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Bachmann AI204/SI Analog Input Module
1. Product Description
A high-precision industrial analog input module engineered for accurate acquisition of low-level and standard analog signals in automation systems. The Bachmann AI204/SI features 4 dedicated analog input channels, optimized for capturing signals from sensors (e.g., temperature, pressure, and strain gauges) in harsh industrial environments. It supports multiple signal types, robust isolation, and seamless integration with Bachmann controllers (MPC240) and backplanes (BS208/BS209), making it ideal for applications requiring precise, noise-resistant analog data collection.
2. Detailed Specifications
2.1 Channel & Signal Configuration
- Total Channels: 4 independent analog input channels
- Standard signals: 4-20 mA DC, 0-20 mA DC, 0-10 V DC, ±10 V DC (software-configurable)
- Low-level signals: ±50 mV DC, ±100 mV DC, ±5 V DC (for strain gauges, thermocouples)
- Measurement Accuracy: ±0.05% of full scale (at 25°C ±5°C); ±0.1% over operating temperature range
- Sampling Rate: Up to 200 Hz per channel (configurable in 1 Hz increments)
- Input Impedance: ≥10 MΩ (voltage signals); ≤25 Ω (current signals); 120 Ω (low-level mV signals)
2.2 Electrical Performance
- Isolation: 3 kV AC isolation between channels; 5 kV AC isolation between I/O and power lines (prevents cross-interference)
- Common-Mode Rejection Ratio (CMRR): ≥100 dB (at 50/60 Hz, for voltage signals)
- Noise Level: <5 μVrms (for low-level signals, 0-100 mV range)
- Overload Protection: ±30 V DC (voltage channels); ±50 mA DC (current channels, self-recovering)
2.3 Communication & Integration
- Interface Type: 1×backplane connector (compatible with Bachmann BS208/BS209 backplanes)
- Data Transmission: Real-time data upload to host controllers; maximum throughput 100 Mbps
- Protocol Support: Bachmann proprietary analog acquisition protocol; compatible with Modbus RTU (via backplane)
2.4 Power Supply
- Input Voltage: 24 V DC ±20% (powered via backplane or external 24 V DC)
- Power Consumption: Typical 3 W, Maximum 5 W (excluding sensor power)
- Power Protection: Overvoltage, undervoltage, and reverse polarity protection
2.5 Operating Environment
- Operating Temperature: -40°C ~ +70°C
- Storage Temperature: -40°C ~ +85°C
- Relative Humidity: 5% ~ 95% (non-condensing)
- Vibration Resistance: 10-500 Hz, 2 g acceleration (IEC 60068-2-6)
- Shock Resistance: 30 g acceleration, 11 ms duration (IEC 60068-2-27)
- EMC Compliance: EN 61000-6-2 (immunity), EN 61000-6-4 (emissions)
2.6 Physical & Software
- Dimensions: 100×75×28 mm (L×W×H)
- Mounting: DIN rail (via backplane integration; EN 50022 standard)
- Programming Software: Bachmann Studio (v4.0+; channel configuration, zero/full-scale calibration, status monitoring)
- LED Indicators: 4 channel-status LEDs (green: normal acquisition); 1 power LED (green); 1 fault LED (red: overload/isolation fault)
3. Advantages & Features
- High Precision Acquisition: ±0.05% full-scale accuracy and low noise (<5 μVrms) ensure reliable data for critical control processes.
- Multi-Signal Compatibility: Supports both standard (4-20 mA) and low-level (mV) signals, adapting to diverse sensors (thermocouples, strain gauges).
- Strong Isolation: 3 kV channel isolation and 100 dB CMRR reduce electromagnetic interference in noisy industrial sites.
- Seamless Integration: Works with Bachmann PLCs (MPC240) and backplanes (BS208/BS209), simplifying system expansion.
- Easy Calibration: Software-based zero/full-scale calibration (no manual potentiometers) saves maintenance time.
4. Application Fields
- Process Control: Chemical/petroleum plants (pressure/temperature signal acquisition for reactor control); pharmaceutical production (flow rate monitoring for dosing systems).
- Industrial Sensing: Strain gauge monitoring (structural health of heavy machinery); thermocouple-based temperature measurement (metal processing).
- Energy Monitoring: Power plants (current/voltage signal collection for energy consumption analysis); renewable energy (solar panel voltage/current monitoring).
- Automotive Testing: Vehicle component testing (pressure sensors for brake systems); engine temperature monitoring via thermocouples.
- Aerospace & Defense: Ground equipment monitoring (low-level sensor signals for radar or communication systems); harsh-environment data logging.
5. Precautions
- Installation: Integrate only with compatible Bachmann backplanes (BS208/BS209); power off backplane before inserting/removing the module to avoid connector damage.
- Wiring: Use shielded twisted-pair cables (24 AWG minimum) for low-level signals; ground shields at one end to reduce noise; separate analog cables from high-voltage/power cables.
- Sensor Compatibility: Verify sensor signal range matches channel configuration (e.g., do not connect 24 V signals to ±10 V channels); use external signal conditioners for ultra-low-level signals (<50 mV) if needed.
- Calibration: Perform calibration annually (or after module relocation) in a temperature-stable environment (20°C ~ 25°C); back up calibration settings via Bachmann Studio.
- Maintenance: Inspect cable connections quarterly (tighten loose terminals); clean module housing with a dry cloth (avoid liquids); do not disassemble the module (voids warranty and risks isolation failure).
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