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Bachmann CNT204 Counter Module (Simplified)

1. Product Description

A high-precision industrial counter module designed for accurate counting, frequency measurement, and event monitoring in automation systems. The Bachmann CNT204 features 4 independent counter channels, supporting both incremental and absolute encoder signals, as well as digital pulse inputs. It enables real-time data processing, threshold alarm triggering, and seamless integration with Bachmann controllers (e.g., MPC240) and backplanes (e.g., BS203/BS208), making it ideal for applications requiring reliable, high-speed counting in harsh industrial environments.

2. Detailed Specifications

2.1 Channel & Counting Configuration

Total Channels: 4 independent counter channels

Supported Signal Types:

Incremental encoder signals (A/B phase, up to 1 MHz)

Digital pulse signals (5-24 V DC, NPN/PNP configurable)

Absolute encoder signals (SSI protocol, 16-32 bit resolution)

Counting Range: ±2,147,483,647 (32-bit signed integer per channel)

Counting Speed: Up to 1 MHz per channel (max frequency for pulse inputs)

Measurement Modes: Up-count, down-count, up/down count, frequency measurement (0.1 Hz-1 MHz), period measurement

2.2 Electrical Performance

Input Voltage Range: 5-24 V DC (compatible with industrial encoders/pulse sensors)

Input Current: <10 mA per channel (at 24 V DC)

Isolation: 2.5 kV AC isolation between channels; 5 kV AC isolation between I/O and power lines

Noise Immunity: ≥60 dB (at 100 kHz, for differential input signals)

Threshold Alarm: Configurable upper/lower count thresholds; supports relay or digital output triggering

2.3 Communication & Integration

Interface Type: 1×backplane connector (compatible with Bachmann BS203/BS208/BS209 backplanes)

Data Transmission: Real-time count data upload to host controllers; maximum throughput 100 Mbps

Protocol Support: Bachmann proprietary counter 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 encoder 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 (compliant with IEC 60068-2-6)

Shock Resistance: 30 g acceleration, 11 ms duration (compliant with IEC 60068-2-27)

EMC Compliance: EN 61000-6-2 (industrial immunity), EN 61000-6-4 (industrial emissions)

2.6 Physical & Software

Dimensions: 105×75×28 mm (Length×Width×Height)

Mounting: DIN rail (via backplane integration; EN 50022 standard)

Weight: ~140 g

Programming Software: Bachmann Studio (v4.0+; channel configuration, count reset, threshold setting, real-time monitoring)

LED Indicators: 4 channel-status LEDs (green: active counting); 1 power LED (green); 1 alarm LED (red: threshold triggered)

3. Advantages & Features

High-Precision Counting: 32-bit resolution + 1 MHz speed ensures accurate measurement of fast pulses/encoders.

Multi-Signal Compatibility: Supports incremental/absolute encoders and digital pulses, adapting to diverse industrial sensors.

Flexible Modes: Counting, frequency, and period measurement modes meet multiple application needs (e.g., speed monitoring, part counting).

Seamless Integration: Works with Bachmann controllers/backplanes; no extra adapters needed for system build.

Alarm Function: Configurable thresholds enable real-time fault alerts, improving process safety.

4. Application Fields

Manufacturing Counting: Part counting in assembly lines (e.g., electronics component placement, automotive part production).

Motion Control: Encoder-based position/speed monitoring for conveyors, robotic arms, and CNC machine tools.

Packaging Machinery: Bag/box counting, film length measurement (via encoder pulse tracking).

Material Handling: Pallet counting in warehouses, conveyor belt speed measurement (frequency mode).

Test & Measurement: Frequency measurement of industrial sensors (e.g., flow meters, vibration sensors), period testing of mechanical components.

5. Precautions

Installation: Integrate only with compatible Bachmann backplanes; power off backplane before inserting/removing the module to avoid connector damage.

Wiring: Use shielded twisted-pair cables for encoder signals; ground shields at one end to reduce noise; ensure encoder power matches module input voltage (5-24 V DC).

Encoder Compatibility: Verify encoder signal type (incremental/absolute) and frequency (<=1 MHz) matches channel specs; use differential signals for long-distance wiring (>10 m).

Calibration: Reset count values before system startup; test threshold alarms offline to avoid false triggers during operation.

Maintenance: Inspect cable connections quarterly (tighten loose terminals); clean module with a dry cloth; do not disassemble (voids warranty and risks isolation failure).

The structure and details of the product：
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