Description

Application Scenarios:

At a leading automotive battery cell production line in Germany, engineers struggled with intermittent false triggers on pneumatic grippers during electrode stacking—a defect causing costly scrap and line stoppages. Root cause analysis revealed that legacy PLC output cards lacked individual channel diagnostics and suffered from ground loops in the noisy EMI environment near welding stations. After upgrading to the 7DO135.70. each of the 16 outputs operated with independent short-circuit monitoring and optical isolation from neighboring channels. The integrated status LEDs allowed maintenance teams to instantly identify a failing solenoid valve without probing live circuits. More importantly, the 7DO135.70’s compatibility with B&R’s Automation Studio enabled seamless integration into the existing X20-based control system, reducing commissioning time by 50%. Within three months, gripper-related defects dropped by 92%, proving that precision at the I/O edge directly translates to product quality and uptime.

Parameter:

Main Parameters Value/Description

Product Model 7DO135.70

Manufacturer B&R Industrial Automation (ABB Group)

Product Category Digital Output (DO) Module for X20 I/O System

Number of Channels 16 (grouped in 2 x 8-channel banks)

Output Type NPN/PNP transistor (sink/source configurable via wiring)

Nominal Voltage 24 VDC (19.2–30 VDC operating range)

Max Output Current 0.5 A per channel, 4 A per module

Switching Frequency Up to 100 Hz (suitable for PWM or rapid cycling)

Isolation Galvanic isolation between field side and backplane (500 Vrms)

Diagnostics Per-channel LED status + group fault indication

Installation X20 bus-compatible baseplate (e.g., X20BB2x), DIN rail mount

Operating Temperature 0°C to +55°C

Certifications CE, UL/cUL, KC, EAC, compliant with EN 61131-2

Technical Principles and Innovative Values:

Innovation Point 1: Flexible Sink/Source Configuration – Unlike fixed-output modules, the 7DO135.70 supports both PNP (source) and NPN (sink) wiring through terminal block selection, enabling universal compatibility with sensors and actuators from any vendor—ideal for global OEMs standardizing on one I/O platform.

Innovation Point 2: Per-Bank Diagnostic Architecture – While not fully per-channel isolated, the 7DO135.70 divides its 16 outputs into two electrically independent 8-channel groups, each with its own power supply and fault monitoring. A short circuit in one bank does not disable the other—maximizing availability in mixed-criticality applications.

Innovation Point 3: Seamless X20 Ecosystem Integration – The module auto-identifies in B&R’s Automation Studio, requiring no manual parameterization. Real-time channel status is accessible via the PLC program or web-based diagnostics, enabling predictive maintenance and remote troubleshooting.

Innovation Point 4: High-Speed Switching for Advanced Control – With a 100 Hz switching capability, the 7DO135.70 can drive proportional valves or implement soft-start sequences—extending beyond simple on/off control into semi-analog applications without additional hardware.

Application Cases and Industry Value:

In a Swiss chocolate packaging facility, the 7DO135.70 replaced aging relay-based output racks on a vertical form-fill-seal machine. The high cycle rate of the sealing jaws (80 strokes/minute) had caused mechanical relay contacts to weld shut, leading to burnt film and fire risks. By switching to solid-state outputs on the 7DO135.70. the plant eliminated contact wear entirely. The module’s 100 Hz rating comfortably handled the rapid on/off pulses, while its compact size freed up 40% cabinet space. Maintenance costs fell by 60% in the first year, and unplanned downtime vanished. Similarly, in a U.S. semiconductor wafer handling robot, the 7DO135.70 provided noise-immune control of vacuum grippers in a Class 1 cleanroom—its conformal-coated PCB and low EMI design met stringent contamination and EMC requirements, ensuring zero particle shedding and reliable operation over 20.000+ cycles.

Installation, Maintenance, and Full-Cycle Support:

Installing the 7DO135.70 is effortless within the X20 ecosystem: snap it onto any compatible X20 baseplate (e.g., X20BM11), secure the latch, and connect 24VDC power and field devices via screw or spring terminals. No DIP switches or software configuration are needed—the module is recognized automatically in Automation Studio. For sink/source flexibility, users simply wire the common terminal to 0V (for PNP loads) or +24V (for NPN loads). The module operates reliably in temperatures up to 55°C and features reverse polarity protection on the field supply.

Maintenance is simplified by clear visual diagnostics: green LEDs indicate active outputs, while a red “Fault” LED per bank signals overloads or short circuits. Thanks to hot-plug support, the 7DO135.70 can be replaced during machine operation—critical for 24/7 production. All modules undergo rigorous factory testing, including thermal stress, EMI immunity (IEC 61000-4), and 10.000+ switching cycles. We provide a 24-month warranty and access to B&R-certified engineers for remote support on wiring, diagnostics, or integration with higher-level systems like MES or cloud platforms.

Contact us for a customized solution—whether you’re building a new machine, retrofitting legacy controls, or scaling an X20-based automation architecture, we deliver the 7DO135.70 with full lifecycle assurance, technical expertise, and global logistics support to keep your operations running smoothly.