operate.
24 V DC Power Source → 2MLR-DC42 → MasterLogic-200R Base → CPU and Communication Modules → I/O Modules → Field Devices
| System Component | Function |
|---|---|
| 2MLR-DC42 | Supplies regulated 5 V DC power from a 24 V DC input |
| 2MLR-AC12 | Redundant power supply, 110 V AC input, 5.5 A |
| 2MLR-AC22 | Redundant power supply, 220 V AC input, 5.5 A |
| 2MLR-AC13 | Redundant power supply, 110 V AC input, 8.5 A |
| 2MLR-AC23 | Redundant power supply, 220 V AC input, 8.5 A |
| 2MLR-CPUH/T | Redundant CPU configuration with TP communication |
| 2MLR-CPUH/F | Redundant CPU configuration with FO communication |
| 2MLR-M02P | Main CPU base for a two-module installation |
| 2MLR-M06P | Main CPU base for a six-module installation |
| 2MLR-E12H | Redundant expansion base with 12 slots |
| MasterLogic I/O Modules | Process digital and analog field signals |
The choice between AC and DC power supply variants depends on the available cabinet power source and the electrical requirements of the installation. The 2MLR-DC42 is specifically intended for 24 V DC input applications.
Industrial Applications
The 2MLR-DC42 is used in industrial control installations where the MasterLogic-200R PLC system operates from a 24 V DC power distribution source.
| Industrial Application | Typical Use |
|---|---|
| Oil and Gas Processing | Supplying the PLC hardware used for process monitoring and equipment control |
| Petrochemical Plants | Powering redundant controller installations in continuous production processes |
| Chemical Processing | Maintaining the 5 V DC supply for PLC control and monitoring modules |
| Power Generation | Supporting the electrical supply of distributed automation equipment |
| Water Treatment Facilities | Powering PLC systems responsible for pumps, valves, and treatment processes |
| Compressor Stations | Supplying controller hardware for compressor monitoring and protection systems |
| Refinery Automation | Supporting PLC-based process control and equipment monitoring |
| Industrial Manufacturing | Powering modular PLC installations across production lines |
| Pipeline Control Systems | Supplying automation hardware used for remote process monitoring |
| Continuous Process Industries | Supporting redundant PLC power arrangements where control availability is important |
Installation and Maintenance
- Verify the Model Number: Confirm that the replacement is 2MLR-DC42 and not one of the AC-input power supply variants.
- Check the DC Input Source: Verify that the available supply is 24 V DC and remains within the specified 19.2–28.8 V input range.
- Calculate Power Requirements: Check the combined current consumption of the installed modules to ensure that the 7.5 A output rating is sufficient.
- Inspect the Installation Position: Confirm that the module is installed in the designated power supply position of the compatible basic or expansion base.
- Isolate the Power Source: Disconnect the external DC supply and follow the applicable electrical isolation procedures before removing the module.
- Inspect Input Wiring: Check the DC supply terminals for loose connections, damaged insulation, or incorrect polarity.
- Check Output Connections: Inspect the power distribution connections between the module and the PLC base for signs of overheating or mechanical damage.
- Verify Grounding: Check that the cabinet grounding arrangement follows the installation requirements of the MasterLogic-200R system.
- Check the Voltage Indicator: After restoring power, inspect the LED to confirm that the output voltage status is normal.
- Test the RUN Relay: Verify the relay contact operation and confirm that the power supply status is correctly reflected in the associated monitoring circuit.
- Investigate Overcurrent Conditions: If the power supply shuts down, inspect the connected modules and wiring for short circuits or excessive current consumption before restarting the system.
- Record Maintenance Results: Document the input voltage, output status, connected load, relay condition, and replacement module identification.
The internal input fuse is not user-replaceable. If a fuse-related fault or internal power supply failure is suspected, the module should be evaluated as a complete assembly rather than opened for routine fuse replacement.
Compatible System Components
| Component | Function |
|---|---|
| Honeywell 2MLR-CPUH/T | Redundant CPU configuration with TP communication |
| Honeywell 2MLR-CPUH/F | Redundant CPU configuration with FO communication |
| Honeywell 2MLR-M02P | Main CPU base, two-module installation |
| Honeywell 2MLR-M06P | Main CPU base, six-module installation |
| Honeywell 2MLR-E12H | Redundant expansion base with 12 slots |
| Honeywell 2MLR-AC12 | Alternative redundant AC power supply, 110 V input |
| Honeywell 2MLR-AC22 | Alternative redundant AC power supply, 220 V input |
| Honeywell 2MLR-AC13 | Redundant AC power supply, 110 V input, 8.5 A |
| Honeywell 2MLR-AC23 | Redundant AC power supply, 220 V input, 8.5 A |
| MasterLogic-200R CPU Modules | Execute PLC programs and coordinate system operation |
| MasterLogic-200R I/O Modules | Handle digital and analog field signals |
Recommended Related Models
| Model / Product Family | Product Type | Typical Application |
|---|---|---|
| Honeywell 2MLR-AC12 | Redundant Power Supply Module, 110 V AC, 5.5 A | AC-input redundant power configuration |
| Honeywell 2MLR-AC22 | Redundant Power Supply Module, 220 V AC, 5.5 A | 220 V AC redundant power configuration |
| Honeywell 2MLR-AC13 | Redundant Power Supply Module, 110 V AC, 8.5 A | Higher-current AC power configuration |
| Honeywell 2MLR-AC23 | Redundant Power Supply Module, 220 V AC, 8.5 A | Higher-current 220 V AC power configuration |
| Honeywell 2MLR-CPUH/F | Redundant CPU Module, FO | Fiber-optic redundant controller system |
| Honeywell 2MLR-M06P | Main CPU Base, 6 Slot | MasterLogic-200R main controller installation |
Key Advantages
- 24 V DC input for industrial DC power distribution systems.
- Regulated 5 V DC output for MasterLogic-200R hardware.
- 7.5 A rated output current.
- Built-in input fuse and overcurrent protection.
- RUN relay output for power status monitoring.
- LED indication of normal output voltage.
- Dedicated power module for redundant PLC installations.
- Compact modular installation within the MasterLogic-200R base.
Technical FAQs
1. What is the input and output voltage of the Honeywell 2MLR-DC42?
The 2MLR-DC42 accepts a nominal 24 V DC input, with an allowable input range of 19.2–28.8 V DC. It converts this supply into a regulated 5 V DC output with a specified voltage accuracy of ±2%.
2. What is the maximum rated output current of the 2MLR-DC42?
The module has a rated output current of 7.5 A. Its rated output power is 37.5 W. When selecting the power supply, the combined current consumption of the installed PLC modules must remain within the available power capacity.
3. What is the purpose of the RUN relay output?
The RUN relay provides a status contact associated with the power supply operating condition. Its rated switching capacity is 24 V DC at 0.5 A. The contact can be used in a monitoring circuit to provide information about the power supply status.
4. What should be checked if the 2MLR-DC42 output voltage becomes abnormal?
First, measure the external DC input and confirm that it remains within the specified voltage range. Next, check the connected load for excessive current consumption or short circuits. Also inspect the power distribution connections and voltage status LED. Because the input fuse is built in and not user-replaceable, suspected internal fuse or power conversion failures require evaluation of the complete module.