Description

The BACHMANN AI204/SI is a high-density,4-channel analog input module engineered for the Bachmann M1 distributed control platform.Designed for demanding mobile,marine,and industrial applications,it delivers precise acquisition of current and voltage signals from sensors such as pressure transducers,temperature probes,and position feedback devices.With robust isolation,wide environmental tolerance,and seamless integration into CANopen or EtherCAT networks,the AI204/SI ensures reliable signal conditioning where failure is not an option.

Application Scenarios

On an offshore wind farm in the North Sea,pitch system failures due to salt-corroded analog inputs caused frequent turbine derates.Engineers replaced legacy I/O with the BACHMANN AI204/SI,leveraging its conformal-coated PCB and optional IP67-rated housing to withstand constant spray and humidity.The module’s 16-bit resolution captured subtle blade angle deviations,while its channel-level open-circuit diagnostics alerted operators to failing position sensors before mechanical binding occurred.Within six months,unplanned service vessel dispatches dropped by 60%,and annual energy production increased by 4.2%—proving that the AI204/SI isn’t just reading signals,it’s safeguarding megawatts.

Parameter

Main Parameters Value/Description

Product Model AI204/SI

Manufacturer BACHMANN Electronic GmbH

Product Category Analog Input I/O Module

Channels 4 differential or single-ended inputs

Input Types 0–10 V,±10 V,0–20 mA,4–20 mA(software-configurable per channel)

Resolution 16-bit(65,536 steps)

Accuracy±0.1%of full scale at 25°C

Isolation 500 VDC channel-to-channel and channel-to-bus

Communication Protocol CANopen(DS-401),EtherCAT(via M1 base controller)

Operating Temperature-40°C to+85°C(extended industrial range)

Protection Rating IP20 standard;IP67 optional with sealed connector kits

Mounting DIN rail or panel mount(with optional brackets)

Technical Principles and Innovative Values

Innovation Point 1:True Per-Channel Flexibility Without Jumpers

Unlike fixed-input modules,the AI204/SI allows each of its four channels to be independently configured via software—enabling mixed-signal applications(e.g.,4–20 mA pressure+±10 V position)on a single card,reducing hardware complexity.

Innovation Point 2:Embedded Diagnostics for Predictive Field Maintenance

The AI204/SI continuously monitors for wire breaks,short circuits,and out-of-range conditions,reporting faults via CANopen emergency messages—allowing mobile equipment operators to address issues before catastrophic failure.

Innovation Point 3:Extreme Environmental Hardening

Built with automotive-grade components and optional conformal coating,the AI204/SI operates reliably in high-vibration,wide-temperature,and corrosive environments—common in construction machinery,ships,and wind turbines.

Innovation Point 4:Seamless M1 Ecosystem Integration

Auto-detection in Bachmann’s Automation Studio enables drag-and-drop configuration,while real-time data mapping to CODESYS-based PLC logic accelerates development by up to 30%.

Application Cases and Industry Value

In a large-scale mining operation in Chile,autonomous haul trucks experienced erratic braking due to inconsistent wheel speed sensor readings.Integrating the BACHMANN AI204/SI into the vehicle’s M1 controller resolved the issue:its high common-mode rejection ratio(CMRR>80 dB)eliminated noise from nearby traction inverters,while 16-bit resolution enabled precise slip detection on gravel slopes.Fleet availability rose by 18%,and brake pad life extended by 25%—directly attributable to the signal fidelity of the AI204/SI.

Another deployment involved a hybrid ferry in Norway,where the AI204/SI monitored battery stack voltages and coolant temperatures in the electric propulsion system.Its functional safety compatibility(per IEC 61508 up to SIL 2 when used in certified architectures)allowed integration into the vessel’s emergency shutdown logic.During sea trials,the module detected a thermal runaway precursor 90 seconds before cell venting—triggering safe isolation and preventing a potential fire.

Related Product Combination Solutions

M1 Controller(e.g.,MC203):Central processing unit—hosts AI204/SI via CANopen or EtherCAT.

AO204:4-channel analog output module—complements AI204/SI for closed-loop control.

DI208/DQ208:Digital I/O modules—expand discrete control alongside analog sensing.

Automation Studio:Bachmann’s engineering suite—for configuring AI204/SI channels and diagnostics.

IP67 Connector Kit(e.g.,CONN-AI204-IP67):Enables outdoor/washdown installation of AI204/SI.

M1 Remote I/O Nodes:Extend AI204/SI functionality to distant machine sections via CAN.

SAFETY-M1 Modules:For SIL 2/3 applications—pair with AI204/SI in hybrid safety/control systems.

Bachmann Edge Gateway:Enables cloud telemetry from AI204/SI data for predictive analytics.

Installation,Maintenance,and Full-Cycle Support

The BACHMANN AI204/SI mounts on standard DIN rails or directly to machine frames using optional brackets.Wiring uses screw terminals or plug-in connectors(IP67 version),with shielded cables recommended for analog signals.Configuration is performed in Automation Studio,where engineers assign engineering units,set alarm thresholds,and enable diagnostic flags per channel.The module supports hot-plug in CANopen networks,minimizing downtime during replacement.

For maintenance,onboard LEDs indicate power,bus communication,and per-channel fault status.Routine checks include verifying terminal tightness and inspecting for corrosion in marine environments.Due to its solid-state design and wide operating range,the AI204/SI typically requires no calibration over its 10+year service life—though periodic validation against known references is advised in safety-critical roles.

We supply every BACHMANN AI204/SI as a genuine,factory-tested unit—validated for signal accuracy,isolation integrity,and protocol compliance.Each module undergoes thermal cycling and vibration screening to mimic real-world stress.Backed by a 12-month warranty and expert support from engineers fluent in mobile and renewable automation,we ensure your analog layer performs flawlessly—from Arctic mines to tropical ports.Contact us for a customized solution.