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The Bachmann WT205 is a compact, standalone Programmable Logic Controller (PLC) designed for small-to-medium industrial automation tasks, combining robust performance with space-efficient design. Unlike Bachmann’s modular M1 system components (e.g., ME203/N processor), the WT205 is an all-in-one controller—integrating a processor, digital I/O, communication ports, and power management in a single DIN-rail-mounted unit. It is optimized for applications requiring localized control, minimal cabinet space, and easy deployment: small machinery (e.g., packaging machines, conveyors), building automation (HVAC zones, lighting), and auxiliary industrial systems (pump control, sensor monitoring). With support for standard programming languages and industrial protocols, it balances flexibility with simplicity, making it suitable for both novice and experienced automation engineers.
- Integrated I/O & Processing: Eliminates the need for separate modules (processor, I/O, power supply) by combining 16 digital inputs, 8 digital outputs, and a 32-bit CPU in one unit. This reduces cabinet space requirements by 50% compared to modular PLC systems, making it ideal for small machinery (e.g., a desktop 3D printer’s control panel) or tight installation spaces.
- Plug-and-Play Setup: No complex backplane wiring—simply mount the WT205 on a DIN rail, connect field devices (sensors, actuators) to the terminal blocks, and power it on. Configuration is done via Bachmann’s WT Configurator software (intuitive, Windows-based), with pre-built templates for common tasks (e.g., "conveyor start/stop control") to speed up commissioning.
- Built-in Digital I/O: 16 sinking inputs support NPN sensors (proximity switches, photoelectric sensors) for status monitoring, while 8 sourcing outputs control small actuators (solenoid valves, indicator lights, relay coils). Output overcurrent protection (0.6A per channel) prevents damage from short circuits.
- Analog Expansion: For applications requiring temperature, pressure, or flow measurement, the WT205 supports plug-in analog modules (e.g., Bachmann WT-AI4/AO2) to add 4 analog inputs and 2 analog outputs. Expansion modules connect directly to the PLC’s side connector, maintaining a compact footprint.
- Multi-Protocol Support: Enables seamless integration with other systems via:
- Modbus RTU (RS-485): Connects to legacy serial devices (e.g., Modbus RTU temperature transmitters, VFDs) as a master or slave.
- Modbus TCP/IP (Ethernet): Communicates with SCADA systems, HMIs, or cloud platforms (e.g., Bachmann’s M1 Cloud) for remote monitoring and control.
- TCP/UDP: Supports custom Ethernet-based communication for integration with non-Modbus devices (e.g., barcode scanners, IoT gateways).
- Reliable Data Transfer: RS-485 ports feature 2.5kV AC isolation and differential signaling to resist EMI from nearby motors or power cables, while Ethernet auto-negotiation ensures stable 10/100 Mbps connections.
- Standardized Programming: Supports all IEC 61131-3 languages, allowing engineers to use familiar tools (e.g., Ladder Logic for electrical technicians, Structured Text for software developers). The WT Configurator includes a simulator for testing code offline, reducing on-site debugging time.
- Battery-Backed Data Retention: Critical data (e.g., batch counts, process setpoints) is stored in battery-backed RAM, ensuring no data loss during power outages. The backup battery has a 5-year lifespan under normal operating conditions.
- Wide Temperature & Voltage Tolerance: Operates reliably at -25°C ~ +60°C and 18–30V DC input, adapting to unstable factory power grids and unheated cabinets.
- EMC Immunity: Complies with EN 61000-6-2 industrial EMC standards, preventing false triggers or communication errors caused by electrical noise (e.g., from welding equipment or large motors).
- Small Packaging Machines: Controls a tabletop bag-sealing machine—16 digital inputs monitor film presence, seal temperature, and door interlocks; 8 digital outputs activate the sealing heater, film feed motor, and alarm buzzer. Modbus TCP/IP connects to a local HMI for operator control.
- Building HVAC Zones: Manages a single office floor’s HVAC—inputs read thermostat settings, occupancy sensors, and filter clog alarms; outputs control air handlers, dampers, and fan speed. RS-485 connects to a building-wide Modbus RTU network for centralized monitoring.
- Pump Control Systems: Monitors and controls 4 water pumps in a small irrigation system—inputs track tank levels (float switches) and pump overloads; outputs start/stop pumps based on level thresholds. Analog expansion modules read flow meters (4–20mA) to optimize water usage.
- Auxiliary Industrial Equipment: Controls a conveyor in a warehouse—inputs detect package presence (photoelectric sensors) and emergency stops; outputs drive the conveyor motor and divertors. Ethernet connects to a warehouse management system for order tracking.
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I/O Wiring Guidelines:
- Use 0.14–0.5mm² shielded cables for digital inputs to reduce EMI. For outputs, use 0.5–1.0mm² cables for loads >0.2A (e.g., small motors) to avoid voltage drop. Ensure total output current does not exceed 4A.
- For inductive loads (e.g., relay coils, motors), install flyback diodes across the load to suppress voltage spikes during switching—this protects the PLC’s output circuitry.
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Communication Setup:
- For Modbus RTU: Set a unique slave address (1–247) for each device on the RS-485 bus. Match baud rates, parity, and stop bits across all devices (e.g., 9600 bps, 8N1). Enable the 120Ω termination resistor on the WT205 if it is the first or last device in the bus.
- For Modbus TCP/IP: Assign a static IP address to the WT205 (compatible with the SCADA/HMI subnet) to avoid IP conflicts. Test communication with a Modbus client tool (e.g., Modbus Poll) before full deployment.
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Programming Best Practices:
- Use modular code structure (e.g., separate function blocks for "pump control" and "alarm handling") to simplify maintenance. The WT Configurator’s code library stores reusable blocks for future projects.
- Test code in the simulator first to validate logic (e.g., ensure emergency stops override normal operation). Use breakpoints and variable monitoring to debug on-site issues quickly.
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Power & Environmental Protection:
- Connect the WT205 to a dedicated 24V DC power supply with a 10A circuit breaker to prevent overcurrent. Avoid sharing power with high-current devices (e.g., motors) to prevent voltage dips.
- Mount the PLC in a cabinet away from heat sources (e.g., power supplies, inverters) and maintain ≥20mm clearance for airflow. In humid environments (e.g., food processing), use a dehumidifier to keep relative humidity <85% (non-condensing).
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Maintenance & Troubleshooting:
- Replace the backup battery every 5 years (or when the "battery low" alarm triggers) to prevent data loss. Use only Bachmann-approved batteries (part no. WT-BAT-01) to avoid compatibility issues.
- If inputs/outputs fail: Check wiring for loose connections or short circuits. Use the WT Configurator’s "I/O Test" tool to verify if the PLC detects signals correctly—this isolates faults between the PLC and field devices.
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