Bachmann DIO216 Product Introduction
1. Product Description
The Bachmann DIO216 is a 16-channel universal digital I/O module belonging to Bachmann’s M1 automation system product line, engineered for high-reliability industrial control applications. As a key component in distributed control systems (DCS) and machine automation, it provides flexible digital input/output functionality to monitor and control discrete devices such as sensors, limit switches, solenoids, and indicator lamps—making it ideal for industries including manufacturing, energy, transportation, and process engineering.
Unlike standard discrete I/O modules, the DIO216 features channel-to-channel isolation, configurable I/O logic, and robust industrial design, enabling seamless integration into harsh environments with high electromagnetic interference (EMI) or temperature fluctuations. It communicates with Bachmann’s M1 controllers (e.g., M1-CPU-100) via the Bachmann Bus (BNet), ensuring deterministic data transfer with sub-1ms latency—critical for time-sensitive control tasks such as production line synchronization or power grid monitoring. Its modular design also supports hot-swapping (when used with compatible M1 racks), minimizing downtime during maintenance or module replacement.
2. Product Parameters
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Parameter
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Specification
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Product Type
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16-Channel Universal Digital I/O Module (8 inputs + 8 outputs)
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Compatibility
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Bachmann M1 Automation System (M1-CPU series controllers)
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I/O Configuration
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8 x Digital Inputs (DI), 8 x Digital Outputs (DO)
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Input Voltage Range
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DI: 24V DC (18V DC – 30V DC), sinking/sourcing configurable
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Output Voltage Range
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DO: 24V DC (18V DC – 30V DC), sinking (NPN) type
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Output Current Capacity
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DO: 0.5A per channel, 4A total per module (overcurrent protected)
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Isolation
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Channel-to-channel: 500V AC (1min); I/O to bus: 2500V AC (1min)
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Response Time
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DI: <1ms (for 24V DC signal); DO: <0.5ms (output switching)
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Communication Interface
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Bachmann Bus (BNet), baud rate up to 100Mbps (deterministic)
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Operating Temperature
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-25°C – +60°C
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Storage Temperature
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-40°C – +85°C
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Relative Humidity
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5% – 95% (non-condensing, per IEC 60068-2-3)
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Protection Rating
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IP20 (module); IP40 (when installed in M1 rack)
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Dimensions (W×H×D)
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35mm×100mm×120mm (1U rack height, DIN rail-mountable via M1 rack)
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Mounting Type
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DIN rail-mountable (35mm, per EN 50022) via Bachmann M1 rack
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Certifications
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CE, UL 508, IEC 61131-2, ATEX (for hazardous areas: Zone 2/22)
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3. Product Specifications
3.1 Hardware Architecture
- I/O Circuit Design: The 8 digital input channels support both sinking (NPN) and sourcing (PNP) configurations via hardware jumpers, eliminating the need for external signal converters when connecting to different sensor types. Each DI channel includes a surge protection circuit (IEC 61000-4-5: 2kV contact discharge) and a debounce filter (configurable 0.1ms–10ms) to suppress noise from mechanical switches or EMI. The 8 digital output channels use MOSFET-based sinking circuits (NPN) with overcurrent protection (0.5A per channel) and short-circuit protection—automatically limiting current to 1A per channel to prevent damage from wiring errors.
- Isolation & EMI Protection: Incorporates optocoupler isolation for each I/O channel (500V AC between channels) and transformer isolation between the I/O section and Bachmann Bus (2500V AC), eliminating ground loops and protecting the M1 controller from high-voltage transients. The module complies with EMI/EMC standards EN 61000-6-2 (industrial immunity) and EN 61000-6-4 (industrial emissions), ensuring stable operation near high-power motors, inverters, or radio frequency (RF) sources.
- Communication & Control: Interfaces with the M1 controller via the Bachmann Bus (BNet), a proprietary industrial bus optimized for deterministic control—supporting cyclic data transfer (update rate ≤1ms) and acyclic data exchange (for configuration or diagnostics). The module includes a dedicated microcontroller (32-bit ARM Cortex-M4) to handle local I/O processing (e.g., debouncing, overcurrent detection) and bus communication, reducing the computational load on the central M1 CPU.
3.2 Functional Capabilities
- Configurable I/O Logic: Via Bachmann’s Automation Studio software, users can configure each DI channel for edge detection (rising/falling/both edges) or level detection (high/low), and set DO channels for latched (maintained) or momentary output. The module also supports “watchdog” functionality—if communication with the M1 controller is lost for >100ms, DO channels can be programmed to default to a safe state (e.g., all outputs off) to prevent unsafe machine operation.
- Diagnostics & Monitoring: Provides real-time diagnostic data for each channel, including DI signal status (high/low), DO output status (on/off), and fault conditions (overcurrent, short-circuit, or power loss). Faults are transmitted to the M1 controller via BNet and can trigger visual alerts (via LED indicators on the module front panel) or system-level alarms (e.g., email notifications via the M1 controller’s Ethernet port). The module also logs the last 100 fault events with timestamps for root-cause analysis.
- Hot-Swapping Support: When installed in a Bachmann M1 rack with redundant power supplies, the DIO216 supports hot-swapping—allowing module replacement without powering down the rack or interrupting other I/O modules. This feature is critical for mission-critical applications (e.g., power plant control, continuous production lines) where downtime must be minimized.
3.3 Environmental & Mechanical Compliance
- Durability: Undergoes rigorous environmental testing per IEC 60068 standards, including temperature cycling (-25°C to +60°C, 10 cycles), vibration testing (10–500Hz, 1g acceleration, per IEC 60068-2-6), and shock testing (30g acceleration, 11ms half-sine pulse, per IEC 60068-2-27). The module’s front panel is constructed from flame-retardant ABS plastic (UL 94 V-0), and internal components are rated for extended temperature operation (-40°C to +85°C) to ensure reliability in extreme environments.
- Power Management: The module draws power from the M1 rack’s 24V DC bus (typical current: 100mA idle, 300mA max with all DO channels active). It includes overvoltage protection (≥36V DC) and reverse polarity protection (≤-24V DC) to prevent damage from unstable rack power supplies or incorrect wiring.
4. Product Features
4.1 Flexible I/O Configuration
The 8 DI/8 DO channel split with configurable sinking/sourcing for inputs and overcurrent-protected outputs eliminates the need for multiple specialized modules, reducing inventory costs and simplifying system design. The ability to adjust debounce filters and edge detection settings ensures compatibility with a wide range of sensors and switches.
4.2 Deterministic Performance
Bachmann Bus (BNet) communication enables sub-1ms I/O response times and cyclic data update rates, making the DIO216 suitable for time-critical applications such as motion control, process synchronization, or emergency shutdown systems (ESD).
4.3 Robust Isolation & EMI Immunity
Channel-to-channel and I/O-to-bus isolation (up to 2500V AC) and compliance with strict EMC standards ensure stable operation in harsh industrial environments—critical for applications near high-voltage equipment or RF sources (e.g., welding machines, radio transmitters).
4.4 Mission-Critical Reliability
Hot-swapping support, fault diagnostics, and wide-temperature operation (–25°C to +60°C) minimize downtime and ensure continuous operation in mission-critical industries such as energy, transportation, and process engineering. The module’s MTBF (mean time between failures) is rated at ≥200,000 hours per IEC 61709.
5. Other Bachmann Automation Models
- Bachmann DIO232: A 32-channel digital I/O module (16 DI + 16 DO) with extended output current (1A per channel), ideal for large-scale discrete control applications (e.g., automotive assembly lines).
- Bachmann AIO208: An 8-channel analog I/O module (4 AI + 4 AO) supporting 0–10V DC/4–20mA signals, designed for process control applications (e.g., temperature, pressure, or flow monitoring).
- Bachmann M1-CPU-100: A compact industrial controller compatible with all M1 I/O modules, featuring a 1GHz dual-core processor, Ethernet (Profinet/EtherNet/IP), and support for IEC 61131-3 programming.
- Bachmann AI816: A 16-channel analog input module with 16-bit resolution and thermocouple/RTD support, optimized for precision temperature monitoring in food processing, pharmaceuticals, or HVAC systems.
- Bachmann DO216: A dedicated 16-channel digital output module with 2A per channel current capacity, suitable for driving high-power loads such as contactors, motors, or heating elements.
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