CP20.242-IOL
24 V, 20 A, 480 W, SINGLE PHASE

CP-Series

POWER SUPPLY AC 100-240 V wide-range input
 Width only 48 mm
 With IO-Link communication interface
 Efficiency up to 95.5 % 20 % output power reserves (PowerBoost) Easy Fuse Breaking – 3 times nominal current for 12 ms
 Safe HiccupPLUS Overload Mode Full power between -25 °C and +60 °C
 Current sharing feature for parallel use
 3 Year warranty

PRODUCT DESCRIPTIONSHORT-FORM DATAThe CP20.242-IOL is a high-quality power supply based on
the popular CP20 series. With the integrated IO-Linkinterface the unit is giving access to real-time andrecorded data informing about the condition of thepower supply itself and the power line. Amongst manyelectrical operation parameters, event signals areavailable via the interface as well as a remote ON/OFF
function and “Parallel Use” feature for load sharing
between power supplies connected in parallel.

Output voltage
Adjustment range

Like its series members, the CP20.242-IOL comes withadvanced features like e.g. PowerBoost: Power reservesof 20 %, which may even be used continuously attemperatures up to +45 °C. Additionally it can deliver 3
times the nominal output current for 12 ms, which helps
to trip fuses on faulty output branches.
The Dimension CP-Series are cost optimized power supplies
without compromising quality, reliability and performance.
The most outstanding features of this series are the highefficiency, electronic inrush current limitation, active PFC,
wide operational temperature range and the extraordinary
small size.

48x124x127 mm
835 g

Without DIN rail

For details and the complete approval list, see chapter 21.

Power Supply CP20.242-IOL
ZM10.WALL

Output current
PowerBoost
Derating
Input voltage AC
Mains frequency
Input current AC
Power factor
Input voltage DC
Input current DC
AC Inrush current
Efficiency
LossesHold-up time
Temperature
range
Size (WxHxD)
WeightMAIN APPROVALSORDER NUMBERS
Accessory

Output current
PowerBoost
Derating

DC 24 V
Nominal24 – 28 V
Factory setting 24.1 V
AC 120–240 V mains, DC 150-300 V mains
20.0 – 17.1 A
Up to +60 °C ambient
24.0 – 20.6 A
Up to +45 °C ambientlinear 12.5 W/K> +60 °C ambient
AC 100 V mains, DC 110-150 V mains
17.5 – 15.0 A
Up to +60 °C ambient
21.0 – 18.0 A
Up to +45 °C ambientlinear 10.5 W/K> +60 °C ambient
AC 100-240 V-15 %/+10 %50-60 Hz
±6 %4.26 / 2.23 A
At 120 / 230 Vac
0.99 / 0.98
At 120 / 230 Vac
DC 110-300 V±20 %4.64 / 1.66 A
At 110 / 300 Vdc
10.0 / 4.5 Apeak
At 120 / 230 Vac
94.1 / 95.5 %At 120 / 230 Vac
30.0 / 23.0 W
At 120 / 230 Vac
32 / 32 ms
At 120 / 230Vac-25 °C to +70 °C

Wall/Panel mounting
bracketUL 61010-2-201

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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CP-Series

Index
Page
1. Intended Use .......................................................3
2. Installation Instructions ......................................3
3. AC-Input...............................................................5
4. DC-Input...............................................................6
5. Input Inrush Current ...........................................6
6. Output .................................................................7
7. Hold-up Time .......................................................9
8. DC OK Function ...................................................9
9. Remote ON / OFF Function ...............................10
10. IO-Link Interface................................................10
11. Efficiency and Power Losses..............................12
12. Functional Diagram...........................................13
13. Front Side and User Elements ...........................14
14. Terminals and Wiring ........................................15
15. Lifetime Expectancy ..........................................16
16. MTBF ..................................................................16
17. EMC ....................................................................17
18. Environment ......................................................19
19. Safety and Protection Features ........................20
20. Dielectric Strength ............................................21
21. Approved, Fulfilled or Tested Standards .........22Page
22. Regulatory Product Compliance ...................... 22
23. Physical Dimensions and Weight ..................... 23
24. Accessories ........................................................ 24
24.1. ZM10.WALL –Wall/Panel Mounting Bracket .................. 24
24.2. UF20.241 Buffer Module .......................... 25
24.3. YR40.241 - Redundancy Module .............. 25
24.4. YR40.242 - Redundancy Module .............. 25
24.5. YR40.245 - Redundancy Modules ............ 26
25. Application Notes ............................................. 27
25.1. Peak Current Capability ........................... 27
25.2. Output Circuit Breakers............................ 28
25.3. Charging of Batteries ............................... 29
25.4. Series Operation ....................................... 29
25.5. Parallel Use to Increase Output Power .... 29
25.6. Parallel Use for Redundancy .................... 30
25.7. Operation on Two Phases ........................ 31
25.8. Mounting Orientation.............................. 31

The information given in this document is correct to the best of our knowledge and experience at the time of
publication. If not expressly agreed otherwise, this information does not represent a warranty in the legal sense of theword. As the state of our knowledge and experience is constantly changing, the information in this data sheet issubject to revision. We therefore kindly ask you to always use the latest issue of this document (available underwww.pulspower.com).
No part of this document may be reproduced or utilized in any form without our prior permission in writing.
Packaging and packaging aids can and should always be recycled. The product itself may not be disposed of as
domestic refuse.

Terminology and Abreviations
PE andsymbolPE 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 230 V

A figure displayed with the AC or DC before the value represents a nominal voltage withstandard tolerances (usually ±15 %) included.
E.g.: DC 12 V describes a 12 V battery disregarding whether it is full (13.7 V) or flat (10 V)

230 Vac

A figure with the unit (Vac) at the end is a momentary figure without any additional
tolerances included.

50 Hz vs. 60 Hz

As long as not otherwise stated, AC 230 V parameters are valid at 50 Hz mains frequency.

may

A key word indicating flexibility of choice with no implied preference.

shall

A key word indicating a mandatory requirement.

shouldA key word indicating flexibility of choice with a strongly preferred implementation.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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CP-Series

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
WARNING

Risk of electrical shock, fire, personal injury or death- Turn power off before working on the device. Protect against inadvertent re-powering.
- 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 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 surfaces may cause burns.
Obey the following installation instructions:This device may only be installed and put into operation by qualified personnel.
This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to
the factory for inspection.
Install the 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.
Make sure that the wiring is correct by following all local and national codes. Use appropriate copper cables that aredesigned 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. Use ferrules for wires on the input terminals. Unused screw terminals should besecurely tightened.
The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed.
The enclosure 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
terminals and the PE potential must not exceed 300 Vac.
The input can also be powered from a battery or a similar DC source. The continuous voltage between the supply
voltage and the PE/ground potential must not exceed 375 Vdc.
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 notcover ventilation grid!
The device is designed for altitudes up to 5000 m. Above 2000 m a reduction in output current and over voltage
category is required.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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Keep the following minimum installation clearances:
Output power
related to nominal< 50 %≥ 50 %≥ 90 %

top
40
40
40

Installation clearance (mm)bottom
side
20
0
20
5
20
15

The device is designed, tested and approved for branch circuits up to 32 A (IEC) and 30 A (UL) without additional
protection device. If an external fuse is utilized, do not use circuit breakers smaller than 10A B- or C-Characteristic toavoid a nuisance tripping of the circuit breaker.
The maximum surrounding air temperature is +70 °C. The operational temperature is the same as the ambient or
surrounding air temperature and is defined 2 cm below the device.
The device is designed to operate in areas between 5 % and 95 % relative humidity.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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3. AC-Input
The device is suitable to be supplied from TN, TT or IT mains networks.
nom.
nom.

Allowed voltage L or N to earth
Input frequency
Turn-on voltage
Shut-down voltage
External input protection

AC 120-240 V-15 %/+10 %AC 100-240 V-15 %/+10 %85-264 Vac
264-300 Vac
Occasionally for maximal 500 ms
max.
300 Vac
Continuous, according to IEC 60664-1
nom.
50–60 Hz±6 %typ.
82 VacSteady-state value, see Fig. 3-1
typ.
72 VacSteady-state value, see Fig. 3-1
See recommendations in chapter “Installation Instructions”.

Input current
Power factor
Crest factor

typ.
typ.
typ.

AC 100 V
5.15 A
0.99
1.65

AC 120 V
4.26 A
0.99
1.63

AC 230 V
2.23 A
0.98
1.63

Start-up delay
Rise time

typ.
typ.

710 ms
119 ms647 ms
116 ms

506 ms
114 mstyp.

123 ms

122 ms

121 msmax.

200 mV

200 mV

200 mV

Turn-on overshootFig. 3-1 Input voltage range

Rated
input range

Fig. 3-2 Turn-on behavior, definitions

Input
Voltage

max.
500ms

Turn-onShut-down

POUT

- 5%

OutputVoltage

VIN
85V

At 24 V, 20 A, see Fig. 3-3
At 24 V, 20 A, see Fig. 3-4
At 24 V, 20 A, The crest factor isthe mathematical ratio of the peakvalue to RMS value of the input
current waveform.
See Fig. 3-2
At 24 V, 20 A const. current load,
0mF load capacitance, see Fig. 3-2
At 24 V, 20 A const. current load,
20 mF load capacitance, see Fig. 3-2
In single use mode, see Fig. 3-2

Start-up
delay

Rise
Time

264V 300Vac

OvershootAC input voltage Range A
AC input voltage Range B
AC input range

Fig. 3-3 Input current vs. output current at 24 V
output voltage

Fig. 3-4 Power factor vs. output current at 24 V
output voltage

Input Current, typ.

Power Factor, typ.

6A

a

5

b

a) 100Vacb) 120Vacc) 230Vac4320Output Current

2

4

6

c

0.95
0.9

c

1

a, b

1.0

8 10 12 14 16 18 20 22 24Aa) 100Vacb) 120Vacc) 230Vac

0.85
0.8
0.75

Output Current

2

4

6

8 10 12 14 16 18 20 22 24A

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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CP-Series

4. DC-Input
The device is suitable to be supplied from a DC input voltage. Use a battery or a similar DC source.
A supply from the intermediate DC-bus of a frequency converter is not recommended and can cause a malfunction ordamage the unit.
Connect +pole to L, –pole to N and the PE terminal to an earth wire or to the machine ground.
DC input voltage Range A
DC input voltage Range B
DC input range
DC input current

nom.
nom.

Allowed Voltage L/N to Earth
Turn-on voltage
Shut-down voltage

max.
typ.
typ.

DC 150-300 V
DC 110-150 V
88-360 Vdc
4.64 A
1.66 A375 Vdc
80 Vdc70 Vdc

typ.

±20 %
±20 %
At 110 Vdc, at 24 V, 20 A
At 300 Vdc, at 24 V, 20 A
Continuous, according to IEC 62477-1
Steady state value
Steady state value

Fig. 4-1 Wiring for DC Input

Battery+

Power Supply
AC
L

+

N
PE
-

-

Load

DC

5. Input Inrush Current
An active inrush limitation circuit limits the input inrush current after turn-on of the input voltage.
The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
Inrush current

max.
typ.

AC 100 V
15 Apeak
12 ApeakAC 120 V
12 Apeak
10 ApeakAC 230 V
5.5 Apeak
4.5 Apeak

Temperature independent
Temperature independent

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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CP-Series

6. Output
The output provides a SELV/PELV rated voltage, which is galvanically isolated from the input voltage.
The output is electronically protected against no-load, overload and short circuit. In case of a protection event, audible
noise may occur.
The output is designed to supply any kind of loads, including inductive and capacitive loads. If capacitors with acapacitance > 1 F are connected, the unit might charge the capacitor in an intermittent mode.
At heavy overloads (when output voltage falls below 13 V), the power supply delivers continuous output current for
2 s. After this, the output is switched off for approx. 18 s before a new start attempt is automatically performed. This
cycle is repeated as long as the overload exists. If the overload has been cleared, the device will operate normally.
The device is equipped with a “Single Use / Parallel Use” feature, which can be selected via IO-Link. The “Parallel Use”
mode regulates the output voltage in such a manner that the voltage at no load is approx. 4 % higher than at nominal
load. This achieves a load sharing between power supplies when they are connected in parallel.
Output voltage
Adjustment range

Factory setting output voltage

Line regulation
Load regulation

Ripple and noise voltage
Output current Range A

PowerBoost Range A1)

Output current Range B

PowerBoost Range B1)

nom.
min.
max.

24 V
24-28 V
30 V

Guaranteed value
This is the maximum output voltage which can occur
at the clockwise end position of the potentiometer
due to tolerances. It is not a guaranteed value which
can be achieved.
typ.
24.1 V±0.2 % in “single use” mode at full load, cold unit
±0.2 % in “parallel use” mode at 20 A, cold unit
typ.
24.1 V(results to 23.9 V ±0.2 % at 24 A and 25.1 V ±0.2 %at no load), see Fig. 6-2
max.
10 mV
Between 85 and 300 Vac input voltage change
Between 0 and 24 A in “single use” mode, staticmax.
100 mVvalue
Between 0 and 20 A in “parallel use” mode, static
typ.
1000 mVvalue
typ.
60 mVpp
Bandwidth 20 Hz to 20 MHz, 50 Ohm
nom.
20.0 AAt 24 V and up to +60 °C ambient temperaturenom.
14.8 AAt 24 V and +70 °C ambient temperaturenom.
17.1 AAt 28 V and up to +60 °C ambient temperaturenom.
12.7 AAt 28 V and +70 °C ambient temperature
Derate linearly between +60 °C to +70 °C, see chapter 18
At 24 V and up to +45 °C ambient temperature, seenom.
24.0 A
Fig. 18-1
At 28 V and up to +45 °C ambient temperature, seenom.
20.6 A
Fig. 18-1
PowerBoost decreases linearly to nominal power between +45 °C and +60 °C, seechapter 18
nom.
17.5 AAt 24 V and up to +60 °C ambient temperaturenom.
13.1 AAt 24 V and +70 °C ambient temperaturenom.
15.0 AAt 28 V and up to +60 °C ambient temperaturenom.
11.3 AAt 28 V and +70 °C ambient temperature
Derate linearly between +60 °C to +70 °C, see chapter 18
At 24 V and up to +45 °C ambient temperature, seenom.
21.0 A
Fig. 18-1
At 28 V and up to +45 °C ambient temperature, seenom.
18.0 A
Fig. 18-1
PowerBoost decreases linearly to nominal power between +45 °C and +60 °C, seechapter 18

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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CP-Series

Fuse breaking current

typ.

60 A

max.
typ.

Continuous current
Intermittent current
29.8 A
29.0 A

max.

9.8 A

typ.

8 500 µF

max.

35 V

Overload behavior
Overload/ short-circuit current

Output capacitanceBack-feeding loads

1)

Up to 12 ms once every five seconds, see Fig. 6-4.
The fuse breaking current is an enhanced transientcurrent which helps to trip fuses on faulty output
branches. The output voltage stays above 20 V.
For output voltage above 13 Vdc, see Fig. 6-1
For output voltage below 13 Vdc, see Fig. 6-1
Continuous current, see Fig. 6-1
Intermitted current peak value for typ. 2 s
Load impedance 10 mOhm, see Fig. 6-3
Discharge current of output capacitors is notincluded.
Intermitted current average value (R.M.S.)
Load impedance 10 mOhm, see Fig. 6-3
Included inside the power supply
The unit is resistant and does not show
malfunctioning when a load feeds back voltage tothe power supply. It does not matter whether the
power supply is on or off. The absorbing energy canbe calculated according to the built-in large sized
output capacitor.

PowerBoost
This power/ current is continuously allowed up to an ambient temperature of +45 °C.
Above +45 °C, do not use this power/ current longer than a duty cycle of 10 % and/ or not longer than 1 minute every 10 minutes.

Fig. 6-2 Output voltage in “parallel use” mode,
typ.

Fig. 6-1 Output voltage vs. output current, typ.

Output Voltage (Parallel Use, typ.)Output voltage (single use)
28V
24V

28V
27V

A

26V

13V
A: continuous current
B: intermitted current
0V

Adjustment
Range

29V

Adjustment range

0A

5A

10A

15A

25V

B

20A

25A

Factory
setting

24V
23V
22V

30A
35A
Output current

Output Current

40

Fig. 6-3 Short-circuit on output, HiccupPLUS® mode, typ.

12

8

20

16

24A

Fig. 6-4 Dynamic overcurrent capability, typ.
Output Voltage (dynamic behavior, < 12ms)

28V

OutputCurrent
Normaloperation

Normaloperation

Short -circuit

29A

24
Adjustment
Range

20
16
12

t

0
2s

18s

2s

18s

2s

18s

8
4
0

Output Current

0

10

20

30

40

50

60

70A

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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7. Hold-up TimeThe hold-up time is the time during which a power supply’s output voltage remains within specification following theloss of input power. The hold-up time is output load dependent. At no load, the hold-up time can be up to several
seconds. The green DC OK LED is also on during this time.
Hold-up TimeAC 100 V
65 ms
54 ms
32 ms
24 ms

typ.
min.
typ.
min.

AC 120 V
65 ms
54 ms
32 ms
24 ms

Fig. 7-1 Hold-up time vs. input voltage

AC 230 V
65 ms
54 ms
32 ms
24 ms

Fig. 7-2 Shut-down behavior, definitions

Hold-up Time

80ms
70
60
50
40
30
20
10
0

At 24 V, 10 A, see Fig. 7-1
At 24 V, 10 A, see Fig. 7-1
At 24 V, 20 A, see Fig. 7-1
At 24 V, 20 A, see Fig. 7-1

Zero Transition
Input
Voltage

24V, 10A, typ.
24V, 10A, min.
24V, 20A, typ.

Hold-up Time

Input Voltage

85

120

155

190

- 5%

OutputVoltage

24V, 20A, min.

230Vac8. DC OK Function
This feature monitors the output voltage on the output terminals of a running power supply.
The DC OK Function can be monitored via the IO-Link-Interface. It corresponds with the DC OK LED.
The value of the setpoint can be adjusted via the IO-Link interface.
DC OK
DC NOK
Hysteresis

As soon as the output voltage reaches the setpoint (default 22 V)
As soon as the output Voltage dips below a value, which is typically 0.5 V lower than the
setpoint value (Hysteresis)
Typically 0.5 V

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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9. Remote ON / OFF Function
This feature enables to switch off the output voltage via the IO-Link interface.
Note: The remote ON / OFF function has no safety feature included.

10.

IO-Link Interface

The IO-Link interface used in this power supply complies with the IO-Link protocol V1.1 and can be connected to any IOLink master that is compatible with V1.1 of the IO-Link protocol. This enables a transparent data flow to the sensors andactuators and therefore a more transparent and easier way of monitoring the current status of the power supply.
If no IO-Link connectivity is available, the power supply continues to operate without interruption. Thanks to a built-in
EEPROM, previously stored data is retrieved from its memory.
To operate the IO-Link interface it is necessary to install/upload the IODD-File (IO-Link Device Description) to theconnected IO-Link master. The most recent IODD file can be found on IODDfinder (https://ioddfinder.io-link.com) andon the PULS website (www.pulspower.com) in the download section of the individual product page. The device can also
be accessed via IO-Link, if the power supply is not connected to AC-mains and in a switched off mode.
IO-Link version

V1.1

Bit rate

COM3 (230.4 kBaud)Minimum cycle time

2.0 ms

SIO-Mode support

noProcess data length

6 bytes

Cycle time refers to the reloading speed of certain process
d
t A
Class

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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Three different types of data are exchanged via the IO-Link interface (for detailed information please refer to the “IOLink interface description”):
Process data
Process data is cyclically sent to the IO-Link master. CP20.242-IOL provides output current (A) and output voltage (V) as
process data. The data length is 6 bytes, showing actual current between 0 – 65 A in the first two bytes. The next two
bytes shows the actual voltage between 0 – 35 V. The last two bytes shows different warning and error flags. If thesebytes are 0, no warning or error is active. This process data is transmitted every 2 ms automatically. The accuracy is 100
mA for output current and 100 mV for output voltage.
Parameter values
Parameter values are exchanged acyclically and at the request of the IO-Link master. Depending on the access rights
device data can be written to the device, read from the device or both.
Parameter values are generated every 52 ms and stored in the IO-Link registers. A timer is used to supervise the timeinterval. If the time interval between two received bytes is longer than 100 ms or any error occurs (e.g. checksum
error), the previously received data will be discarded and the IO-Link read access returns the error 0x8082 “Application
not ready”.
EventsEvents report the status of the power supply. Typical events are warnings and errors in non-ideal and abnormal
situations (e.g. temperature too high, input voltage too low, etc.). These events are triggered by certain situations andwill result in an automated notification to the IO-Link master.
•

Actual RMS input voltage•

Min. RMS input voltage•

Input undervoltage event counter•Max. RMS input voltage•

Actual PEAK input voltage•

Max. PEAK input voltage•

Input overvoltage event counter•

Actual device temperature•

Min. device temperature•

Max. device temperature•

Overtemperature warning threshold•

Actual output current•

Max. output current•

Overcurrent warning threshold•

Actual output voltage•

Max. output voltage•

Output overvoltage warning threshold•

DC not OK threshold (Output undervoltage warning threshold)•Operating time•Turn-on counter•

Parallel mode•

Switch off output voltage•

Actual IO-Link voltage

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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11.

Efficiency and Power Losses

Efficiency

AC 100 V
93.6 %
93.3 %
93.5 %

typ.
typ.
typ.

AC 120 V
94.1 %
94.0 %
94.1 %

AC 230 V
95.5 %
95.4 %
95.5 %At 24 V, 20 A
At 24 V, 24 A (PowerBoost)
25 % at 5 A, 25 % at 10 A,
Average efficiency
25 % at 15 A, 25 % at 20 A
Power losses
typ.
0.7 W
0.8 W
1.3 W
in “Remote OFF” mode
typ.
2.7 W
2.4 W
2.3 W
At 24 V, 0 A
typ.
17.5 W
14.6 W
13.0 W
At 24 V, 10 A
typ.
33.9 W
30.0 W
23.0 W
At 24 V, 20 A
typ.
41.5 W
37.7 W
28.1 W
At 24 V, 24 A (PowerBoost)
The average efficiency is an assumption for a typical application where the power supply is loaded with 25 % of thenominal load for 25 % of the time, 50 % of the nominal load for another 25 % of the time, 75 % of the nominal load
for another 25 % of the time and with 100 % of the nominal load for the rest of the time.
Fig. 11-1 Efficiency vs. output current at
24 V, typ.

Fig. 11-2 Losses vs. output current at 24 V, typ.

Efficiency

Power Losses

96%
95
94
93
92
91
90
88
87

(c)
(b)
(a)

(a) 100Vac(b) 120Vac(c) 230Vac

Output Current

4

6

40W
35
30
25
20
15
10
5
0

8 10 12 14 16 18 20 22 24A

Fig. 11-3 Efficiency vs. input voltage at 24 V,
20 A, typ.
Efficiency(c)

Output Current

0

2 4

6

8 10 12 14 16 18 20 22 24A

Fig. 11-4 Losses vs. input voltage at 24 V,
20 A, typ.
Power Losses

96%

40W

95

35

94

30

93

25

92

20

91
90

(a)
(b)

(a) 100Vac(b) 120Vac(c) 230Vac

15

Input Voltage

100 120180

230

264Vac10Input V oltage

100 120180

230

264VacAll parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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12.

Functional Diagram
Fig. 12-1 Functional diagram

L
N

Input Fuse
Input Filter
Input Rectifier
Active Inrush Limiter

PFC
ConverterPower
Converter

OutputFilterOutputVoltage
Regulator
Temperature
Shutdown

OutputPower
Manager

OutputOverVoltage
Protection

Condition
MonitorIO-Link
Interface

+
+
VOUT
DC-ok
LED
L+
C/Q
LIO-Link ERR LED
IO-Link OK LED

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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13. Front Side and User Elements
Fig. 13-1 Front side

A

B

C

D

E

F

Input Terminals
L
Phase (Line) input
N Neutral conductor input
PE (Protective Earth) input
Output Terminals
Three terminals for the negative and two terminals forthe positive pole. Identical poles are internallyconnected.
+ Positive output- Negative (return) output
Output Voltage Potentiometer
for adjustment of output voltage.
Factory setting: 24.1 V
DC OK LED (green)
ON, when the voltage on the output terminals is > levelset by IO-Link parameter index 100 (Level for minimum
output voltage warning)
IO-Link Communication LEDs
ERR:
Red LED ON:•
IO-Link event is present (additionally green LED on /flashing)•
IO-Link voltage too low (additionally green LED off)
OK:
Green LED ON:•
IO-Link powered, no communicaton to IO-Link
MasterGreen LED Flashing:•
IO-Link communication up and running
IO-Link Terminals

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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14.

Terminals and Wiring

The terminals are IP20 Finger safe constructed and suitable for field- and factory wiring.

Type
Solid wire
Stranded wire
American Wire Gauge
Max. wire diameter (including ferrules)
Recommended tightening torque
Wire stripping length
Screwdriver

Input

OutputScrew terminal
Max. 6 mm2Max. 4 mm2
AWG 20-10
2.8 mmMax. 1 Nm
7 mm
3.5 mm slotted or crosshead No 2Screw terminal
Max. 6 mm2Max. 4 mm2
AWG 20-10
2.8 mmMax. 1 Nm
7 mm
3.5 mm slotted or
cross-head No 2

IO-Link/Signal
Terminals
Push-in terminal
Max. 1.5 mm2Max. 1.5 mm2
AWG 24-16
1.6 mm
8 mm
3 mm slotted to open
the spring

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 minimum+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) Do not use the unit without PE connection.
e) Unused terminal compartments should be securely tightened.
f) Ferrules are allowed.
Daisy chaining:
Daisy chaining (jumping from one power supply output to the next) is not allowed. Use a separate distribution
terminal block as shown in Fig. 14-1.
Fig. 14-1 Using distribution terminals

Power
SupplyPower
Supply

+ + -

+ + -

-

OutputDistribution
Terminals-

OutputLoad+-

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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15.

Lifetime Expectancy

The Lifetime expectancy shown in the table indicates the minimum operating hours (service lifetime) and isdetermined by the lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified inoperational hours and is calculated according to the capacitor’s manufacturer specification. The manufacturer of theelectrolytic capacitors only guarantees a maximum lifetime of up to 15 years (131 400 h). Any number exceeding thisvalue is a calculated theoretical lifetime which can be used to compare devices.

Lifetime expectancy

16.

AC 100 V
159 000 h

AC 120 V
185 000 h

AC 230 V
223 000 h

450 000 h
48 000 h

523 000 h
63 000 h

630 000 h
121 000 h

137 000 h
23 000 h

179 000 h
38 000 h

422 000 h
73 000 h

69 000 h

108 000 h

207 000 h

At 24 V, 10 A and +40 °C
At 24 V, 10 A and +25 °C
At 24 V, 20 A and +40 °C
At 24 V, 20 A and +25 °C
At 24 V, 24 A and +40 °C
At 24 V, 24 A and +25 °C

MTBFMTBF stands for Mean Time Between Failures, which is calculated according to statistical device failures, and indicatesreliability 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. 1 000 000 hmeans that statistically one unit will fail every 100 h if 10 000 units are installed in the field. However, it cannot be
determined if the failed unit has been running for 50 000 h or only for 100 h.
For these types of units the MTTF (Mean Time To Failure) value is the same value as the MTBF value.

MTBF SN 29500, IEC 61709
MTBF MIL HDBK 217F

AC 100 V
370 000 h

AC 120 V
388 000 h

AC 230 V
493 000 h

692 000 h

724 000 h

891 000 h

178 000 h

183 000 h

214 000 h

251 000 h

259 000 h

306 000 h

40 000 h

41 000 h

50 000 h

53 000 h

55 000 h

67 000 h

At 24 V, 20 A and +40 °C
At 24 V, 20 A and +25 °C
At 24 V, 20 A and +40 °C;
Ground Benign GB40
At 24 V, 20 A and +25 °C;
Ground Benign GB25
At 24 V, 20 A and +40 °C;
Ground Fixed GF40
At 24 V, 20 A and +25 °C;
Ground Fixed GF25

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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17.

EMC

The EMC behavior of the device is designed for applications in industrial environments as well as in professional
equipment in commercial and light-industrial locations.
The device complies with EN IEC 61000-6-1, EN IEC 61000-6-2, EN IEC 61000-6-8, EN IEC 61000-6-4, EN IEC 61000-3-2 andEN 61000-3-3.
The device complies with FCC Part 15 rules. Operation is subjected to following two conditions: (1) this device may notcause harmful interference and (2) this device must accept any interference received, including interference that may
cause undesired operation.
EMC Immunity
Electrostatic discharge

Power lines and housing
Contact discharge
EN 61000-4-2
Air discharge
80 MHz-2.7 GHz
EN 61000-4-3
2.7-6 GHz
Input lines
EN 61000-4-4
Output lines
LN
EN 61000-4-5
N  PE
L  PE+EN 61000-4-5+  PE-  PEEN 61000-4-6
0.15-80 MHz
0 % of 100 Vac
EN 61000-4-11
40 % of 100 Vac
70 % of 100 Vac
0 % of 120 Vac
40 % of 120 Vac
70 % of 120 Vac
0 % of 200 Vac
40 % of 200 Vac
70 % of 200 Vac

8 kV
15 kV
10 V/m
10 V/m
4 kV
2 kV
2 kV
4 kV
4 kV
500 V
1 kV
1 kV
10 V
0 Vac, 20 ms
40 Vac, 200 ms
70 Vac, 500 ms
0 Vac, 20 ms
48 Vac, 200 ms
84 Vac, 500 ms
0 Vac, 20 ms
80 Vac, 200 ms
140 Vac, 500 ms

Voltage interruptions
Powerful transients

EN 61000-4-11
VDE 0160

5000 ms
750 V, 0.3 ms

Criterion A
Criterion A
Criterion A
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 C
Criterion A
Criterion A
Criterion A
Criterion A
Criterion C
Criterion A

EMC Immunity
Fast transients (Burst)
Surge voltage
Conducted disturbance

Signal and communication lines
EN 61000-4-4Signals with coupling clamp
EN 61000-4-5
IO-Link lines  PE
EN 61000-4-6
IO-Link lines

2 kV
1 kV
10 V

Criterion B
Criterion B
Criterion A

Electromagnetic RF field
Fast transients (Burst)
Surge voltage on input

Surge voltage on output

Conducted disturbance
Mains voltage dips

0V
Over entire load range

Performance criterions:
A: Device shows normal operation behavior within the defined limits.
B: Device shows normal operation behavior within the defined limits. During burst or surge events small reduction of IO-Link transmission
rate is possible.
C: Temporary loss of function is possible. The device may shut-down and restarts by itself. No damage or hazards for the device will occur.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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EMC Emission
Conducted emission
input lines
Conducted emission
output lines
Conducted emission
IO-Link lines
Radiated emission
Harmonic input current

EN 55011, EN 55032, FCC Part 15, CISPR 11,
CISPR 32
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
EN 55032, CISPR 32

Voltage fluctuations, flicker

EN 55011, EN 55032, CISPR 11, CISPR 32
EN IEC 61000-3-2 - Class A equipment
EN IEC 61000-3-2 - Class C equipment
EN 61000-3-3

Switching Frequencies
PFC converter
Main converter
Auxiliary converter
Microcontroller

100 kHz80 kHz to 140 kHz
60 kHz24 MHz, 29.4912 MHz, 48 MHz

Class BEN IEC 61000-6-8 Limits for DC power
ports fulfilled
EN IEC 61000-6-8 Limits for wired ports
fulfilledClass A
Fulfilled
Fulfilled in the load range from 8 to 24 A
Fulfilled, tested with non-pulsing
constant current loads.

Fixed frequency
Output load dependent
Fixed frequency
The device utilizes in total 3 microcontrollers

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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18.

Environment
The operational temperature is the ambient or
surrounding temperature and is defined as the airtemperature 2 cm below the device.
For storage and transportation

Operational temperature-25 °C to +70 °C

Storage temperature-40 °C to +85 °C

Output derating

Humidity

Between +60 °C and +70 °C
12.5 W/ K
For altitudes > 2000 m, see Fig. 18-2
32 W/1000 m or 5 K/1000 m
Between +60 °C and +70 °C at AC 100 V
10.5 W/K
For altitudes > 2000 m, see Fig. 18-2
28 W/1000 m or 5 K/1000 m
The derating is not hardware controlled. The user has to take care by himself to stay
below the derated current limits in order not to overload the unit.
5 to 95 % r.h.
According to IEC 60068-2-30

Atmospheric pressure110-54 kPa

See Fig. 18-2 for details

Altitude

Up to 5000 m

See Fig. 18-2 for details

Overvoltage category

II

According to IEC 60664-1, for altitudes up to 5000 m

Impulse withstand voltage

4 kV (according toovervoltage category III)
2

Input to PE
According to IEC 60664-1, for altitudes up to 2000 m
According to IEC 60664-1, not conductive

Degree of pollution

2-17.8 Hz: ±1.6 mm
According to IEC 60068-2-6
17.8-500 Hz: 2 g
2 hours / axis
30 g 6 ms, 20 g 11 ms
According to IEC 60068-2-27
3 bumps / direction
18 bumps in total
Shock and vibration is tested in combination with DIN rails according to EN 60715
with a height of 15 mm and a thickness of 1.3 mm and standard orientation.

Vibration sinusoidal

Shock

Fig. 18-1 Output power vs. ambient temp.

Fig. 18-2 Output power vs. altitude
Allowed O utput Pow er at 24V

Allowed Output Power at 24V

120%

120%

C
B
A

100%

100%
80%

75%
A: 100Vac, continuous
B: 120 to 240Vac, continuous
C: short term(max. 60s every 10 minutes)

0

-25

0

45

60 70°C

Ambient Temperature

Altitude 0mAP*) 110kPa*) Atmospheric pressure

2000m
80kPa

5000m
54kPa

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
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19.

Safety and Protection Features

Insulation resistanceAt delivered condition between input and output,
measured with 500 Vdc
At delivered condition between input and PE,
measured with 500 Vdc
At delivered condition between output and PE,
measured with 500 Vdc
At delivered condition between output and DC OK
or Alarm contacts, measured with 500 Vdc
Resistance between PE terminal and the housing in
the area of the DIN rail mounting bracket.

min.

500 MOhmmin.

500 MOhmmin.

500 MOhmmin.

500 MOhm

PE resistancemax.

0.1 Ohm

Output over-voltage protection

min.
max.

30.5 Vdc
32 VdcIn case of an internal defect, a redundant circuit limits the maximum output
voltage to 32 V. The output switches off and performs three restart
attempts. If the failure continues, the output shuts down. Cycle input power
to reset.
I
According to IEC 61140
A PE (Protective Earth) connection is required
IP20
According to EN/IEC 60529
Output shuts down with automatic restart.
Included
Temperature sensors are installed on criticalcomponents inside the unit and turn the unit off insafety critical situations, which can happen e.g.
when ambient temperature is too high, ventilation
is obstructed or the derating requirements are notfollowed. There is no correlation between theoperating temperature and turn-off temperaturesince this is dependent on input voltage, load andinstallation methods.
MOV (Metal Oxide
For protection values see chapter “EMC”.
Varistor)
Not user replaceable slow-blow high-breaking
Includedcapacity fuse
0.12 mA / 0.31 mA
At 100 Vac, 50 Hz, TN-,TT-mains / IT-mains
0.18 mA / 0.45 mA
At 120 Vac, 60 Hz, TN-,TT-mains / IT-mains
0.30 mA / 0.76 mA
At 230 Vac, 50 Hz, TN-,TT-mains / IT-mains
0.16 mA / 0.38 mA
At 110 Vac, 50 Hz, TN-,TT-mains / IT-mains
0.23 mA / 0.55 mA
At 132 Vac, 60 Hz, TN-,TT-mains / IT-mains
0.39 mA / 0.94 mA
At 264 Vac, 50 Hz, TN-,TT-mains / IT-mains

Class of protection
Degree of protection
Over-temperature protection

Input transient protection
Internal input fuse
Touch current (leakage current)

typ.
typ.
typ.
max.
max.
max.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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20.

Dielectric Strength

The output voltage is floating and has no ohmic connection to the ground.
The output is insulated to the input by a double or reinforced insulation.
Type and routine tests are conducted by the manufacturer. Field tests may be conducted in the field using theappropriate test equipment which applies the voltage with a slow ramp (2 s up and 2 s down). Connect all inputterminals 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.
We recommend that that pole where the actuators in a control system are connected shall be grounded via protective
earth. This helps to avoid situations in which a load starts unexpectedly or cannot be switched off when unnoticed
earth faults occur.
Fig. 20-1 Dielectric strength

Input

B *)

L
N

IO-Link
Port

B
A

Earth, PE

D

DC

Output+-Type test
60 s
Routine5s
test
Field test
5s
Cut-off current
setting for field test

A

B

C

D

2500 Vac

3000 Vac

1000 Vac

500 Vac2500 Vac

2500 Vac

500 Vac

500 Vac2000 Vac

2000 Vac

500 Vac

500 Vac> 10 mA> 10 mA> 20 mA> 10 mA

B*)
When testing input to IO-Link-Terminals ensure that the maximal voltage between IOLink-Terminals and the output is not exceeded (column D). We recommend connecting
IO-Link-Terminals and the output terminals together when performing the test.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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21.

Approved, Fulfilled or Tested Standards

IEC 61010-2-201

CB Scheme Certificate
IEC 61010-2-201 Electrical Equipment for Measurement, Control
and Laboratory Use - Particular requirements for control
equipment
UL Certificate
Listed equipment for category NMTR - Electrical Equipment for
Measurement, Control and Laboratory Use - Particularrequirements for control equipment
Applicable for US and Canada
E-File: E198865
Test Report
Voltage Sag Immunity for Semiconductor Processing Equipment
Tested for AC 208V L-L or L-N mains voltages, nominal output
voltage and nominal output load

UL 61010-2-201

SEMI 47

22.

Regulatory Product Compliance

EU Declaration of Conformity

REACH Regulation (EU)

WEEE Regulation

RoHS (China RoHS 2)

EU Declaration of Conformity
Trade conformity assessment for Europe
The CE mark indicates conformance with the European- RoHS directive,- EMC directive and the- Low-voltage directive (LVD)
Manufacturer's Statement
EU regulation regarding the Registration, Evaluation,
Authorisation and Restriction of Chemicals (REACH) fulfilled.
Manufacturer's Declaration
EU Regulation on Waste Electrical and Electronic Equipment
Registered as business to business (B2B) products.
EU Regulation 2012/19/EU
Manufacturer's Statement
Administrative Measures for the Restriction of the Use ofHazardous Substances in Electrical and Electronic Products
25 years

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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23.

Physical Dimensions and Weight

Width
HeightDepth

WeightDIN rail
Housing material
Installation clearances

48 mm
124 mm
127 mmThe DIN rail depth must be added to the unit depth to calculate the total required
installation depth.
835 g
Use 35 mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15 mm.
Body: aluminium alloy
Cover: zinc-plated steel
See chapter 2

Fig. 23-1 Front view

8

31.8

14

19
48

Fig. 23-2 Side view127
DIN rail depth

All dimensions in mm

All dimensions in mm

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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24.

Accessories

24.1. ZM10.WALL – Wall/Panel Mounting Bracket
This bracket is used to mount the devices on a wall/panel without utilizing the DIN rail. The bracket can be mounted
without detaching the DIN rail brackets from the power supply. Product for illustration purposes only.
Fig. 24-1 Isometric viewFig. 24-4 Wall/panel mounting, front viewFig. 24-2 Isometric viewFig. 24-5 Hole pattern for wall
mounting

Fig. 24-3 Isometric viewFig. 24-6 Wall/panel mounting, side view

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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24.2. UF20.241 Buffer ModuleUF20.241 buffer module is a supplementary device for DC 24 V power supplies. It
delivers power to bridge typical mains failures or extends the hold-up time after the
AC power is turned off.
When the power supply provides a sufficient voltage, the buffer module storesenergy in the integrated electrolytic capacitors. When the mains voltage is lost, thestored energy is released to the DC-bus in a regulated process.
The buffer module can be added in parallel to the load circuit at any given point anddoes not require any control wiring.
One buffer module can deliver 20 A additional current and can be added in parallel
to increase the output ampacity or the hold-up time.

24.3. YR40.241 - Redundancy Module
The YR40.241 is a dual redundancy module, which can be used to build 1+1 or N+1
redundant system.
The device is equipped with two 20 A nominal input channels, which are individually
decoupled by utilizing MOSFET technology. The output can be loaded with a nominal
40 A continuous current.
Using MOSFETs instead of diodes reduces heat generation, losses and voltage drop
between input and output. Due to these advantages, the unit is very narrow andonly requires 36 mm width on the DIN rail.
The device does not require an additional auxiliary voltage and is self-powered evenin case of a short circuit across the output.
A feature of this redundancy module is a special circuit, which keeps the losses andtemperature low, even at overload and short circuit conditions up to 65 A continuous
current.
See chapter “Parallel Use for Redundancy” for wiring information.

24.4. YR40.242 - Redundancy Module
Using MOSFETs instead of diodes reduces heat generation, losses and voltage drop
between input and output. Due to these advantages, the unit is very narrow andonly requires 36 mm width on the DIN rail.
The device does not require an additional auxiliary voltage and is self-powered evenin case of a short circuit across the output. It requires suitable power supplies on the
input, where the sum of the continuous short circuit current stays below 26 A. This is
typically achieved when the power supplies are featured with an intermittent
overload behavior (Hiccup Mode).
See chapter “Parallel Use for Redundancy” for wiring information.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

www.pulspower.com Phone +49 89 9278 0Germany

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CP-Series

24.5. YR40.245 - Redundancy Modules
The YR40.245 is a 40 A single channel redundancy module, which is equipped with aplug connector on the output. The plug connector allows replacing the power supply
or the redundancy module while the system is running. The plug connector prevents
the output wires from touching and creating a short on the load circuit.
The input of the device is decoupled by utilizing MOSFET technology.
Using MOSFETs instead of diodes reduces heat generation, losses and voltage drop
between input and output. Due to these advantages, the unit is very narrow andonly requires 46 mm width on the DIN rail.
The device does not require an additional auxiliary voltage and is self-powered evenin case of a short circuit across the output. It requires a suitable power supply on the
input, where the continuous short circuit current stays below 22 A. This is typicallyachieved when the power supply is featured with an intermittent overload behavior(Hiccup Mode).
See chapter “Parallel Use for Redundancy” for wiring information.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

www.pulspower.com Phone +49 89 9278 0Germany

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CP20.242-IOL
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CP-Series

25.

Application Notes

25.1. Peak Current Capability
The unit can deliver peak currents (up to several milliseconds) which are higher than the specified short term currents.
This helps to start current demanding loads. 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 capacitive load.
The peak current capability also ensures the safe operation of subsequent circuit breakers of load circuits. The loadbranches are often individually protected with circuit breakers or fuses. In case of a short or an overload in one branch
circuit, the fuse or circuit breaker need a certain amount of over-current to open in a timely manner. This avoids
voltage loss in adjacent circuits.
The extra current (peak current) is supplied by the power converter and the built-in large sized output capacitors of
the power supply. The capacitors get discharged during such an event, which causes a voltage dip on the output. The
following three examples show typical voltage dips for resistive loads:
Fig. 25-1 40 Apeak current for 50 ms, typ.
(2x the nominal current)

Fig. 25-2 100 Apeak current for 5 ms, typ.
(5x the nominal current)

Fig. 25-3 60 Apeak current for 12 ms, typ.
(3x the nominal current)

Peak current voltage dips

typ.
typ.
typ.

from 24 V to 16 V
from 24 V to 21 V
from 24 V to 17 V

At 40 A for 50 ms, resistive load
At 100 A for 2 ms, resistive load
At 100 A for 5 ms, resistive load

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

www.pulspower.com Phone +49 89 9278 0Germany

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CP20.242-IOL
24 V, 20 A, 480 W, SINGLE PHASE

CP-Series

25.2. Output Circuit Breakers
Standard miniature circuit breakers (MCB’s or UL 1077 circuit breakers) are commonly used for AC-supply systems andmay also be used on 24 V branches.
MCB’s are designed to protect wires and circuits. If the ampere value and the characteristics of the MCB are adapted to
the wire size that is used, the wiring is considered as thermally safe regardless of whether the MCB opens or not.
To avoid voltage dips and under-voltage situations in adjacent 24 V branches which are supplied by the same source, afast (magnetic) tripping of the MCB is desired. A quick shutdown within 10 ms is necessary corresponding roughly tothe ride-through time of PLC's. This requires power supplies with high current reserves and large output capacitors.
Furthermore, the impedance of the faulty branch must be sufficiently small in order for the current to actually flow.
The best current reserve in the power supply does not help if Ohm’s law does not permit current flow. The following
table has typical test results showing which B- and C-Characteristic MCBs magnetically trip depending on the wire crosschapter and wire length.
Fig. 25-4 Test circuit
Power Supply

MCB

Load

+

AC

+
Wire length

DC-

S1... Fault simulation switch

S1-

Maximal wire length*) for a fast (magnetic) tripping:
0.75 mm²
1.0 mm²
1.5 mm²
2.5 mm²
C-2A
31 m
37 m
63 m
98 m
C-3A
28 m
34 m
51 m
78 m
C-4A
18 m
25 m
38 m
58 m
C-6A
9m
11 m
18 m
26 m
C-8A
6m
7m
12 m
14 m
C-10A
4m
6m
11 m
13 m
C-13A
2m
2m
4m
7m
B-6A
B-10A
B-13A
B-16A
B-20A
B-25A

*)

23 m
11 m
7m
5m
1m

28 m
14 m
11 m
6m
1m

46 m
19 m
16 m
8m
2m

66 m
32 m
29 m
15 m
4m
1m

Don’t forget to consider twice the distance to the load (or cable length) when calculating the total wire length (+ and – wire).

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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CP-Series

25.3. Charging of Batteries
The power supply can be used to charge lead-acid or maintenance-free batteries. Two 12 V SLA or VRLA batteries areneeded in series connection.
Instructions for charging batteries:a)

Use only matched batteries when putting 12 V types in series.

b)

Ensure that the ambient temperature of the power supply stays below +40 °C..

c)

Use a 30 A or 32 A circuit breaker or a 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 is typically 3.5 mA. This return current can discharge the battery when the
power supply is switched off except in case a blocking diode is utilized.

f)

Set the device into “Parallel Use” mode and adjust the output voltage, measured at no load and at the battery
end of the cable, very precisely to the end-of-charge voltage of 27.8 V at +10 °C, 27.5 V at +20 °C, 27.15 V at
+30 °C and 26.8 V at +40 °C ambient temperature.

25.4. Series Operation
Devices of the same type can be connected in series for higher output voltages.
It is possible to connect as many units in series as needed, providing the sum of
the output voltage does not exceed 150 Vdc. Voltages with a potential above
60 Vdc must be installed with a protection against touching.
Avoid return voltage (e.g. from a decelerating motor or battery) which isapplied to the output terminals.

Unit A

Input

Output++Unit B

Input

Keep an installation clearance of 15 mm (left / right) between two power
supplies and avoid installing the power supplies on top of each other. Do not
use power supplies in series in mounting orientations other than the standard
mounting orientation.

Output

Load

+
-

-

Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple devices.

25.5. Parallel Use to Increase Output Power
Devices can be paralleled to increase the output power. The output voltage ofall power supplies shall be adjusted to the same value (±100 mV) in “Single
Use” mode with the same load conditions on all units, or the units can be left
with the factory settings. After the adjustments, set the unit to “Parallel Use”
mode via IO-Link interface, in order to achieve load sharing. The “Parallel Use”
mode regulates the output voltage in such a manner that the voltage at noload is approx. 4 % higher than at nominal load.

Unit A

Input

Output++Unit BInput

The ambient temperature is not allowed to exceed +60 °C.

Load

+
-

-

OutputIf more than three units are connected in parallel, a fuse or circuit breakerwith a rating of 30 A or 32 A is required on each output. Alternatively, a diode or redundancy module can also be
utilized.

Energize all units at the same time. It also might be necessary to cycle the input power (turn-off for at least fiveseconds), if the output was in overload or short circuits and the required output current is higher than the current of
one unit.
Keep an installation clearance of 15 mm (left / right) between two devices and avoid installing devices on top of eachother. Do not use devices in parallel in mounting orientations other than the standard mounting orientation or in any
other condition where a reduction of the output current is required (e.g. altitude).
Pay attention that leakage current, EMI, inrush current will increase when using multiple devices.

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

www.pulspower.com Phone +49 89 9278 0Germany

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CP20.242-IOL
24 V, 20 A, 480 W, SINGLE PHASE

CP-Series

25.6. Parallel Use for Redundancy
1+1 Redundancy:
Devices 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 device fails. The simplest way is to put two devices in parallel.
This is called a 1+1 redundancy. In case one device fails, the other one is automatically able to support the load current
without any interruption. It is essential to use a redundancy module to decouple devices from each other. This
prevents that the defective unit becomes a load for the other device and the output voltage cannot be maintained any
more.
1+1 redundancy allows ambient temperatures up to +70 °C.
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple devices.
Recommendations for building redundant power systems:- Use separate input fuses for each device.
- Use separate mains systems for each device whenever it is possible.
- Monitor the individual devices. Therefore, use the DC OK signal of the device.
- It is desirable to set the output voltages of all devices to the same value (± 100 mV) or leave it at the factory setting.
- Set the devices into “Parallel Use” mode via IO-Link interface.
N+1 Redundancy:
Redundant systems for a higher power demand are usually built in a N+1 method. E.g. four devices, each rated for
20 A are paralleled to build a 60 A redundant system.
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
Keep an installation clearance of 15 mm (left / right) between two power supplies and avoid installing the power
supplies on top of each other.
Do not use devices in parallel in mounting orientations other than the standard mounting orientation or in any othercondition, where a derating of the output current is required.
For N+1 redundancy the ambient temperature is not allowed to exceed +60 °C.
Wiring examples for 1+1 and N+1 redundancy:
Fig. 25-5 1+1 Redundant configuration for 20 A load
current with a dual redundancy module+ + - Output
24V, 20A+ + - Output
24V, 20A+ - + Input Input
1
2+ + - Output
24V, 20A+ + - Output
24V, 20A+ - + Input Input
1
2+ + - Output
24V, 20A

Power
SupplyRedundancy
ModulePower
SupplyPower
SupplyRedundancy
ModulePower
SupplyPower
SupplyRedundancy
ModulePower
SupplyOutput- +Input
L N PE

Output- +Input
L N PEIInput
L N PE
20A
Load

I

L

N

N

PE

PE

I

optional+ - + Input Input
12

optional+ + - Output
24V, 20AInput
L N PE

L

Fig. 25-6 N+1 Redundant configuration for 60 A load current with multiple power supplies
and redundancy modules

Input
L N PE

Output- +Input
L N PE
60A
Load

I

I

I

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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CP20.242-IOL
24 V, 20 A, 480 W, SINGLE PHASE

CP-Series

25.7. Operation on Two Phases
The power supply can also be used on two-phases of a three-phase-system. Such a phase-to-phase connection isallowed as long as the supplying voltage is below 240 V+10 %.
Ensure that the wire, which is connected to the N-terminal, isappropriately fused.

Power Supply

240V +10% max.

L1

L3

AC
L
N
PE

L2

DC

25.8. Mounting Orientation
Install the device onto a DIN rail with the input terminals on the bottom of the device.
The test environment is set up installing wiring ducts (depth: 80 mm) with clearances seen in chapter 2.
Fig. 25-7
Mounting
Orientation A(Standardorientation)

All parameters are typical values specified 230 Vac, 50 Hz input voltage, 24 V, 20 A output load, +25 °C ambient and after a 5 minutes runin time unless otherwise noted.
Aug. 2024 / Rev 1.1 DS-CP20.242-IOL-EN

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CP20.242-IOL
24V, 20A, 480W, SINGLE PHASE

CP-Series

Apr. 2023 / Rev 0.1 DS- CP20.242-IOL-EN All parameters are typical values specified 230Vac, 50Hz input voltage, 24V, 20A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0Germany